ipcm n. 81 | May-June 2023

The smart journal for surface treatments

ISSN 2280-6083

ipcm digital on

® Special issue on AUTOMOTIVE

www.myipcm.com 2023

INTERNATIONAL PAINT&COATING MAGAZINE

14th Year - Bimonthly N° 81 - MAY/JUNE

How to specify E-Coats more sustainably Key Considerations for Achieving Performance and Environmental Responsibility

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CONTENTS MAY/JUNE 2023

© Adapta Color

18

© Estrallum

ADVANCEMENTS

38

All That Glitters is not Gold

The Added Value of Estrallum’s High-Quality Aluminium Components: Sustainable Co-Design and Environmentally Friendly Pre-Treatment

© Porsche Deutschland

© Ferrari S.p.A.

58

FOCUS ON TECHNOLOGY

FOCUS ON TECHNOLOGY

Painstaking Search for Excellence on a Product that Exceeds the Boundaries of the Imaginable: Ferrari Confirms the Choice of Powder Primers for All Its Vehicles

07 EDITOR’S LETTER 08 BRAND NEW 16 ASK JOE POWDER

The “Ask an Expert” Column

22 HIGHLIGHT OF THE MONTH

IST Presents the TW and ROTO PLUS, Two Game-Changing Solutions to Clean Process and Paint Storage Vessels and Recover Waste Water

26 RESEARCH BREAKTHROUGH

SUSU Researchers Developed a New Metal Matrix Heat Resistant Coating

74

28 ROAD TO 2050

About Zinc Flake Systems and How They Help Reduce CO2 Emissions

32 FOCUS ON TECHNOLOGY

At O.M.F.A., Insourcing the Coating Process Closes the Circle of Quality Control on Metal Furniture Components

46 BRAND NEW 49 WHERE WE HAVE BEEN 51 52 BRAND NEW

SPECIAL ISSUE ON AUTOMOTIVE

HOW IT’S COATED

Long-Standing Porsche Lover Has a Colour Named After Him

IT’S COATED 54 HOW BMW 3.0 CSL: Paintwork Artistry from Landshut in the Name of the Most Powerful Letter in the World

57 BRAND NEW ON TECHNOLOGY 66 FOCUS MAK Chooses a New Automated Coating Plant for the Three-Coat Finishing of its Aluminium Alloy Wheels for the Aftermarket Sector

78 ADVANCEMENTS

How to Specify E-coats More Sustainably

TIGER Drylac® Digital Finishes

Color and effect files for realistic digital surface visualization The new generation of digital finishes for CGI rendering systems are based on real scans – showing color and gloss as well as effect and texture. Discover more than 1,600 innovative TIGER Drylac® Digital Finishes in our Webshop and use the unique opportunity of powder coating your rendered object with only one mouse click.

Download for free now!

www.tiger-coatings.com/shop

CONTENTS MAY/JUNE 2023

© Walther Spritz- und Lackiersysteme GmbH

82

FOCUS ON TECHNOLOGY

110

Resource-saving Coating Technology for Wheels of Rail Vehicles

© ipcm

134

ART WITHIN SURFACES

Alfa Romeo F1 Team Stake x BOOGIE: a New Artistic Project to Bring Fans Closer to the Team

© ipcm

FOCUS ON TECHNOLOGY

RI-ME’s New 4.0 Coating Line Embraces Virtual Reality with the New VR-Tracking System for Robot Self-Learning

86 RESEARCH BREAKTHROUGH

Electric Vehicle Batteries Could Get Big Boost with New Polymer Coating

88 SUCCESS STORIES

Expansion of E-Component Production in Leipzig: First Cell Coating Line for Battery Modules Goes on Stream

90 FOCUS ON TECHNOLOGY

L.T.E. Lift Truck Equipment: Two Industry 4.0-Oriented Automatic Coating Plants to Optimise Production, Achieve High Quality, and Reduce Consumption

98 FOCUS ON TECHNOLOGY

MANTA Group: Flexibility and Speed of Production Guaranteed by Automation and Digitalisation of the Commercial Vehicle Engines Coating Phase

152

106 SUCCESS STORIES

Unparalleled Efficiency with Paint Shop and Final Assembly Systems for Electric Vehicles from Dürr

112 SUCCESS STORIES

Revamping a ZLD Waste Water Treatment Plant

114 FOCUS ON TECHNOLOGY

ENOLGASiTech Reduced Energy Consumption by 25% through Low-Cure Polyester Powder Coatings

120 BRAND NEW 124 HIGHLIGHT OF THE MONTH

Euroimpianti Polska Opens Its Doors

SUCCESS STORIES

A Quality-Conscious Approach to Purchasing Powders: Colortec’s Philosophy

ON TECHNOLOGY 126 FOCUS Pasturi’s Green Soul: 2-Megawatt Photovoltaic Panels and a Zero Liquid-Discharge Pre-Treatment Water Purification Plant

ON TECHNOLOGY 142 FOCUS An Infrared RHT Radiant Gelling Plant Halves A.P.M.’s Two-Coat Application Time

148 ROAD TO 2050

New Interpon Initiative Helps Customer Reduce their Energy Consumption

150 HIGHLIGHT OF THE MONTH

Claudio Minelli Appointed as the Honorary President of Verind after a Fifty-Six Year Long Career

CONTENTS MAY/JUNE 2023

© ipcm

164

© Adobe Stock

SUCCESS STORIES

Saveral Achieved Unparalleled Improvements in Powder Coating Quality with Its New IPS Coating Centre

© ipcm

196

RESEARCH BREAKTHROUGH

174

Silver as Functional Filler for Protective and Antibacterial Coatings

© BvL Group

CASE STUDY - ICT

208

A flexible, hybrid cleaning process to meet high cleanliness standards in the Swiss watch industry

ON TECHNOLOGY 156 FOCUS Stelma Paint Invests in a New Powder Coating Plant with a Cutting-Edge Application System to Perform over 80 Colour Changes per Week

161 BRAND NEW 168 COLOUR STUDY

The Most Controversial Colour: Red

172 STANDARD & LEGISLATION

The New Digital Legislative Pillars and Their Relationship with Finishing Equipment and Mechanics in General

180 MEETING THE INDUSTRY

TECHNOLOGY OVERVIEW - ICT

Cleaning tumble dryer drums with short cycle times

191 OVERVIEW 192 TECHNOLOGY Improved cleaning performances and ICT - Industrial Cleaning Technologies

lower media consumption: acp Systems launches an innovative nozzle technology for CO2 snow jet cleaning

STUDY 202 CASE Freudenberg sealing technologies chooses bicarbonate-based detergent cleaning technology for the future of its electrical batteries

210 CASE STUDY

Development of new quicker cleaning process for ceramic components

212 HIGHLIGHT OF THE MONTH

A fast, efficient, and gentle shot peening solution

214 INDUSTRY NEWS OVERVIEW 218 TECHNOLOGY Sensible repair measures on worn vibratory finishing systems in the focus of the expected service life and feasibility

222 MEETING THE INDUSTRY

and spare parts

CONVEYORS

MORE innovation performance nano technology R&D ESG technical assistance

dn-chemicals.com

EDITOR’S LETTER

Richiedi la versione in italiano a info@ipcm.it

T

he language of our age is pervaded by the use of the prefix “e-”. E-mobility, e-economy, e-vehicles, e-commerce, e-fuel, e-learning, e-mail, e-bike, and e-coat are just a few examples of the use of this prefix, which, however, does not have an unambiguous meaning.

Originally, “e-” was merely a contraction of “electronic” to create modern compound words relating to communication via telematic networks or, more generally, anything that is digitally mediated. We are living in the era of the e-economy, characterised by the extensive use of the Internet and information technology, which has revolutionised the technological and organisational structures of companies but also their approach to products, introducing concepts such as the holistic view of a product and its life cycle or the value generated by a business’ network and general ecosystem.

In recent years, however, “e-” has also emerged as a contraction of “electric” and by extension of meaning “ecological”, since everything electric (and digital, I might add) is considered sustainable and efficient. The vehicles of the future thus become e-vehicles thanks to electric propulsion; liquid or gaseous fuels of synthetic origin become e-fuels because they are produced by energy-intensive processes that however are powered by electricity; human mobility becomes e-mobility if it entails the use of electric means of transport (cars, bicycles, buses...).

Why am I making this reflection at the opening of this ipcm® issue? Because what you are reading is the Editor’s letter of one of the most eagerly awaited issues of the year, as well as our record issue in terms of advertising sales since 2010 (and for this achievement I would like to thank all the international companies that believe in our publishing project): the annual “automotive & transport” special that places finishing and surface treatment technologies in the broader context of the industry of cars and their components in particular and of transport vehicles in general, a sector that sets the pace for the entire industry, experiments, constantly challenges itself, and is also a source of dreams for so many of us. The result is a set of technological, operational, and management trends that are then transposed, interpreted, and adopted by the industry at large.

Well, in the articles that make up the “automotive & transport” special insert of this issue of ipcm®, which is also accompanied by the ICT insert on surface cleaning and preparation technologies, you will find the prefix “e-” repeated very frequently. Electricity supply has been the biggest topic of debate within the automotive industry for some years now, and with increasing urgency, not least in view of the 2035 deadline for the EU-dictated ban on petrol and diesel for all new vehicles.

The subject of electric mobility has driven R&D in the field of vehicle propulsion and generated new industrial and manufacturing needs (let us just think of the production of battery modules, motors, and in general all the electric components of a vehicle). It has even been identified with some precise colours, such as acid green and electric blue, generating a cascading effect on the entire finishing sector.

You will find much of this in the next several pages, starting with a report on a major car manufacturer, Ferrari, which shared with ipcm®’s readers its technological choices in terms of finishing, electric mobility, and related infrastructure investments.

And that is not all because, as in every issue, ipcm® goes beyond the contents of its special insert to reveal much more about technological innovation in numerous manufacturing sectors and present scientific and technical research on different coatings and their application.

Alessia Venturi Editor-in-chief Direttore Responsabile

international PAINT&COATING magazine - MAY/JUNE 2023 - N. 81

07

BRAND-NEW

ipcm® Is Now an Internationally Registered Trademark We are pleased to announce that ipcm® – synonymous for over 10 years of highly specialized technical publications for the surface treatment sector – is now a registered and internationally protected trademark.

T

he editorial team is pleased to announce that ipcm® is now a

EOS Mktg&Communication Srl, together with Paola Giraldo (CFO) and

registered and protected trademark in Italy, Europe, the United

Francesco Stucchi, (Commercial Director). “In the past few years, we have

Kingdom, Brazil, China, India, Mexico and the United States.

worked to offer truly relevant content for the sector and for the various

This new registration updates and expands the products and services

reference markets. Under the aegis of the ipcm® brand there are, in fact,

covered by the ipcm® brand in Italy and Europe, and further corroborates

five magazines that cover the main surface processes and sectors – from

the international presence of the ipcm journals in some of the countries

surface preparation to finishing; from automotive to oil&gas – published

with the highest readership rate.

in four different languages. That’s not all: over time we have expanded

“This is an important investment that we have undertaken in 2022 in light

our offer with an online portal updated daily, by integrating various digital

of the global circulation of our magazines, not only to protect ourselves

tools – such as webinars, newsletters, social media and even a web app –

from imitations, copies or brand theft, but also to give a further push

and by building and cultivating a truly international community”.

forward to the very vocation for which the ipcm brand was created

“It is an important milestone, which would not have been possible without

back in 2009: providing all stakeholders with a reliable, accurate and

the great teamwork of the ipcm® editorial office and without the trust

highly specialized source to stay up-to-date with the latest innovations

placed in us by our customers and readers in these fourteen years of

and trends in the industrial finishing world, and able to speak to an

activity”, concludes Alessia.

®

®

international audience”, says Alessia Venturi, editor- in-chief of the ipcm® magazines and one of the founding members of the publishing house

© AdobeStock

08

N. 81 - MAY/JUNE 2023 - international PAINT&COATING magazine

For further information: www.ipcm.it/en

BRAND-NEW

Axalta Launched the New ICONICA Powder Coatings Collection The ICONICA collection from Axalta retains a focus on product performance and aesthetics, with a renewed emphasis on sustainability.

A

xalta Coating Systems, an international

focus on the environment. The Alesta® SD range of

manufacturer of coatings solutions for

powder coatings is solvent- and VOC emissions-free

the architectural and design segment, has

and produces significantly less hazardous waste

recently announced the launch of its latest ICONICA

compared with solvent borne coatings solutions,

collection of Alesta® SD powder coatings aimed at the

assisting in obtaining LEED® credits for projects

United States of America. The collection, composed

on which they are used and are supported by an

by coatings based on a super-durable polyester

EPD certification. “We are proud to unveil the latest

resin system, combines higher grade pigments and

ICONICA collection, which addresses the changing

stabilisers with an exterior durability that extend

performance, sustainability and design requirements

the life cycle of architectural projects. ICONICA is

of the global architecture and design community. This

compliant with international standards such as

newest trend collection underlines our commitment

Qualicoat Class 2 and AAMA2604 and also comes

to supporting architects around the world with

with a warranty up to 25 years.

expert insights and guidance to facilitate better, more

ICONICA identifies a palette of 40 key finishes which

sustainable designs,” has stated Olaf Conreur, the

capture the essence of our time, identified by

Global Business Strategy Director of Axalta. “ICONICA

research carried out by the team of colour experts of

enables customers to turn their project into a piece

Axalta. The findings provide architects and designers

of art, while making the most of advancements in

with clear and actionable insights to help create

coating technology to ensure superior performance.

designs that can withstand the test of time.

We are constantly exploring ways to innovate with

The arrival of fourteen new colours to the collection,

purpose, and we are motivated by a focus on the

with innovative additions such as Grained Stone,

planet and its resources.”

Russet Scarabea and Lunar Chrome, reflect the degree of change witnessed over the past five years, following major disruptive events such as the climate

For further information:

crisis and pandemic. It was developed with a key

www.axalta.com/iconica © Axalta

BRAND-NEW

The Powder Coatings of Interpon Ensure the Legacy of the Latest Luxury Hotel in Dubai The super-durable powder coatings developed by Interpon are helping to protect and enhance, the latest billion-dollar luxury hotel and resort of Dubai, Atlantis The Royal.

T

he Superdurable Interpon D

was to find a powder coating that could

can collect overspray and reuse the powder,

architectural powder coatings from

protect aluminium surfaces and girders in a

making it a better choice for the environment.

AkzoNobel are helping to protect and

climate of extreme heat and corrosive salt

Although the design was completed and

enhance Atlantis The Royal, the latest billion

spray from the coast, and with a finish that

specified in the U.S.A., the global presence

dollar luxury hotel and resort of Dubai,

would complement the warm terracotta tones

of Interpon, the consistency of its products

with products that beautifully mimic the

of the landscape surrounding Dubai.

worldwide and its flexibility in offering different

appearance of terracotta, ensuring its beauty

The solution was an Interpon D2525 super.

textures and finishes everywhere meant that

and style for generations to come.

durable powder coating, which delivers the

the coating itself could be handled in Dubai

Constructed in two Lego like structures

classic appearance of terracotta without

without the need for costly shipments.

connected by a bridge, the $1.4 billion project

having any of the downsides of sourcing,

“The project is a great example of the ongoing

is the latest jewel in Dubai’s crown of luxury

transporting, installing and maintaining the

commitment of Interpon to support its

hotels and resorts and opened its doors to

real thing.

customers with innovative and sustainable

the public on 10 February 2023. The unique

Crucially, the Interpon D2525 is free of

solutions. Extraordinary buildings need

concept was designed by the award-winning

harmful substances and Volatile Organic

extraordinary solutions. Our architectural

team of Kohn Pedersen Fox Associates.

Compounds (VOCs). And no powder coating is

range of powder coatings gives architects

The challenge for the designers and architects

lost to the environment when applied: coaters

and designers the freedom to make the

th

improbable possible and dreams a reality.

Our products were chosen for their ability to help create earthy natural tones whilst meeting tight industry specifications and demanding weather conditions,” has declared Sanal Limoncuoglu, the Commercial Director Powder Coatings South & East Europe and Middle East and Africa Launched during a three-day star-studded event, Atlantic The Royal welcomed Beyonce and other celebrities to officially open the resort, ensuring its introduction to the world was as breath taking as the Interpon powder coating protecting it.

For further information: www.interpon.com

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N. 81 - MAY/JUNE 2023 - international PAINT&COATING magazine

BRAND-NEW

Cortec Presented the Water-Based MCI® Peel-Off Coating The coating of Cortec provides temporary masking and protection for non-porous surfaces against physical abrasion, weathering and corrosion.

C

ortec Corporation has recently presented MCI® Peel-Off

The coating, that emits low Volatile Organic Compounds (0.2 lbs/gal

Coating, a newly developed acrylic water-based solution that

[24 g/L]), can be applied by spray, roll or dip. When no longer needed,

offers temporary protection for non-porous surfaces such as

it can be peeled off the surface and disposed as solid waste. It also

windows, doors, light fixtures, ceilings, doorknobs and frames against

offers UV resistance for outdoor applications, in addition to temporary

physical abrasion, weathering and corrosion.

protection from salt and chemical induced corrosion.

Windows and doors often go into place before the construction work

Moreover, it can be tinted to several basic colours to blend in with or

is finished, leaving them vulnerable to drips or splatters from paints or

stand out from the surrounding environment and will not be softened

putties or nicks and scratches from tools and equipment being jostled

or penetrated by most solvent-based paints.

around the construction site. MCI Peel-Off Coating allows then to protect them from the time they are installed until the rest of the job is completed.

For further information: www.cortecvci.com

eosmarketing.it

AUT O MO TIV E

cataphoresis and liquid or powder spray applications

70 years of experience and innovation in surface finishing lines pre-treatment | spray applications | electroplating | vertical & horizontal plants | enameling | aluminium | white goods | automotive | general industry

www.trasmetal.net

BRAND-NEW

Zeus Presents the New J-Cup Gun Zeus has launched the new generation of J-Cup guns for powder coating operations.

T

he manufacturer of powder coating booths and guns, Zeus Electrostatic System, has presented the new generation of J-Cup guns. Suitable for

making small samples, the J-Cup guns are the ideal tool for laboratories and for quality control.

The technical characteristics of the new Zeus’ J-Cup gun: • gravity rear cup integrated in the gun body; • equipped with fan nozzle and and micro venturi pump controlled by J series command modules; • easy to clean; • suitable for continuous colour changes.

For further information: www.zeus-el.it © Zeus Electrostatic System Srl

Elementis Expands Its Powder NiSAT Rheology Modifiers Range with RHEOLATE® PHX 7025 The 100% solid urethane rheology modifiers of Elementis provide high-performance and more sustainable formulations.

E

lementis has recently announced the expansion of its RHEOLATE®

“The paint & coating industry is constantly seeking higher performing,

Powder NiSAT product range of 100% solid urethane rheology

safer and more sustainable solutions. At Elementis, we had already

modifiers for paints and coatings with RHEOLATE PHX 7025, a

understood that our urethane rheology modifiers could offer the

new solution that helps to provide safer and more sustainable high-

needed improvements. So, we have successfully designed a 100% active

performance formulations. It creates up to 10% more efficiency on

powdered version of our urethane rheology modifiers, RHEOLATE®

usage as a high shear builder, ensures superior spatter and also

Powder NiSAT range, suitable for high performing formulations,” has

creates excellent stain resistance. The patented portfolio of Elementis

declared Carlos Feito Fraile, the technical director of the Performance

exemplifies the commitment of the company to use its expertise and

Specialties division of Elementis. The rheology modifiers are free of any

knowledge in rheology science to develop sustainable solutions that

hazardous labels and powder thickeners allow paint manufacturers

outperform conventional market alternatives. As a matter of fact, thanks

to formulate asthma and allergy friendly coatings. Moreover, due to

to its unique chemical design, RHEOLATE Powder NiSAT can easily

the 100% solid form of RHEOLATE PHX 7025, biocides, emulsifiers and

be incorporated into a variety of formulations resulting in improved

surfactants are not needed, resulting in a VOC-free product.

handling, increased efficiency and meeting the latest eco-labelling requirements.

For further information: www.addingfuture.com/page/rheolate/

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N. 81 - MAY/JUNE 2023 - international PAINT&COATING magazine

BRAND-NEW

Fast & Fluid Management Showcased Cutting-Edge Innovations at ECS 2023 Fast & Fluid Management has stepped into the future of the paint industry with unified tinting solutions.

F

ast & Fluid Management, a unit of IDEX Corporation, is thrilled to

configuration introduced in the X-PROTINT dispenser – allowing

have taken part in the European Coatings Show 2023, the leading

customers to tint additional products at their point-of-sales with the

exhibition for the international paint and coating industry held

X-PROTINT.

from 28 to 30 March. The company showcased its latest innovations

“We couldn’t be happier to meet our customers and partners in person

designed to meet the market and the customer needs. The edition

again and share our latest product innovations that address key

of the trade fair marked a significant milestone for FFM, as it globally

challenges in the industry currently. We are incredibly proud of what we

announced Tintelligence™ — unified tinting solutions.

have achieved with Tintelligence. Our customers received a

The industry is continually changing, so are the needs and subsequent

hands-on experience of early versions of apps and also a sneak preview

focus areas of paint tinting businesses. There is a need and opportunity

of our first-ever Tintelligence equipment,” said Ana Garcia, President

to empower the stakeholders of the tinting business to drive it to new

Global Dispensing, IDEX Corporation.

th

th

levels of operational and commercial performance holistically. Which is why the company has developed Tintelligence - propel the tinting

For further information: www.emea.fast-fluid.com

business with unified tinting solutions. Tintelligence is an ecosystem of seamlessly integrated state-of-the-art tinting equipment and advanced digital applications, giving one experience enterprise-wide. The Tintelligence advanced suite of applications enables colour management and data-driven operational and business decisions, helping paint businesses enhance profitability, increase efficiency, lower TCO and enable online ordering (www.tintelligence.com).

During the European Coatings Show, Fast & Fluid Management also

Competence in Shot Blast Technology

presented a line-up of new innovations introduced in its current portfolio to address important market trends: a solution for customers to use biocide-free colorant systems in HA180 and HA480 dispensers, new sample dispensing pumps for the HA480 and HA680 dispensers to consistently and accurately dispense down to 0,015 ml of colorant, new industrial solutions customisation options for the HA480 and HA680, to tint under the most demanding conditions, and the 24-canister

AGTOS | GmbH | 48282 EMSDETTEN | GERMANY info@agtos.de | www.agtos.com

390-01/23-4c-GB

As a full-range supplier, we design and manufacture shot blast machines including filter and transport technology. ➜ New shot blast machines ➜ Second hand machines ➜ Service and spare parts ➜ Reparation & maintenance ➜ Inspection & consulting ➜ Performance improvement

© Fast & Fluid Management

international PAINT&COATING magazine - MAY/JUNE 2023 - N. 81

13

BRAND-NEW

CMA Robotics: New Logo, New Challenges, New Story CMA Robotics, specialising in the industrial automation industry, has renewed its corporate image with a new logo. of them deal with advanced robotics in the most different industrial sectors and all of them have earned important recognition in the world of technological innovation.

CMA thus further entrenches its international positioning thanks to the Efort group, which also has offices in France, Germany, Brazil, Poland and India, with a turnover of 200 million Dollars and a structure that has more than 1,400 employees who are experts in the field.

The CMA logo today chooses so once again to follow the evolution of its imprint in the market. To unify with the group for one strong identity, also in image. “Changing brands after so many years of activity,” says general manager Sergio Della Mea, “is an important step and acquires a twofold strength: on the one hand, the strength of our knowhow and, on the other, that of an increasingly marked international competitiveness. Being part of a group of companies specializing

A

in robotics, we will be able to count on important synergies and logo is the story of itself, it represents the original and distinctive

collaborations to offer customers increasingly advanced technologies

mark of a company. After years of strong and recognized

and better services.”

presence in the area of industrial automation, today CMA

CMA Robotics, precisely, makes each coating robot “tailor-made” and

Robotics presents a new look, direct, essential and professional, just

also takes care of its final integration into advanced and complex

like the products and services that the company offers to its customers.

production systems and processes, always developing everything

CMA Robotics was born 30 years ago, from the passion and vision

in-house, both the mechanical part and the software, guaranteeing

of three experts who combined their knowledge to introduce to the

direct control, quality and performance, flexibility and speed of

market an automatic spraying robot that could optimize production

implementation.

and timing of the territory’s activities. The company grew quickly, and

Being a group therefore means sharing research, development, design

along with it grew knowledge and demands from customers, who were

and innovation with other European and international companies,

increasingly in need of innovation and quality.

creating new technological, commercial and financial synergies at all

Thus, with the product, the logo also changes and prospers, and is

levels and new growth and expansion scenarios for the coming years.

identified with a colour that will be recognized and associated with CMA

“For example,” Della Mea continues, “Evolut Service, which is part of the

in all markets: green, the colour of life that continues and renews itself,

group, will take care of after-sales and technical assistance for all the

a sign of balance and growth. “To design” means “to throw forward”

other companies in the Group: this means that the thousands of our

from the Latin project, “logo” from the Greek “logos,” means “to tell.” To

customers and the 2,000 CMA robots installed around the world today

design a logo therefore means to project one’s story forward. And the

will have a more widespread, flexible and highly specialized service. An

story of CMA Robotics, is one that never stops, so from the union of

area dedicated entirely to supporting customers around the globe.”

the three founding experts, it flows across borders, uniting even more

New logo, new challenges and new history then for CMA Robotics, the

knowledge, markets and cultures.

company that changes along with its customers.

Becoming part of Efort Group in 2015, China’s largest producer of robots, CMA Robotics is now one of eight companies, five of which are Italian, that are part of the group’s holding company based in Turin: all

14

N. 81 - MAY/JUNE 2023 - international PAINT&COATING magazine

For further information: www.cmarobot.it/en/

BRAND-NEW

© RIPOL

RIPOL Unveils Clear-Sandy RIPOL presents RIPOL Clear-Sandy, a new fine-textured clearcoat that can change the look of a previously smooth-effect coated surface.

R

IPOL, an Italian manufacturer of powder coatings, presented

can also be used on indoor furniture, bicycles or even as a finish on

RIPOL Clear-Sandy (product code 66RT3H04312), the new matt

radiators or industrial products for outdoor use, as well as a topcoat

fine-textured clearcoat for coating interior and exterior surfaces.

over silkscreens and printings to protect them with an excellent

RIPOL Clear-Sandy offers weather resistance and superior protection

aesthetic result.

against corrosion and abrasion, as well as high levels of gloss retention

RIPOL Clear-Sandy also allows for a wide range of colours: up to now,

and colour stability.

in fact, the choice of colours for a fine-textured finish has always been

Based on polyester resin, RIPOL Clear-Sandy is able to change the

extremely limited compared to the infinite options available for a

look of a smooth powder-coated surface into a fine-textured one. This

smooth finish. RIPOL Clear-Sandy instead allows to easily transform any

powder coating is easy to apply and suitable for treating not only all

smooth colour into a fine-textured finish.

kinds of metal substrates, but other materials as well such as glass to achieve a stunning satin ice effect or to easily transform the smooth powder coated surface of a ceramic pot into a fine-texture effect. It

For further information: www.ripol.com

www.camitimpianti.it info@camitimpianti.it

outdoor sandblasting and coating plant

www.rimor.eu info@rimor.eu

www.tekimp.it info@tekimp.it

ASK JOE POWDER

The “Ask an Expert” Column Kevin Biller

kbiller@chemquest.com

These are typically phosphate based for steel and chromate based for aluminium. Chromate is rather hazardous (actually carcinogenic) so I would strongly recommend that you investigate alternate materials if you need to pre-treat aluminium.

Newer chemical treatment types are emerging that are based on zirconates, titanates and silanes. These are essentially non-toxic. Process control with these is critical and therefore it is necessary to carefully follow the supplier’s application parameters.

It is also very important to recognise that although cleaning techniques may be universally acceptable for both steel and aluminium, chemical pre-treatments do not translate across these very different metals.

Iron phosphate works well on ferrous substrates however it does not prepare aluminium adequately for high performance powder coating performance. You will need chemistry specific to your metal type.

Dear Mr. Powder,

Best regards,

What do you think is the best way to degrease steel and

Mr. Joe Powder

aluminium prior to coating? I have seen various opinions out there, but I was wondering what you thought was the best option. More specifically, when media blasting is not an option

Hello Joe,

due to the “coarse” surface area left. I know media blasting can

Is moisture an important measurement in the manufacturing

be fine, but it is still difficult to get a smooth surface.

of powders used in coating? If so, how is water measured?

Thanks in advance,

Also, does water affect polyurethane powder coating curing

Jeff Arbuckle

mechanism?

Rangiora, New Zealand

Geoffrey Brown Pullman, Washington

Hi Jeff, Thank you for your questions. Here is the lowdown on preparing metal

Hi Geoff,

for powder coating.

(You don’t mind if I call you Geoff?)

First, the durability requirements of the finish must be carefully

Believe it or not, powder coatings can tolerate a fair amount of moisture

considered. If this is a basic indoor application that will not see much

– up to 0.5% or more. As a matter of fact, completely dry powders in a

wear and tear or moisture, heat, etc. then simple solvent cleaning and

very low humidity environment (< 15% RH) exhibit electrostatic charging

possibly media blasting will suffice. For anything that will reside outdoors

problems. Think of the charge picked up by dragging your feet (with

you need more than that.

socks) across carpeting on a very dry day in a cold winter. Excess static

Powder chemistry has a significant influence on durability and

charge abounds. Therefore, a little bit of moisture is better than none.

performance. For instance, epoxies and hybrids adhere well over

Nevertheless, high levels of moisture (>1.0%) can cause clumping issues

blasted metal and can provide decent corrosion resistance with a

and poor fluidization. These phenomena create handling and application

minimum of surface preparation. Essentially all other chemistries

problems. As for moisture interfering with cure in an isocyanate cured

require metal cleaning followed by chemical pre-treatment. So, if you

polyester powder: this is not an issue because there is negligible free

are using a polyester, acrylic or polyurethane powder, it is best to clean

NCO available because a blocking agent is present.

the metal first with an alkaline solution, rinse well then apply a chemical

Best regards,

pre-treatment.

Joe Powder

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N. 81 - MAY/JUNE 2023 - international PAINT&COATING magazine

Dear Joe,

of a surfactant, otherwise the silicon dioxide would

Water Jet metal cutting uses silica sand (silicon

not mix well into the water and the process would

dioxide SiO2). Will this type of silicon cause

be ineffective. In addition, the use of a surfactant

adhesion problems and fisheye craters? I have

to disperse the abrasive may require a defoamer

adhesion problems around the edges of steel

to minimise foaming. Surfactants and defoamers

that have been cut this way. The flat areas are

are known to cause adhesion and cratering issues

fine, no issues with cure and adhesion just the

in powder coatings. The use of a high-pressure

edges the steel cut edges are 10mm thick and

stream of abrasive slurry would only exacerbate the

peeling off. The metal was washed with hot

problem by embedding the surfactant/defoamer into

iron phosphate water solution rinsed, dried and

the steel surface. I would guess that the surfactant

primed before the topcoat! It was not rusty and

cannot be eliminated from the slurry. Perhaps there

came from the water jet cutter clean and rust

is an alternate surfactant that does not cause this

free and was powder coated the same day.

problem, but I would not expect this to be the case.

Sincerely,

Consequently, you will need to identify a method that

David Beaver (aka Mr. D. Henley)

can aggressively remove residual surfactant on the

East Liverpool, Ohio

machined edges.

Two paths are possible: • use mechanical means to abrade the edges

Thank you for your question regarding abrasive

(sanding, grinding, etc.);

waterjet cutting and its effect on the surface of

• use a strong acid to etch the edges.

metal. It requires a bit of digging to understand

The mechanical approach is either labour intensive

what the cause of the adhesive failures could be and

or costly to automate. The chemical approach is

fisheyes in your powder coating. On the surface (pun

expensive and requires the handling of a hazardous

intended) what could be a problem? Water should not

material. No easy answers here. Alternately you can

cause an issue with adhesion or cratering. In addition,

consider using a different cutting technique, but you

silicon dioxide is inert and is not known to cause

are probably also aware that laser cutting can cause

fisheyes or craters. And you report that the surface is

similar adhesive failures for a different reason.

not corroded when you apply the powder coatings.

Good luck digging around for a solution. Let me know

Here’s where I would look for the root cause and

if you have any other ideas or questions.

hopefully the eventual solution: dispersion of the

Best regards,

SiO2 in the water most probably requires the use

Joe

© Kevin Biller

From left to right: Powder coating with less than 0.5% moisture content – free flowing; Powder coating with approx. 1.0% moisture content – slight clumping; Powder coating with greater than 2.0% moisture content – significant clumping.

EN 1527

H

el

m

A.

Hi David (or are you really Mr. Don Henley?),

Hellas S

.

ADVANCEMENTS

All That Glitters is not Gold Edited by Adapta Color SL, Peñíscola – Spain

adaptacolor@adaptacolor.com

Adapta Color, a Spanish company specializing in the production of powder coatings, has developed a new bonding technology to respond to the market’s latest trends for increasingly metallic finishes.

I

n recent years, technological advances in the manufacture of powder

The latest bonding technologies, a process through which metallic effect

coatings have made it possible to incorporate new pigments with

pigments are bonded to powder particles, make it possible to increase

a wide range of metallic effects that have led the offer of these

the percentage of pigments, pearlescent or metallic, reaching levels of

products competing with the state-of-the-art liquid finishes.

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N. 81 - MAY/JUNE 2023 - international PAINT&COATING magazine

finishes that would have been unthinkable a decade ago.

ADVANCEMENTS

At Adapta, always focused on the market of

The latest evolutions of Adapta Bonding

demand, means that it is also becoming more

special products and functional paints, the

System technology, as a response to the

and more common to find product proposals

continuous improvement of metallic effect

increasingly demanding levels of metallic

that ensure they are bonded. Both simple dry

finishes, both in its formulations and in its

effect finishes by some of its most innovative

mixing and the most evolved processes of

production processes, has been one of the

customers, have led to achieve levels of

particle incorporation give the powder coating

main strategic commitments. The company

bonding close to 100%. It should be noted

the adjective “bonded”, so the differentiating,

currently has a highly trained team for the

that some metallic effects or counter types

or critical, aspect when purchasing this type

control and execution of these processes that,

of paints already developed are incompatible

of product is the percentage of metallic effect

combined with a strict policy of invariability

with high levels of bonding, such as sparkle

particles that have managed to adhere to

in the allocation of products to mixers,

finishes, i.e., those that incorporate large

the powder particles (Fig. 2). The images

enables to achieve great homogeneity in

metallic effect particles (Fig. 1).

show the different degree of bonding of the

each batch and a very high degree of colour

The current market trend, where these

same product with different parameters

reproducibility between production orders.

metallic effect finishes are increasingly in

in the bonding process. In the image on

© Adapta Color

© Adapta Color

Figure 1: Powder particle with bonded blue aluminium particles.

international PAINT&COATING magazine - MAY/JUNE 2023 - N. 81

19

© Adapta Color

© Adapta Color

Figure 2: In the image on the left you can see a product with a low degree of bonding. On the right, the Adapta Bonding System product with a high degree of bonding. Image capture at 1,280x magnification in the Adapta Color lab’s video microscope.

the right, it can be seen that the product with the highest degree of

and correct maintenance will allow us to obtain better results.

bonding has powder particles with more rounded edges due to the

The reliability that comes from using a product with technical

particle incorporation process. Unfortunately, this is only visible under a

characteristics with narrow quality ranges translates into an

microscope, so an easy way to check the degree of bonding is to look at

improvement in productivity by allowing a greater number of recoveries

the transparency of the plastic bag containing the product.

in the application process and a higher transfer ratio between the

A low degree of bonding causes the metallic effect particles that are

projection and the part (Table 1).

not adhered to the paint particles to cling to the bag, making it less

The use of a product with a high degree of bonding does not guarantee

transparent.

that the desired colour or shades will be obtained. There are various

Adapta Bonding System has achieved an optimal combination of three

factors that can cause changes in the appearance-colour of metallic

key aspects of this type of coating: colour, application and reliability,

appearance powder coatings, such as: application voltage (Kv),

which places us at the forefront of the powder coating industry.

amperage limitation (µA), distance between spray guns and parts to

In terms of colour, this process provides optimum consistency in

be coated, thickness deposited, type of equipment and installations,

appearance (colour-effect) with different application parameters in the

etc. Therefore, in addition to the use of a powder with a high degree of

equipment and processes. In other words, the shades or colours of the

bonding such as those manufactured under the latest Adapta Bonding

product are more stable because the range of tolerance to variations

System technology, Adapta Color invites you to always observe the

in the application conditions of the equipment is greater, for example,

following recommendations:

small differences in electrostatic charge between the spray guns.

• Paint batch. To achieve uniformity of the colour effect, we also

In the application, a high degree of bonding allows a more stable flow

strongly recommend using a single batch to cover the entire job. Given

and avoids the accumulation of metallic particles on the electrode, thus

the correlation between the conditions, parameters and manner of

eliminating possible surface defects on the parts when they are sprayed.

application, and the colour, appearance and finish of the products, we

The technology of the application equipment has also evolved in recent

strongly recommend prototyping and industrial application at your

years in parallel with the metallic effect coatings, therefore, its updating

premises to check the result, colour accuracy and reproduction.

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ADVANCEMENTS

TECHNOLOGY

RECIRCULATION 1

RECIRCULATION 2

RECIRCULATION 3

Inc. Normal Dry Blend

ΔL= -1.98

ΔL= -3.21

ΔL= -3.82

ADAPTA Bonding System

ΔL= -0.22

ΔL= -0.35

ΔL= -0.84

Test performed on a TGIC free polyester with metallised effect (9006).

Table 1: Comparison of traditional bonding technology and Adapta Bonding System.

• Hanging. To avoid chromatic differences caused by the reflection of

cleaning of the spray head and will avoid the formation of bubbles due

colours, especially in the case of mottled, metallic and/or transparent

to accumulation in the nozzles. The powder pressure can be adapted to

products, the elements should be hung in the same direction during

the surface to be painted, bearing in mind that the higher the powder

their application as when they are assembled on site. It is recommended

pressure, the less electrostatic charge is released.

to use a part detection system to switch the spray guns on and off if

• Nozzles. A mushroom nozzle will be more useful for painting flat parts,

there are large gaps between frames or parts.

whereas flat spray nozzles give better results when coating angles and

• Voltage. To avoid particle separation, we recommend applying with

profiles.

electrostatic voltages higher than 70 kV. Ideally, the maximum voltage of

• Spray guns. The most modern equipment with self-cleaning heads

the equipment can be used to ensure a homogeneous transfer.

and free ion capturing devices (SuperCorona) can give better results.

• Distance to the part. To avoid electrostatic repulsion phenomena

• Booths and cyclones. The recovery of metallic paints is not always

caused by retro-ionisation, it is necessary to maintain the appropriate

possible and depends on the type of booth, the geometry and efficiency

distance to achieve a good application (minimum 30 cm from spray gun

of the cyclone and, of course, the type of part to be painted. If we paint

to part).

sheet metal, we will have a transfer of 70-80%, whereas if they are tubes,

• Contacts. Contacts with the part to be painted must be as clean as

we can have 25-30% with the consequent increase of recycling cycles

possible in order to maintain a good conductivity up to the chain. When

and the corresponding loss of particle.

using products formulated with pearlescent pigments, special care must

• Tanks. It is preferable to apply from fluidised bed tanks rather than

be taken to ensure a good earthing system.

directly from the container. Always maintain the highest possible

• Pressures. A slightly higher than normal air pressure will favour the

proportion of pure powder.

international PAINT&COATING magazine - MAY/JUNE 2023 - N. 81

21

HIGHLIGHT OF THE MONTH

IST Presents the TW and ROTO PLUS, Two Game-Changing Solutions to Clean Process and Paint Storage Vessels and Recover Waste Water From an interview with Massimiliano Mingacci Global Sales & Marketing Manager of IST- Italia Sistemi Tecnologici

© IST

IST Italia Sistemi Tecnologici, a manufacturer of solvent recovery and cleaning systems, presented its latest technological innovations at the European Coatings Show. During the launch event of its new TW and ROTO PLUS machines, we exclusively interviewed Massimiliano Mingacci to discuss the reasons behind the development of these innovative systems, their use, and their technical features.

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The TW system supplies paint, resin, and ink manufacturers with an innovative solution to simplify and speed up their process and storage vessel cleaning operations.

HIGHLIGHT OF THE MONTH

I

buy a new machine. A second bay can also be

announced the launch event organised

added to increase the plant’s cleaning capacity

by IST to present its latest solutions 1

© IST

n the March/April issue of ipcm®, we

or treat tanks and containers with different

developed for the industrial coating sector.

geometries.

During the first day of the 2023 European

Another big advantage offered by the TW

Coatings Show, IST’s technical and sales team

system is the reduction of waste water

officially presented the TW, a new series of

disposal costs. Manual cleaning of a single

machines for cleaning process and storage

container requires an average of 100-150

vessels, and the ROTO PLUS, a range of

litres of water or 5-10 litres of solvent: with

distillers designed to process up to 2,000 litres

this machine’s cleaning liquid recirculation

of product in 24 hours.

function, consumption drops to 15-20 litres of water and 1-3 litres of solvent. The amount of

The innovative drive

waste produced therefore decreases by 70%-

The new machines recently launched by IST

90%, resulting in lower disposal costs and

have been designed to mark a turning point in

significant ecological benefits.

the industrial cleaning sector, providing users

Finally, when there is the need to clean

with truly unique solutions. The TW system

vessels containing solvents, the TW machine

(an acronym for Tank Washer) was born out

can be perfectly integrated with the ROTO

of IST’s will to offer to the coating industry,

PLUS distiller, not only in terms of design and

and to paint manufacturers in particular,

modularity but also of functionality, as they

a machine to clean the vessels used for

are both based on IST’s new integrated control

formulating, mixing, and storing paints and

hardware, DISTI-touch.

similar products. The cleaning of such tanks is in most cases still carried out manually, but it

The new ROTO PLUS distiller

is a cumbersome and unsafe operation due

Another innovation presented by IST during

to exposure to harmful chemicals. IST’s new

the ECS was ROTO PLUS, the latest evolution

system, however, simplifies the vessel cleaning

of its distillers. This solution is designed to

process, thus reducing costs and improving

process up to 2,000 litres of polluted product

operator safety, but also the quality of the

in 24 hours but now, thanks to a unique

cleaning cycle itself. The TW machine can be perfectly integrated with another system, also

combination of advanced design, heating

The new ROTO PLUS distiller manufactured by IST.

technology, and a vacuum system, it is able to

presented during the world’s leading trade

process and achieve peak efficiency even with

fair for the coating industry: the ROTO PLUS

smaller batches.

distiller.

As well as having the potential of much larger Their main peculiarity is the fact that, despite

machines, this new distiller also lowers solvent

their small dimensions, they integrate all the

consumption, as it can recover almost all of

features and technological innovations that

the product, with a waste rate of about 4-5%.

Designed for numerous different sectors,

are usually the prerogative of larger, more

Thanks to optimal solvent management,

including industrial coatings, the TW

complex cleaning plants.

ROTO PLUS allows companies to store fewer

machine series supplies paint, resin, and ink

These machines have been developed to work

chemicals, reducing the risks and safety

manufacturers with an innovative solution

at high pressures, reaching 40 bar for cleaning

obligations associated with this activity.

to simplify and speed up their process and

solvent-based products and 200 bar for water-

ROTO PLUS includes a distillation tank fitted

storage vessel cleaning operations. The TW

based products. The TW system is also highly

with a stirrer and equipped with robust,

systems have a robust, modular, and very

flexible: it is possible to switch from cleaning

reliable scrapers with a self-cleaning function

compact layout.

storage tanks to transport containers simply

to prevent fouling on the inner surfaces of the

by changing its washing bay, without having to

boiler.

TW: the new series of process and storage vessel cleaning machines

1

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international PAINT&COATING magazine - MAY/JUNE 2023 - N. 81

23

In addition, this revolutionary distiller series is equipped with a life

© ipcm

extension system for diathermal oil, a special product used to transfer and retain heat.

Diathermal oil is a viable alternative to steam-operated machines that must comply with strict regulations and controls to ensure maximum safety: replacing steam with this special oil, on the other hand, extends maintenance intervals and avoids additional costs and downtime. Finally, load control occurs through load cells, eliminating any mechanical control operations using floats or contact sensors, which tend to get dirty quickly and require constant maintenance.

Timely and comprehensive technical service, even remotely IST firmly believes that routine maintenance is essential to extend the service life of plants and keep them efficient at all times. For this reason, the mission of this manufacturer of solvent recovery and cleaning systems based in Modena (Italy) is to provide its customers with the most accurate and timely technical assistance and maintenance service possible. To this end, IST continues to invest in after-sales services and to train its technicians in all the geographical macro-areas in which it is active: from Europe to the USA, from China to New Zealand.

Massimiliano Mingacci, Global Sales and Marketing Manager of IST, with Alessia Venturi of ipcm®.

It has also activated a remote assistance service: its technical team can connect remotely through the control centre in which the data of each system is stored, thus identifying issues, faults, or malfunctions and resolving them very quickly.

Scan or click the QR code to find out more about TW System and ROTOPlus machine

TW System

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N. 81 - MAY/JUNE 2023 - international PAINT&COATING magazine

ROTOPlus machine

INDUSTRIAL WATER-BASED COATING TECHNOLOGY SINCE 1980

www.franchi-kim.it

RESEARCH BREAKTHROUGH

SUSU Researchers Developed a New Metal Matrix Heat Resistant Coating Ekaterina Poroshina South Ural State University – Chelyabinsk, Russia

The new coating will provide heat, corrosion and ionising radiation resistance as well as the ability to absorb or reflect electromagnetic radiation.

S

USU researchers are developing

In the last decades, a new technology to

support of a grant from the Russian Science

new compositions and methods for

produce parts using additive layering of

Foundation, it became possible to apply

obtaining composite coatings with non-

material has been actively developed. This

additive technologies (laser cladding and

metal and intermetal high-entropy compounds

method of synthesizing products is called

detonation spraying) to obtain metal matrix

as part of the New Non-conventional Materials

additive manufacturing and is used to

composite coatings with a fundamentally new

project of the Priority 2030 program. The study

manufacture products from various materials:

composition. The coatings consist of particles

received support from the RSF. Using additive

plastic, metal, concrete, etc. Currently, this

of non-metallic and intermetallic high-entropic

manufacturing technologies makes it possible

technology is widely used to create metallic

compounds.

to create coatings with a unique composition,

and non-metallic prototypes and functional

This project is unique in that additive

which give such material properties as heat

products.

technologies are used to create coatings with

resistance, corrosion resistance, ionizing

The applied aspects of additive manufacturing

high-entropy phases from powders consisting

radiation resistance, and the ability to absorb

technologies have been of interest to

of a mix of pure components or from powders

or reflect electromagnetic radiation.

SUSU scientists for a long time. With the

of low-entropy alloys.

© Ekaterina Poroshina

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RESEARCH BREAKTHROUGH

“To create the coatings, powder mixture

manufacturing coatings have not been

The laboratory has already been used for

compositions are pre-created using

published. The project received support from

a number of research projects ordered by

thermodynamic and kinetic simulation

the Russian Science Foundation (RSF) to the

industrial companies and state corporations

methods. The programs FactSage 8.0 and

tune of 1.5 million roubles for the first year of

including Roscosmos, Transneft, SMS-group,

Thermo-Calc help in this. These mixtures form

research. In total the project includes two years

Chelyabinsk Tube Rolling Plant, and AO

non-metallic and intermetallic high-entropic

of research.

KONAR.

phases in the coating matrix,” has stated

“For a researcher, grants are above all an

South Ural State University is a university of

Natalia Shaburova, the head of the project and

opportunity to continue their research, a

transformations, where innovative research

Associate Professor of the SUSU Department

confirmation that the topic of their research is

is conducted in most of the priority fields

of Materials Science, Physical and Chemical

relevant, promising, and has value not only for

of science and technology development. In

Properties of Materials.

themselves, but also for the future of the entire

accordance with the strategy of scientific and

The adhesive properties, corrosive resistance

country. Working in small research groups, in

technological development of the Russian

in an electrolyte, and gas corrosion of the

addition to the increase in scholarship, allows

Federation, the university is focused on the

obtained coating samples are analysed. The

undergraduate and graduate students to

development of big scientific interdisciplinary

researchers also plan to conduct structural

acquire the necessary skills and knowledge

projects in the field of digital industry,

studies of the material.

that will be useful in further independent

materials science, and ecology. In 2021 SUSU

The new coatings, thanks to their unique

work,” had added the scientist.

became the winner in the competition under

combination of performance properties,

The SUSU research team uses a modern

the Priority 2030 program. The university acts

could be in high demand in several industries

computerised FL-Clad-R-4 laser cladding

as a regional project office of the World-class

including engine manufacturing, rocket

complex and CCDS2000 detonation

Ural Interregional Research and Education

engineering, and others in which surfaces are

sputtering unit at the SUSU Laboratory for

Centre (UIREC), which is aimed at solving the

subjected to heat.

Mechanics, Laser Processes and Digital

tasks of the Science and Universities National

To date, papers on this method of

Production Technologies, founded in 2017.

Project.

© Ekaterina Poroshina

international PAINT&COATING magazine - MAY/JUNE 2023 - N. 81

27

ROAD TO 2050

© Dörken

A zinc flake coating usually consists of a basecoat and a topcoat.

The basecoat is mainly responsible for corrosion protection, while the topcoat provides the coating with functional properties.

About Zinc Flake Systems and How They Help Reduce CO2 Emissions Edited by Dörken Coatings GmbH & Co. KG

It is possible to reduce steel production – and, consequently, the CO2 emissions caused by it - with high-performance corrosion protection guaranteed by the zinc flake systems.

S

ustainability is one of the most important topics of our time.

In the automotive industry, the growing importance is demonstrated

The importance of responsibility towards people and nature is

by goals such as CO2-neutral production or the construction of

an essential part of every company. Sustainable management is

required along the entire value chain, also because of pressure from politics, investors or other stakeholders.

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N. 81 - MAY/JUNE 2023 - international PAINT&COATING magazine

emission-free vehicles. Steel in particular, which is used in many ways in the automotive industry, offers potential for optimising the CO2

balance - for example through the use of zinc flake systems.

ROAD TO 2050

For every tonne of steel produced, around 1.5 tonnes of CO2 emissions

© Dörken

are generated - a figure that increases further due to the subsequent

processing steps. If the need to produce new steel is reduced, savings can be achieved. This is precisely what is accomplished by highperformance corrosion protection. Without it, steel corrodes in a very short time and has to be replaced. If this protection is used, the service life of steel components is significantly extended.

For this reason, efficient protection against corrosion in steel products plays a major role in terms of resource efficiency and sustainability.

It leads to direct savings of CO2 and thus has a positive effect on the energy balance.

What zinc flake coating can achieve Suitable corrosion protection is of utmost importance for every steel component. Whether it is a small bolt or a large chassis part - protection against external influences such as chemicals or moisture should already be considered during the planning stage. If the function of a component is impaired, this not only means costs for repair and maintenance, but can even be a danger to health and safety.

Scanning electron microscope image of a zinc flake coating.

ROAD TO 2050

For decades, zinc flake systems have proven themselves for these

Thus, not three but only one tonne of steel with corrosion protection is

applications. These consist of many small flakes of zinc and aluminium

needed in the life cycle. In the concrete bolt example, 2950 kg of CO2 are

that are connected by an inorganic binder. The system usually consists of a basecoat and a topcoat. The basecoat is applied directly to the component and provides cathodic corrosion protection, in which the zinc contained sacrifices itself for the underlying steel. A topcoat applied on top of this adds further properties to the coating such as friction

saved over the entire service life:

• Without corrosion protection: 3 x 1,500 kg CO2 = 4500 kg CO2

• With corrosion protection: 1 x 1,500 kg CO2 + 50 kg CO2 = 1550 kg CO2

The 2,950 kg of CO2 saved correspond to 24,000 kilometres of car travel, for example. To neutralise these emissions, 300 trees would be needed.

coefficient, resistance to chemical or mechanical loads or colouring.

The question of whether a solvent-based or water-based coating is used

One tonne of bolts: a practical example

the amount of solvent used in the coating and on the other hand to the

The concrete CO2 savings potential can be shown using the example of

energy consumption in the application process. In a direct comparison,

one tonne of bolts. For a more precise calculation of the positive effects

the solvent-based systems can represent the more environmentally

of such a coating, different zinc flake systems - both solvent-based and

friendly option based on the parameters mentioned.

water-based - are used and compared with regard to their raw material

Suitable corrosion protection, as offered by Dörken, makes a major

requirements and the manufacturing process.

contribution to the sustainability of steel components. The longer service

If a tonne of bolts is coated with a zinc flake system, about 50 kg of

life of a coated component means that emissions can be reduced by up

further CO2 emissions are produced in the process. This value accounts

to a third compared to uncoated components. Dörken therefore works

for about three percent of the total emissions for one tonne of steel.

closely with a wide range of partners along the entire value chain and

The applied corrosion protection extends the life of the product up to

offers customised solutions for many areas of application - preferably

three times, depending on the application.

with more sustainable products, always with a lasting effect.

also makes a difference to CO2 emissions. This is due on the one hand to

© Dörken

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N. 81 - MAY/JUNE 2023 - international PAINT&COATING magazine

eosmarketing.it

Your partner for green chemical processes Chemtec’s mission is to update tradition.

Our revolutionary chemicals are designed to have a very limited environmental impact, to reduce consumption of resources and for a greater operational simplicity.

With Chemtec technologies you can replace zinc&iron phosphate:

PRONORTEC multi-metal surface treatment

TORAN 3® multi-metal pre-treatment process

WASTE WATER TREATMENT SYSTEMS

www.chemtecitalia.it

© ipcm

O.M.F.A. Srl is one of the most important metalworking companies in the Treviso furniture district.

FOCUS ON TECHNOLOGY

At O.M.F.A., Insourcing the Coating Process Closes the Circle of Quality Control on Metal Furniture Components Monica Fumagalli, ipcm®

O.M.F.A. Srl, a metalworking company serving the furniture district in the area around Treviso (Italy), internalised its metal furniture components’ powder coating process about one year ago to achieve complete control of its production. As a partner, it chose plant manufacturer IMEL (Codroipo, Udine, Italy), which also integrated the line with its i4paintshop digital management system.

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FOCUS ON TECHNOLOGY

O

ne of the best-known manufacturing districts of the Italian furniture industry lies in the area around Treviso, in the Veneto region: some of the most

famous furnishing producers were established and developed here at the end of World War II. Due to the fluctuating economic trends that have been affecting the entire manufacturing industry, however, this sector is now going through a phase of slow growth, which is also affecting its suppliers of metal components. “Only those with solid business foundations have been able to weather the recent economic downturns unscathed,” says Sergio Soldan, key-account manager at O.M.F.A. Srl, a metalworking company based in Farra di Soligo

© IMEL Spa

(Treviso) and specialising in the fabrication and surface finishing of furniture components. “We built such foundations with the constancy and know-how typical of the inhabitants of our region and with an entrepreneurial vision that always leads us to invest most of our profits in the growth of our company.

“Along with these, another aspect that we consider fundamental is respect for employees, customers, and suppliers. Being able to create and maintain a relationship of mutual trust with all these three resources is truly crucial. This is the reason why, when we decided to insource our powder coating processes in the framework of a workflow optimisation project, we turned to IMEL Spa (Codroipo, Udine), which has been specialising in the design and construction of surface treatment plants since 1964. We were already familiar with the anodising process, having integrated it into our production at a particular stage

© ipcm

in our history, but we were completely lacking in coating skills.

Therefore, we were looking for a partner that would support us even after the start-up of our machine. Moreover, precisely to simplify the management of this process, we also immediately integrated the i4paintshop 4.0 software package developed by this company in 2018.”

From the repair of boilers to the production of metal fabrications: craftsmanship as a key for success Like many other companies in the Treviso district, O.M.F.A. (Officine Meccaniche Fratelli Antoniazzi) is of humble origins.

“My grandfather set up a blacksmith’s business in Pieve di Soligo, repairing anything from wagon wheels to copper boilers to locks,” says company owner Roberto Antoniazzi.

“His three sons ran the business during the economic boom

© ipcm

years, expanding it and opening a repair shop for bicycles and motor scooters. At the same time, a few steps away from

From top to bottom: the coating system designed and installed by IMEL Spa that has been in operation since May 2022; the one-rail overhead conveyor supplied by Futura Convogliatori Aerei; the spray pre-treatment tunnel.

international PAINT&COATING magazine - MAY/JUNE 2023 - N. 81

33

their workshop, what was soon to become the largest furniture factory in the area, Mobilificio Baseggio, was opened. My father and his brothers thus began to receive orders for metal furniture components, which soon became their company’s core business.

Over the following years, production expanded further with the integration of new processes such as aluminium anodic oxidation, which few suppliers in the area offered, and in different sectors, including the production of bicycle hinges and frames, for the surface treatment of which the company had to equip itself with a barrel galvanising plant, a process that we still carry out today in our factory.”

At one of the most delicate economic times, that of the launch of the Euro in 2002, O.M.F.A., which was rapidly expanding, decided to take a crucial step for its growth and moved to a new building © ipcm

that covered 6500 m2, an area more than double the size of the previous one. “Our last major investment, which was strategic to insource our coating processes,” adds Antoniazzi, “was the acquisition of a second 3700 m2-wide hall in October 2021, in which we organised our coating, storage, packaging, and shipping department. Today we employ 62 people in total: our workforce has increased fivefold since the late 1980s.”

The insourcing of the coating phase: a difficult choice Insourcing coating processes is never an easy choice: whereas it streamlines the production flow and gives greater control over the quality of applied finishes, it also means managing a “production within the production”, i.e. a full-fledged line integrating different technical and production structures within the larger and, in most cases, already established general production cycle. © ipcm

“However,” emphasises Soldan, “we could no longer rely on the four coating contractors we used to turn to. Orders were becoming more and more numerous and we were no longer able to meet delivery times due to external delays. As mentioned, we had no experience in the coating field, but we were aware that such a situation could not continue any longer due to customer dissatisfaction. We had to close the circle of quality control by insourcing even the last operation we were outsourcing, investing in a plant capable of meeting all our customers’ needs. And we found it in IMEL’s solution.”

From top to bottom: The 3-column demineraliser with ion exchange resins.

The control PLC’s display with the layout of the coating plant.

© ipcm

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The access area to the gas heating unit connected to the dual-function oven.

FOCUS ON TECHNOLOGY

© ipcm

PASSION FOR MASKING SOLUTIONS www.global-mask.com

WHEELS

The inside of the oven: on the left, the workpieces drying after pre-treatment and, on the right, the coated workpieces in the curing phase.

A sound coating system

powders after application at 180 °C for 33 minutes.

Started in May 2022, the new coating line treats

Inside the oven, the conveyor has a U-shaped

components made of carbon steel and, to a lesser

layout to handle these two delicate heating phases.”

extent, aluminium. “Our production flow does not

Powder application takes place in a booth supplied

include standard processing phases,” indicates

by Gema, equipped with 4 guns per side + 2 manual

Soldan, “because each product is specially co-

guns for pre and post-finishing and a quick colour

designed with our customers. Our plant can process

change system. It also has a part shape detection

parts with a maximum size of 1500x3000x500 mm.

system for guns and reciprocators automatic control

Loading and unloading are done manually on the

and OptiSpray dense phase pumps to achieve the

load bars (with a maximum capacity of 150 kg each)

best application quality and maximum savings in

of the one-rail overhead conveyor installed by Futura

powder consumption.

Convogliatori Aerei Srl (Robecco Pavese, Pavia, Italy),

“We currently carry out seven colour changes per

operating with a continuous flow, a speed of 1.5 m/

shift. The powder recovery system with an ultrasonic

min, and a hanging pitch of 400 mm.”

vibrating screen enables us to carry out a colour

Carlo Salvadori, a founding partner of IMEL,

change operation in about 10 minutes,” explains

describes: “We supplied O.M.F.A. with a plant

Soldan. “In the factory’s area adjacent to the coating

consisting of a spray pre-treatment tunnel

department, we have installed an automatic powder

performing a phosphodegreasing stage, two mains

box warehouse for optimised colour management.

water rinses, a demineralised water rinse, and a

Every day, we pick up the colours that are going to

no-rinse nanotechnology pre-treatment process

be used the next day, getting ahead of the schedule

and a single overhead oven for both the drying of

and avoiding the risk of having to interrupt work due

parts after pre-treatment at 110 °C and the curing of

to any kind of storage issues.”

CUSTOM

STANDARD

The Gema OptiSpray pumps.

The Gema powder coating booth is equipped with eight automatic guns, two manual guns for pre and post touch-up, and an automatic part shape detection system.

i4paintshop: a user-friendly 4.0 management system

Conclusions

The 4.0 management system installed on O.M.F.A.’s plant consists of

“By insourcing our coating operations,” concludes Antoniazzi, “we are

a series of digital modules that guarantee complete part traceability

now able to complete our production cycle in the shortest possible

and processing of consumption data. “Comprehensive monitoring of

time, thus also dramatically reducing our delivery times and managing

the coating process is essential in terms of management and finishing

our process steps in a simple and user-friendly way, thanks to the

quality,” notes Soldan. “We can obtain data on consumption (gas, water,

i4paintshop package. We now only outsource the painting of oversized

electricity, compressed air) and production times and volumes with one

parts that exceed the maximum dimension of our plant. In addition to

click, thanks to the traceability of each load bar. We can also manage the

our optimised production flow, customers who visit our factory are very

preventive maintenance of individual devices through a smart calendar

impressed by the tidiness and cleanliness of our departments, including

based on the operating hours of each system component, the extraction

the coating one, which has been in operation for a year now and is still

of routine maintenance schedules on a daily, weekly, and monthly basis,

as spotless as if it were the first day. This is another important aspect to

and the self-learning of the system. The entire plant documentation

take into account if we want to retain customers and confirm ourselves

is available in digital format and it can be accessed via a browser or a

as one of the most competitive companies in our sector. We found

mobile app.”

the same approach to customer satisfaction in IMEL: before choosing

“With this system, we also provided O.M.F.A. with a direct connection to

them as a supplier, we visited their factory and got to know their highly

our assistance service,” states Salvadori. “In fact, it is possible to directly

professional staff, their long-standing history, and their smart approach

access Service-Imel, structured for booking an intervention according to

to the market. In the end, this company proved to be the best choice

various priority levels and checking the progress of each request in real-

also with a view to the future, for a partnership that is hopefully going to

time and the person responsible for it.”

continue for as long as possible.”

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50 www.gemapowdercoating.com

YEARS

First gun with integrated high voltage cascade 1973 - 2023

Gema Europe Srl | Via Goldoni, 29 20090 Trezzano s/N | Italy T +39 02 48 400 486 F +39 02 48 400 874

© Estrallum

Estrallum Srl specialises in the design, machining, and finishing of aluminium components with a high aesthetic and functional quality.

FOCUS ON TECHNOLOGY

The Added Value of Estrallum’s High-Quality Aluminium Components: Sustainable Co-Design and Environmentally Friendly Pre-Treatment Monica Fumagalli, ipcm®

Estrallum Srl has been designing, machining, and finishing aluminium components with high aesthetic quality for forty-five years. It has based its development on three key elements: the opportunities for co-design and the environmental sustainability of aluminium, combined in what the company calls “Eco Co-Design”, and the reduction of the environmental impact of its production processes, with a particular focus on pre-treatment prior to coating, from which it has eliminated the use of the most polluting chemicals thanks to its partnership with Condoroil Chemical.

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FOCUS ON TECHNOLOGY

A

requirement to differentiate from the competition, being able

A forty-five-year history in the extruded aluminium components

s sustainability is increasingly emerging as an indispensable to assess the environmental impact of a product’s life, and

Founded on 5 May 1978, Estrallum started manufacturing kitchen and

particularly its end of life, already during its design phase has become

oven front panels from aluminium sheets, then immediately expanded

an important added value in today’s market. This is the basis of the

its business to include the manufacturing of hinges, handles, and posts

corporate philosophy of Estrallum Srl, a company headquartered in

made from extrusions and subjected to anodizing. “We have managed

Solaro (Milan, Italy) and specialising in the production of high-quality

to create an efficient corporate structure,” says Pier Luigi Frosini,

anodised and powder-coated aluminium components for various

“which in turn has allowed us to enter more and more the household

sectors, especially that of household appliances. It is currently managed

appliances sector, our core business, specialising in the production and

by Pier Luigi Frosini together with his two children, Chiara and Giorgio.

finishing of handles for refrigerators and oven doors, but also aluminium

“The message we would like to convey,” says Pier Luigi Frosini, the

extrusions for various accessories. Thanks to the experience gained,

firm’s founder and current president, “is that nowadays full customer

we have manufactured some parts for the automotive sector and we

satisfaction is achieved with products capable of meeting not only

believe we have all the prerequisites to enter the furniture sector as

quality but also environmental sustainability requirements. We were

well. This is our next short-term target.”

among the first companies that began to assess this aspect right

“Our current objective is to diversify production as much as possible in

from the component design stage. At the same time, each step of our

a “glocal” perspective,” explains Estrallum sales manager Giorgio Frosini.

production process is carefully controlled in line with precise quality

“In fact, we still maintain a strong link with the area where our firm was

management standards.”

established and developed and where our activity is recognised by all

Estrallum shares the importance placed on the environmental impact

major industry players, but at the same time we take advantage of the

of processes and the meticulous attention with which it carries out

possibilities that globalisation offers us at an international level. We are

controls with its long-standing supplier of pre-treatment chemicals,

on the right track, since we already export 80% of our production. Over

Condoroil Chemical Srl (Casale Litta, Varese, Italy), a company that has

the past year, we have also initiated contacts with some manufacturers

been researching, developing, and producing chemical products and

operating in different sectors, such as, for example, those of coffee

recovery and regeneration units for the surface treatment of metals for

machines, garden furniture, and medical instruments.”

over fifty years. In particular, Condoroil supplies Estrallum with chemicals

“One of the investments that simplified process control also with a view

for degreasing, etching, and passivating aluminium surfaces.

to sustainability,” explains Estrallum administrative manager Chiara

© Estrallum

© Estrallum

Some of the packaging types that Estrallum requires from its suppliers for the delivery of bars.

Bars with different lengths are cut to size in batches with automatic-feeding machines.

international PAINT&COATING magazine - MAY/JUNE 2023 - N. 81

39

Frosini, “was the integration of all our departments, previously located at two sites, into a new building in 2002. On the ground floor, this houses our machining systems, anodizing plant, assembly stations, and warehouse and, on the upper floor, our pre-treatment and powder coating plants, which we have been using in addition to the anodising one since 1984 to offer a wider range of finishes. We also produce the tooling for manufacturing our components in-house. The only operation we outsource is polishing after machining and before anodising.”

Reducing carbon footprint right from design “One of the processes that has always characterised our company is that of co-design,” states Luigi Aiello, Technical and Quality manager at Estrallum. “Indeed, by developing projects together with customers, we offer them two benefits. One is economic: by involving our technical team from the very beginning (early involvement), we can

© Estrallum

study the product in the most economical and advantageous way for the customer. The other is environmental: each component is analysed down to the smallest detail in order to calculate the minimum thickness required and thus reduce material waste, but also so that it can be disassembled and recycled once it reaches the end of its life. We use high-quality aluminium alloys purchased from leading companies. We can also use metal consisting of 75% post-consumer recycled aluminium. The lightening of some sections and the coupling of components in different materials without the use of silicone or adhesives also ensure sustainable product disposal.”

The same green vision characterises the surface treatments. “The chemicals for anodising are nickel-free, whereas for pre-treatment we have been carrying out passivation with chromium-free substances already for a long time.” Finally, to reduce energy consumption, Estrallum installed a photovoltaic system in 2012 that produces 138,000 kWh/year, of which 96,000 kWh are for self-consumption.

© Estrallum

Attention to detail in manufacturing “After the co-design phase and the extruder’s confirmation of the project’s feasibility,” indicates Aiello, “we also analyse the type of packaging in which we would like to receive the profiles, in order to avoid damages during the bars cutting operation, which can be up to 5 m long and weigh up to 30 kg. We also design the required cropping

From top to bottom: - The handle bending process takes place with tooling designed inhouse by Estrallum - The 26 tanks for anodising aluminium components.

- The loading of each component on the titanium hooks is designed to optimise the distribution of parts along the anodising line.

© ipcm

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N. 81 - MAY/JUNE 2023 - international PAINT&COATING magazine

FOCUS ON TECHNOLOGY

Efficient and reliable solutions for surface coating since 1988.

electrostatic systems for liquid painting © Estrallum

The dedicated jigs for anodising operation.

electrostatic systems and spraying booths for powder coating tools, assembly equipment, and control jigs in-house.”

Subsequently, parts, which once cut to dimensions usually do not exceed 600 mm, can be subjected to bending if required, drilling, and

pneumatic systems for high-, medium-, and low-pressure painting

threading with multiple heads via a rotary transfer machine.

“Currently, we outsource the brushing and polishing operations to external companies to eliminate the risk of contaminating environments that must remain dust-free, such as the anodising and

IR and UV drying systems

coating departments.” All components are 100% tested. “After each stage, be it a machining or surface treatment operation, we carry out thorough checks to avoid any non-conformities at the end of the cycle. We also identify the best final packaging to meet customer

robot and reciprocators

requirements in terms of dimensions. Furthermore, we set the most effective coating parameters to achieve maximum performance.”

Hardness, strength, and aesthetics: the characteristics of Estrallum’s finishings The anodising plant consists of 26 tanks, each with a capacity of 2500 litres. “The parts reach the anodising department after external polishing or brushing. The loading of each component on the titanium hooks is designed to optimise the distribution of parts

www.cmspray.it

eosmarketing.it

along the line. In the last few years, this has allowed us to significantly

CM SPRAY s.r.l.

© Estrallum

Overview of the powder coating plant.

increase the productivity of our plant, which can handle a very high

reduced footprint. In turn, this helps reduce water consumption for

quantity of parts. In the same way, we calculate the components to be

rinsing and increase process sustainability. The operating temperature

loaded onto the overhead conveyor of the coating system, obviously

ranges from 20 to 35 °C. This is followed by two rinses and the no-rinse

taking into account the strength of the hook and the shape of the part,

chrome-free nanotechnology passivation stage.”

to define the hourly output and the cost of coating.” After anodising, the

When it comes to developing its chemicals, Condoroil shares the

parts are dried and left to cool at room temperature for about an hour.

same vision as Estrallum for sustainable production. Indeed, as

They are then unhooked, checked, and arranged on the transport units

Giroldi confirms, “For many years now, Condoroil has been striving to

taking them to the assembly department.

guarantee excellent results, especially in the field of aluminium, while

Pre-treatment chemicals tailored to the needs of Estrallum

always taking into great consideration the environmental impact of the chemical solutions developed and, especially in the last few years, the reduction of energy costs. Condorcoat AL 12 is a proven product for

The coating phase takes place in a pre-treatment 4-stage spray tunnel

the passivation of aluminium, one of our company’s flagships. Descal P

using chemicals supplied by Condoroil Chemical. As Condoroil technical

96, on the other hand, is a newer product, but it has enabled Estrallum

sales expert Marco Giroldi explains, “We supply Estrallum with two

to achieve significant results and is also finding successful application

solutions tailored to its needs: Descal P 96, which is dispensed with an

in the automotive sector. It is specifically designed for spray systems

automatic dosing pump and combines two key stages for the pre-

as it contains special surfactants that form very little foam even at low

treatment of aluminium, i.e. degreasing and acid-etching, into one

working temperatures.”

operation, and Condorcoat AL 12 for final nanotechnology conversion. degreasing and etching, as well as allowing the two operations to be

The advantages of a user-friendly pre-treatment solution

carried out in a single pass, thus enabling the use of a tunnel with a

“Thanks to these products,” notes Aiello, “our acetic salt spray test

The organic acids in the Descal P 96 product guarantee optimal

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N. 81 - MAY/JUNE 2023 - international PAINT&COATING magazine

FOCUS ON TECHNOLOGY

© ipcm

© ipcm

© Estrallum

From left to right: The loading of components to be coated; Parts exiting the pre-treatment tunnel; Epoxy-polyester powder application.

results far exceed 1000 hours. We first contacted Condoroil several

A consolidated partnership also for constant control

years ago because one of our major customers required high levels

Careful management of its quality system is another of the Estrallum

of corrosion resistance, verified through neutral salt spray tests. The

team’s prerogatives. “We have been ISO 9001 certified since 2005,” says

results obtained with its parts were such that, at the suggestion of its

Aiello, “and we have been following the automotive PPAP procedures

technical team, we decided to raise the bar and reach 1000 hours with

for more than six years now, which guarantees we manufacture our

more aggressive tests, such as those carried out with acetic acid. Some

products according to the characteristics and times defined with each

customers demand around 400-hour salt spray resistance values, but

customer. From the receipt of extrusion up to the final shipment, we

we only stop our tests once we have reached 1000 hours. Aluminium

perform a thorough inspection after each production step by comparing

passivation performed with Condorcoat AL 12 improves paint adhesion

the produced components with jigs designed and manufactured by

and corrosion resistance, as well as having the advantage of operating

us. What truly enables us to obtain high-quality finishes, however, are

at room temperature. For carrying out alkaline degreasing, acid etching,

the checks we carry out in the pre-treatment tanks in cooperation with

and nanotechnology conversion, Condoroil found this solution to make

Condoroil.”

us competitive in the market, even against competitors equipped with

“For about twenty years now,” explains Giroldi, “we have been sampling

much longer pre-treatment lines: despite the limited length of our

products from the pre-treatment tanks monthly for testing in our

tunnel, we can etch 1 g/m2, which is an excellent result.”

laboratory, whereas the Estrallum team carries out daily pH checks.”

After pre-treatment, the conveyor, moving at a speed of 1 m/min,

“In addition to the daily pH analysis, in which we compare our results

takes the parts, which can be up to 1300 mm long, to the pre-drying

with the data sent by the Condoroil lab,” emphasises Aiello, “we carry out

station with compressed air and then to the drying oven, before epoxy-

cross-cut adhesion, hardness, and thickness tests (the latter must be in

polyester powders are applied and finally cured at 200 °C for 18 min.

a range between 60 and 120 µm) on the parts manufactured the day

This is followed by cooling and manual unloading, 100% inspection,

before. On our coating plant, we also perform a GRENT test once a year,

packaging, and shipping.

which consists of checking the temperature curve of the curing oven.”

international PAINT&COATING magazine - MAY/JUNE 2023 - N. 81

43

Conclusions

which is why every single phase of our production cycle is subjected

“When we first contacted the Condoroil Chemical team, we had to

to careful controls and detailed analyses, not only intending to deliver

solve a poor salt spray resistance issue,” summarises Pier Luigi Frosini,

products in line with the reputation that Estrallum has been building

“and its response was more than satisfactory. Over the years, we have

over the last forty-five years but also to assess the cost of each

then strengthened our relationship with this company because it is

operation. We keep under control all the main stages of our workflow,

developing its products in an increasingly sustainable way, adapting

from cutting to machining, from anodising to coating, in terms of

to the new regulations introduced from time to time. Our focus on

both hourly output and cost, thanks to our well-established quality

sustainability unites us, as does our attention to customer needs –

management system.”

© Estrallum

Handles in different colours produced by Estrallum.

© Estrallum

© ipcm

Coated parts undergoing cooling.

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N. 81 - MAY/JUNE 2023 - international PAINT&COATING magazine

The Frosini family with some employees: from left to right, Federica di Meo, Chiara Frosini, Paolo Madile, Pier Luigi Frosini, Luigi Aiello, and Giorgio Frosini.

BRAND-NEW

Dörken Draws Positive Conclusion After Fastener Fair Global 2023 Fastener Fair Global 2023 was a great success for Dörken, which presented its new topcoat DELTA-PROTEKT® TC 502 GZ.

T

he German manufacturer of zinc flake systems for corrosion

success story of the cooperation with Peiner Umformtechnik, a supplier

protection Dörken has expressed satisfaction for the outcome of

of fasteners for wind turbines, also attracted the attention of the visitors.

the latest edition of Fastener Fair Global, the international trade

The company provided hot-dip galvanised bolt with an additional

fair dedicated to manufacturers, wholesalers, distributors and suppliers

topcoat to keep the friction values stable regardless of weather

of fastening and fixing technology.

conditions. Finally, another big topic was the partnership with EJOT and

The event provided an excellent opportunity to talk about new as well

WMV, that came together in search of a new coating option for micro

as proven solutions and to exchange ideas with other professionals and

screws. WMV was involved in this project as a specialist for surface

experts, with almost 1,000 companies from the industry presenting their

coating plants, while DÖRKEN as a supplier of component-specific

products, machines, tools and related services.

lacquer. Together, after years of work, they managed to develop an

The company presented advanced technologies and innovations

innovative coating process for small parts.

that make a significant contribution to the protection of surfaces and

“We were very pleased to finally be back at Fastener Fair Global after

materials, such as the new topcoat DELTA-PROTEKT® TC 502 GZ: a

four years. For us at DÖRKEN, the fair was exceptionally good. From

hybrid solution with excellent friction coefficient properties for use

the preparation to the last minute, everything worked flawlessly. But

on metric components that provides a very narrow friction coefficient

most important were all the interesting and insightful conversations we

window, is free of polytetrafluoroethylene (PTFE) and has a silver finish.

had with current and potentially new partners,” has declared Christos

Furthermore, the experts from Dörken – including the Key Account

Tselebidis, the vice-president of sales for the Industrial Coatings division

Managers René Rother and Klaus Gradtke – hosted interesting

of Dörken.

discussions with visitors who were informed about the latest developments in the field of corrosion protection. In addition, the

For further information: www.doerken.com

© Dörken

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N. 81 - MAY/JUNE 2023 - international PAINT&COATING magazine

BRAND-NEW

Start-up Nalucoat Aims at Eliminating Polluting Treatments in the Design Industry Nalucoat aims at implementing a green way to finish surfaces that allows manufacturing industrial design products without harming people or the environment. no longer recyclable. The technology adopted by

© Nalucoat

Nalucoat, on the other hand, consists of a cold vitrification process that, together with the use of aluminium, a recyclable material, allows combining aesthetics and environmental sustainability. The result is in fact a very thin aesthetic and functional coating based on silicon dioxide, which is abundant in nature.

Nanoprom has already successfully tested its technologies in a whole range of challenging applications, from ships to satellites. With the Nalucoat process, based on the Nanoprom Chemicals’ patent granted exclusively to Nalucoat, the aim is now to revolutionise the field of cosmetic treatments in industrial design, offering a green alternative to current methods with a high

N

environmental and health impact. Furthermore, alucoat is the name of a new green treatment

unlike traditional treatments, which require invasive

for finishing materials, but also of a benefit

sub-processes generating several surface defects,

corporation start-up established through

the Nalucoat process reduces waste by up to 50%

the combination of the know-how of two Italian

compared with current production technologies,

companies, Leba 1974 and Nanoprom Chemicals

guaranteeing cost-effective performance.

Group, specialising respectively in aluminium finishing

Companies are now called upon to adopt virtuous

treatments and in cold vitrification of surfaces with a

behaviours in order to generate new business

process now used by several aerospace companies

models and activate supply chains that can make

and Formula 1 teams.

sustainability a lever for growth and development, in

This innovative start-up was created in 2023 between

line with the global sustainable development goals

S. Antonino di Casalgrande (Reggio Emilia) and San

of the 2030 Agenda. Through a process that is truly

Genesio ed Uniti (Pavia) by those two companies’

respectful of man and the environment, Nalucoat

founders, Gian Luca Falleti and Ivan Bonvini, joined

reduces the carbon footprint of operations and,

by researcher Claudio Mingazzini, with the precise

thanks to the recyclability of the components on

aim of eliminating the use of chromium, one of

which it is applied, helps the companies that use it to

the most dangerous of pollutants, from surface

transition to a circular economy model.

COMPLETE SOLUTIONS for

HANGING and

MASKING

finishing treatments. Indeed, chrome plating is applied to countless everyday objects to improve their aesthetics, but it makes the treated materials

For further information: www.nalucoat.it

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international PAINT&COATING magazine - MAY/JUNE 2023 - N. 81

49

6

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52 BRAND NEW IT’S COATED 54 HOW BMW 3.0 CSL: Paintwork Artistry from Landshut in the Name of the Most Powerful Letter in the World

57 BRAND NEW ON TECHNOLOGY 58 FOCUS Painstaking Search for Excellence on a Product that Exceeds the Boundaries of the Imaginable: Ferrari Confirms the Choice of Powder Primers for All Its Vehicles

ON TECHNOLOGY 66 FOCUS MAK Chooses a New Automated Coating Plant for the Three-Coat Finishing of its Aluminium Alloy Wheels for the Aftermarket Sector

IT’S COATED 74 HOW Long-Standing Porsche Lover

Has a Colour Named After Him

78 ADVANCEMENTS How to Specify E-coats More Sustainably

ON TECHNOLOGY 82 FOCUS Resource-saving Coating Technology for Wheels of Rail Vehicles

BREAKTHROUGH 86 RESEARCH Electric Vehicle Batteries Could Get Big Boost with New Polymer Coating

STORIES 88 SUCCESS Expansion of E-Component Production in Leipzig: First Cell Coating Line for Battery Modules Goes on Stream

ON TECHNOLOGY 90 FOCUS L.T.E. Lift Truck Equipment: Two

Industry 4.0-Oriented Automatic Coating Plants to Optimise Production, Achieve High Quality, and Reduce Consumption

ON TECHNOLOGY 98 FOCUS MANTA Group: Flexibility and Speed of Production Guaranteed by Automation and Digitalisation of the Commercial Vehicle Engines Coating Phase

STORIES 106 SUCCESS Unparalleled Efficiency with Paint Shop and Final Assembly Systems for Electric Vehicles from Dürr

WITHIN SURFACES 110 ART Alfa Romeo F1 Team Stake x BOOGIE: a New Artistic Project to Bring Fans Closer to the Team

STORIES 112 SUCCESS Revamping a ZLD Waste Water Treatment Plant

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BRAND-NEW

SPECIAL ISSUE ON AUTOMOTIVE

AkzoNobel Powder Coatings Adds Colour, Style and Performance to Brake Calliper Design Interpon launched a new range of powder coatings, Interpon A1243, to protect and enhance brake callipers.

C

olour expertise is at the heart of a new range of Interpon A1243

OEMs. Bespoke colours can also be made to order to complement body

powder coatings to protect and enhance brake callipers, giving

colours and trim.

traditional and Electric Vehicle (EV) automotive manufacturers

In terms of performance, the single coat Interpon A1243 combines

the style they demand matched with superior levels of mechanical

superior mechanical properties with excellent protection against

performance for life out on the road.

corrosion, chemicals (e.g. gasoline, brake fluid etc), and brake dust,

With automotive OEMs leaning towards larger wheels for certain models

keeping the callipers easier to clean and looking better for longer. The

and a more ‘open’ design, brake callipers have become style accessories

powder coating also offers resistance to chips and general wear and

in their own right. Accent colours and finishes – especially bright yellows

tear, as well as specific protection against UV light that stems from the

and reds but also electric blues and greens with metallic pigments and

wheels’ size and design.

other special effects – are particularly on trend, and especially popular

Gustavo Carvalho, Automotive Global Segment Director of AkzoNobel

for more sporting brands.

Powder Coatings says that the innovation behind the new range is

Manufacturers of EVs – which require larger and more heavy-duty brake

significant: “OEMs demand high performance and protection against

callipers and associated components to accommodate the vehicle’s

brake dust and harsh chemicals and oils that brake callipers are

increased power – are also turning this to their advantage, making the

subjected to. That’s standard. But what they also want is colour and

callipers a feature of their design. This is especially true of the higher-

style, and that’s where our true innovation and experience counts,

end models, where the colours, finishes and styles of the brake callipers

working in partnership with the OEMs and going the extra mile with

are chosen to be in harmony with the overall design of the car, and offer

coatings that combine exceptional appearance with the tough, durable

a seamless connection with the brand.

finish for life on the road.”

Colours within the Interpon A1243 powder coatings range are driven by and matched to the designs and style demanded by automotive

© David Shao/Shutterstock

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For further information: https://automotive.interpon.com

BRAND-NEW Custom-built painting installations Macchine e impianti realizzati su misura

Shot blasting booths Cabine di sabbiatura

Washing tunnels Tunnel di lavaggio

© Evonik

Evonik Introduced the New TEGO® Flow 380 Levelling Agent The new product from Evonik has been specifically developed for high-quality industrial and automotive clearcoats.

T

Liquid painting installations

Impianti di verniciatura a liquido

Powder painting booths

Cabine di verniciatura a polvere

he Coating Additives business line of the German company Evonik has expanded its TEGO® Flow series with a new

efficient polyacrylate-based levelling agent that provides

anti-popping properties and good compatibility for solvent-borne clearcoats for the automotive and general industrial sectors.

Very easy to process due to its low viscosity, the new product from Evonik consists of 100 percent active matter content and is based on

Curing ovens

Forni di cottura

a unique polymer technology. So, it is particularly easy to incorporate into the formulation. TEGO Flow 380 also ensures excellent recoatability and shows excellent performance even at low dosages, besides emitting little VOC (Volatile Organic Compounds).

“The key here is controlled incompatibility. With TEGO Flow 380,

Eurotherm S.p.A. T +39 011 98 23 500 | M info@eurotherm.eu

we have balanced the incompatibility well, resulting in an excellent performance. Furthermore, it can be used directly as dilution is not necessary,” has explained Maximilian Morin, the head of the Industrial & Transportation Coatings market segment of Evonik.

For further information: www.coating-additives.com

Eurotherm Oberflächentechnik GmbH T +49-7571-92795-10 | M germany@eurotherm.eu Eurotherm France S.A.S. T +33 (0) 7 89 37 56 88 | M france@eurotherm.eu Eurotherm Benelux T +33 (0) 6 47 44 96 27 | M dekergorlay@eurotherm.eu

www.eurotherm.eu

?

HOW IT’S COATED

SPECIAL ISSUE ON AUTOMOTIVE

BMW 3.0 CSL: Paintwork Artistry from Landshut in the Name of the Most Powerful Letter in the World Saskia Graser BMW Group – Landshut, Germany

saskia.graser@bmw.de

50 years – 50 vehicles: a limited small series marks the anniversary of BMW M GmbH. The exclusive design of the special model accents come from the German custom paint shop of the BMW Group plant in Landshut.

T

o mark its 50th anniversary, BMW M GmbH – the BMW Group’s

The Landshut plant is very familiar with special paint jobs like this.

motorsports subsidiary founded in 1972 – has unveiled the most

In addition to creating small-series and custom paintwork, more than

exclusive special model it has ever developed: the BMW 3.0 CSL

1,200 painted plastic outer panel sections come out of the plant in 40

(fuel consumption combined: 11.0 l/100 km; CO2 emissions combined:

standard and 200 custom colours every workday.

249 g/km WLTP). The small series, strictly limited to just 50 models, is

That adds up to around 273,000 components per year. Now, Landshut’s

inspired by the historic BMW 3.0 CSL – the “Batmobile” – from the early

custom paintwork expertise is also being showcased in the 50 BMW

1970s and features custom paintwork expertise from BMW Group

3.0 CSLs, including in the front and rear side panels, the roof and rear

Plant Landshut. Around 20 exterior components for the unmistakeable

spoilers, the front and rear bumpers, side-sills, bonnet, carbon-fibre roof

design of the special model will be refined by paint finishing specialists

and tailgate.

from Landshut. Several of the carbon-fibre reinforced plastic (CFRP)

The bonnet and roof – both made of CFRP – are manufactured in an

components are also manufactured in Landshut.

elaborate, highly specialised craft-scale process at BMW Group Plant

© BMW Group

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HOW IT’S COATED

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Landshut. Thanks to the high percentage of carbon fibre, the BMW CSL

The Landshut custom paint shop has developed a special process

3.0 boasts a power to weight ratio of just 2.9 kilograms/hp – an excellent

for such demanding tasks: the livery design is projected onto each

example of intelligent lightweight construction in a BMW M car that is in

component using a laser projector, so it precisely aligns with the next

a class of its own.

body element.

The result of 50 years of experience

The meticulous process of masking the lines between differentcoloured surfaces is carried out manually by specially trained experts

It is also clear from the outside that the BMW 3.0 CSL combines the very

following the laser projections. Up to eight customised contour films

best of five decades of motor racing expertise: its paintwork, in the style

and up to seven layers of paint are required for each component.

of classic race cars, sports the brand-defining M stripes, known as the

In addition to adding the M stripes, it is also the job of the Landshut

livery, in blue, dark blue and red, on an Alpine White solid base colour.

paint experts to position the “M Power” badge on the rear spoiler and

The livery stripes along the body trace the curvature of its surfaces to

the “50” on the roof.

great effect, reinforcing the Coupé’s powerful aesthetics. It was precisely

Even these details, which are so central to the appearance of the

these livery stripes that presented the biggest challenge in painting the

special model, are masked by hand. Unlike with the livery stripes, the

mounted parts.

Landshut experts do not expose any layers of paint, but, instead, reveal

“The transitions between the M stripes, from one component to the

the visible carbon fibre. This creates slight indentations in the surface –

next, had to be absolutely perfect. For example, the stripes on the side

so the high-tech material of the components can also be experienced

panel have to be at exactly the same height as on the door to make sure

haptically.

the optics are aligned. That takes a lot of painting know-how, individual

The individual exterior components of the BMW 3.0 CSL are assembled

experience and flair,” has explained Christian Koch, the project manager.

in an advanced craft workshop in Moosthenning, an external site

Unlike many other visually striking special editions, the stripes are not

operated by BMW Group Plant Dingolfing.

applied using film, but they are painted instead. Close coordination with

“We are proud that the craftsmanship and innovative spirit of our highly

the specialists at BMW Group Plant Dingolfing is also required – since

specialised paint finishing experts has once again helped create such

they apply the paint to the door, as well as to the vehicle body.

an exclusive special model as the BMW 3.0 CSL,” has declared Koch.

© BMW Group

© BMW Group

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Products, networking, business and training.

under the patronage of:

BRAND-NEW

SPECIAL ISSUE ON AUTOMOTIVE

BASF Named Supplier of the Year 2022

by General Motors BASF has received its 16th award from General Motors, celebrating global suppliers that distinguish themselves by exceeding requirements.

T

he Coatings division of BASF has recently announced that General

and logistics. General Motors announced the winners during the 31st

Motors has named the company Supplier of the Year 2022.

ceremony, held in San Antonio (Texas, U.S.A.) In total, 121 suppliers from

The annual award celebrates global suppliers that distinguish

over fifteen countries have been recognised during the event.

themselves by exceeding high-quality requirements and providing

“We are thrilled to recognise these outstanding suppliers after yet

innovative technologies for the automotive industry. It is the 16th time

another challenging year in the automotive industry. They overcame

that BASF has received the prize.

countless obstacles and exemplified what it means to be resilient,

“We are humbled and honoured to be recognised by our great

resourceful and determined. Beyond that, these suppliers demonstrated

strategic partner, General Motors, with this award. It reflects decades of

their commitment to sustainable innovation and to driving advanced

collaboration and our strong partnership with General Motors to create

solutions in collaboration with our team,” has added Jeff Morrison, the

solutions for a sustainable future,” has proudly commented Jeffrey Jones,

vice president for the global purchasing and supply chain of General

the vice-president for automotive OEM Coatings of BASF.

Motors. “BASF is culturally aligned with us and supports our journey

Each year, the recipients of the award are selected by a global and

towards zero crashes, zero emissions and zero congestion.”

cross-functional team according to their performances in criteria such as product purchasing, manufacturing services, customer care

HIGH PERFORMANCE IN SMALL SPACE. C-Line

Wheel coating system • Highly automated coating • Fast cleaning & short color change • Compatible with IoT platform COATIFY wagner-group.com

For further information: www.basf.com

© Ferrari S.p.A.

The 296 GTB car proves that Ferrari’s three cornerstones of car development – performance, design, and driving thrills – can also be combined with electric mobility in a fascinating way.

FOCUS ON TECHNOLOGY

SPECIAL ISSUE ON AUTOMOTIVE

Painstaking Search for Excellence on a Product that Exceeds the Boundaries of the Imaginable: Ferrari Confirms the Choice of Powder Primers for All Its Vehicles Alessia Venturi, ipcm®

The word “competence”, the ability to take advantage of one’s knowledge, skills, and talents to cope with a task and achieve a goal, comes from the verb “to compete”. Competitiveness is in the DNA of Ferrari, the Italian pride in the sport and luxury car and motorsport sector, a company that gathers a multitude of different skills, knowledge, and talents in its Maranello factory to produce one thing only: excellence. Ferrari sets the trends and even when it makes maverick choices, it does so with one aim in mind: pushing the boundaries of design, performance, and fun. One of these counter-trend technological choices, which makes Ferrari unique in the automotive sector, is the use of powder coatings as primers for all its cars. As proof of the effectiveness of this solution, at the end of 2022 Ferrari carried out a complete upgrade of its powder coating automation, application, and supply systems with its long-standing technology partner Verind, a Dürr Group company.

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FOCUS ON TECHNOLOGY

“F

or me, the Ferrari brand has always embodied its founder’s

Powder primer: a unicum in the automotive world

spirit: continuous competitiveness in technological choices,

Bold design with daring and exclusive shapes forms the basis of a

products, and processes, not only on the track or in the

precise technological choice made by Ferrari: Maranello is the only

markets,” states Davide Abate, Ferrari Chief Technologies and

OEM plant in Italy to apply powder primers on all its car bodies.

Infrastructures Officer. “Racing is in Ferrari’s DNA, and this also and

This is certainly a counter-trend solution within the automotive

above all means striving for constant evolution and improvement

sector, as most OEMs are transitioning towards primerless systems.

through ever more daring technological challenges and an intrinsic

“This technological choice, however, relates precisely to our focus

desire to outperform ourselves. This is our approach to our cars, to

on Italian design and complex body shapes,” notes Davide Abate.

our infrastructure, and to our production processes.”

“Powder primers give us a competitive advantage because, thanks

Over the past three years, Ferrari’s investment plan has been

to the higher thicknesses achieved, we can design cars with complex

involving all business processes within the Maranello factory, with

geometries and including sheet metal fabrications and sections made

one fundamental rule: “Investing in what we know is going to make

with different moulding and bodywork technologies; metal sheets are

a difference for our customers,” explains Abate. “We have therefore

processed manually with handicraft, welding, and manual reworking

invested in our powertrain, body production, and coating departments

operations performed on their aluminium surfaces. To put it simply,

to further improve and increase the degree of car customisation we

powder primers enable us to give superior mechanical resistance

offer to customers. Needless to say, paintwork is a crucial element for

characteristics to low-height, sports cars that, by their very nature, are

us because, together with bodywork, it represents the final ‘dress’ of

more prone to pebble damage, but above all to guarantee a higher

a car, the embodiment of Ferrari’s three cornerstones: performance,

surface quality and uniformity, levelling out any surface irregularities

design, and driving pleasure. That is why one of our pillars of

caused by our peculiar production method. We thus create the

development is design – all-Italian design that generates particularly

perfect canvas on which to apply colour and any subsequent aesthetic

complex shapes that classic car makers, with much higher production

effects.”

volumes than ours, cannot afford to offer.”

© ipcm

The two new opposing Dürr robots in action.

© ipcm

Davide Abate, Ferrari Chief Technologies and Infrastructures Officer.

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SPECIAL ISSUE ON AUTOMOTIVE

© ipcm

Sustainability Of course, to achieve these results, the powder primers applied must be sprayed (on top of cataphoresis layers) with state-of-theart technology, guaranteeing perfect coverage of Ferrari’s complex-shaped bodies, uniform film distension, and high transfer efficiency to also meet the company’s sustainability goals.

This was the reason behind the most recent investment made within Ferrari’s paint shop for the technological upgrade of its powder primer feeding, automation, and spraying systems, with a Dürr booth featuring two opposing articulated robots that apply the primer on the exterior of bodies. The interiors are manually painted with electrostatic guns.

“We always work on two tracks: product and process,” says Davide Abate. “The investment realised in 2022 for the revamping of our powder coating plant was aimed at

The transfer efficiency of the EcoBell rotary atomiser.

optimising paint consumption for improved sustainability, reduced overspray, reduced © ipcm

need to dispose of special waste, and lightening of our cars through the application of more uniform paint layer thicknesses.

More generally, every technological choice that Ferrari makes is linked to guaranteeing the extreme performance degree of its product, and paintwork falls within this scope.”

“Another important element guiding our paintwork choices is the ‘Ferrari Forever’ concept,” explains Abate. “A unique feature of our cars is that they never reach obsolescence and disposal. The life cycle of a Ferrari is infinite and so must be the duration of its coating. This is the reason behind technical and process decisions including as follows: • Applying cataphoresis and black cosmetic coatings on all non-visible parts of the bodies; • Providing maximum corrosion resistance; • Guaranteeing maximum durability and colour retention.”

Primer application: the advantages gained with the new system are the same for all Ferrari car models.

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FOCUS ON TECHNOLOGY

The details of the investment

internal cascade system for better high-voltage adjustment. Finally, we

An epoxy-polyester primer is applied to the aluminium substrate of

completely rebuilt the powder management unit, the powder feeding

Ferrari car bodies, which provides greater mechanical and corrosion

circuit, and the colour change system, integrating dense phase pumps

resistance. The revamping project that was carried out in collaboration

and state-of-the-art filtering units. All these upgrades have resulted

with Verind, a company of the Dürr Group, involved the automation

in a significant increase in transfer efficiency and an average powder

and application devices as well as the primer feeding unit, handling

saving of 20% compared with the previous equipment. In addition,

two colours: ivory and light grey. “Specifically, we were interested in

the new paint feeding system has solved some powder management

improving the management of the high voltage charge of our spraying

problems due to these products’ sensitivity to temperature

equipment with a view to better transfer efficiency. At the same time,

fluctuations.”

we wanted to take as much advantage as possible from our existing

“The extraordinariness of this technological upgrade lied not only in

systems that were still well-functioning, updating strategic or obsolete

the results obtained but also in its implementation time,” states Abate.

components,” emphasises Davide Abate.

“In just two weeks, during the Christmas break in December 2022 to

“Indeed, we kept the existing Dürr booth and the robots’ seventh axes,”

be precise, we rebuilt all the plants, reprogrammed the systems, and

explains Verind general manager Alessandro Molè. “We replaced the

approved thirteen car models to be ready to start again on 9 January

two articulated robots, which had reached technological obsolescence

without any consequences on production. Normally, it takes up to

having been installed in 2000, with latest generation equipment and

seven days to approve one model and its paintwork: at the Maranello

the electrostatic rotary bells with new EcoBell Powder 2 devices with an

plant, this is the first step in guaranteeing the delivery date of a car.

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

SPECIAL ISSUE ON AUTOMOTIVE

© Verind

From left to right:

considering that there are no test mules at this plant. It was like an

- The paint management unit installed by Verind, a Dürr Group company.

open heart surgery intervention, where the strengths and expertise of

- The applied powder primer ensures perfect coverage of the aluminium body and creates an ideal canvas for the subsequent application of the finishing layers.

- The Dürr EcoBell Powder 2 rotary atomiser.

both parties truly made a difference.”

Lower paint consumption, greater thickness uniformity, and better surface coverage “This new technological infrastructure and the greater transfer efficiency it provides have resulted not only in powder savings but also in more homogenous coverage of all body sections and less variability in thicknesses,” states Davide Abate. “With the old equipment we

With a production of 60 vehicles per day, losing even two days of work

worked with a range between 70 and 100 microns, whereas now it is

could be risky. This installation work was a masterpiece, the result of a

between 90 and 100 microns. We have also noted greater thickness

long-standing technological partnership with Verind and of significant

consistency between one body and another and between one part of

preparation on the part of both.”

the body and another, both on the same model and among different

“Although we were familiar with the process, the necessary preparation

models. This means that even with different powder amounts due to

work was intense because we knew we had very few days to enable

the dimensional differences of the various models, we achieve the

Ferrari to restart production of all models on 9 January,” confirms

same weight reduction.”

Molè. “The offline programming activities, the approval of individual

“This is a very important result, which would have been difficult, if

sub-assemblies in advance, and the study and management of

not impossible to achieve with liquid paints,” notes Alessandro Molè

the workflows together with the Ferrari team worked very well to

from Verind. “Using one-coat powder coatings allows to obtain three

understand how the various test bodies could fit into the process,

times the thickness obtainable with liquid paint, which would require

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FOCUS ON TECHNOLOGY

© ipcm

© Verind

at least two passages in the booth, besides the risk of dripping, uneven

we are going to work on many new cutting-edge concepts for both the

thicknesses, and lower mechanical resistance performance.” After the

sustainability of our processes and the lightening of car weights.”

application of the powder primer, the body coating cycle continues in

“Again with a view to sustainability, we are also working on the logistics

the conventional manner, with the application of a base coat (or base

chains of the products we buy,” adds Davide Abate, “pushing our

coats, in the case of special colours and three-layer systems) and a liquid

suppliers to move their production sites and factories to Italy or at

clear coat.

least to Europe to minimise their carbon footprint. This is one of the reasons why we are currently approving some new products. In 2023,

Sustainability goals in coating

we are almost certainly going to finish changing the logistics chain of

“Since the implementation of low cure top coats in 2018, we have never

our pre-treatment products and powder coatings, limiting it within the

stopped researching and introducing more sustainable processes in our

Italian borders. Both the required skills and production capacities can

paint shop,” says Davide Abate. “In addition to water-based industrial

be found here: it is only right to bring these productions back to Italy.”

1

paints as base coats, we have developed water-based refinish paints for aftersales assistance and the management of our cars after they leave

The future of Ferrari’s technologies and infrastructure

the gates of Maranello. We are also working on some pre-treatment

“At the Capital Markets Day in June 2022, we announced the two main

products to eliminate the phosphating phase and the management

industrial assets Ferrari is investing in,” says Davide Abate. “The first

difficulties it entails. We are also going to make a further important

is the two-storey E-Building, where we are going to manufacture all

technological step forwards with our New Paint Shop, where

the strategic electrical components of several cars in our range. The second is the New Paint Shop, which will help us further increase

Alessia Venturi, Ferrari: The Italian Automaker Revolutionises the Car Painting Process with a Low Cure Clear Coat System, ipcm no. 51, Vol. IX, May-June 2018, pp.

34-48

1

the quality and customisation level of Ferrari cars. Our development philosophy is always the same: we invest in what is truly strategic for our company to create the dream cars of the future while increasing

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SPECIAL ISSUE ON AUTOMOTIVE

the sustainability of our processes and of our cars themselves. This does

in 2019, which is a V8 turbocharged plug-in hybrid car, the first vehicle

not only refer to electric mobility: we are heavily investing in our entire

to contain electric components engineered by ourselves, namely the

corporate infrastructure to execute a plan that will lead us to completely

engine, batteries, and inverter. We then transferred these technologies

decarbonise the processes in Maranello by 2030, the year Ferrari is

to the 296 GTB, which is our mid-engined sedan, with higher production

going to be working with zero emissions.

volumes. The GTB and the convertible 296 GTS, in particular, prove that

“Of course, this decarbonisation plan also concerns our cars: we started

our three cornerstones of car development – performance, design,

working towards electrification back in 2009, in the ‘open-air laboratory’

and driving thrills – can also be combined with electric mobility in a

of Formula 1, from which we draw numerous ideas for the general

fascinating way. Now, we have to push the boundaries reached with

development of our cars. At first, we developed a hybrid supercar called

the 296 GTB again, in the name of the continuous competitiveness that

LaFerrari, in which we applied many technical solutions borrowed from

characterises our DNA.”

F1. This experience enabled us to develop the SF90 Stradale, presented

© ipcm

Luigi Fronduto, Equipment and Tool Manager, who showed us the new powder application system.

© ipcm

Coated bodies subjected to final approval controls.

© Ferrari S.p.A.

The Ferrari Purosangue.

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FOCUS ON TECHNOLOGY

SPECIAL ISSUE ON AUTOMOTIVE

MAK Chooses a New Automated Coating Plant for the Three-Coat Finishing of its Aluminium Alloy Wheels for the Aftermarket Sector Gabriele Lazzari, ipcm®

MAK is a leading company in the Italian automotive aftermarket, which stands out through the meticulous attention paid to the styling, detail degree, and surface treatment of its aluminium alloy wheels. In order to cope with increasing production rates, which call for a high flexibility degree to be able to paint numerous wheels with different shapes and sizes in a short time, it has relied on Silvi to build a multi-purpose plant capable of coating more than three hundred wheels in an hour, divided into batches of down to five units.

© MAK

An aluminium alloy wheel manufactured by MAK.

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T

he automotive industry is constantly evolving and, as a consequence, so is the car accessories market. In particular, alloy wheels,

which account for about 25 to 30% of a vehicle’s side-view surface, are one of the most popular and sought-after products by car owners for both performance and aesthetic reasons. They can improve vehicle performance by offering greater driving stability, better grip, and higher speed, but they can also substantially change the exterior appearance of a car thanks to the high degree of customisation they allow. In Italy, the alloy wheel aftermarket is particularly active and renowned, with numerous companies offering a wide range of high-quality products available in different models, sizes, and finishes to meet the needs of any type of vehicle and personal style.

MAK (Carpenedolo, Brescia, Italy) has a share of over 50% in this market, thanks to significant investment in styling to offer sporty, aggressive, classic, and

© MAK

futuristic wheel looks with new solutions that are often far removed from conventional standards and

Wheels ready to be coated.

capable of catering to the tastes of very different countries. It has a warehouse stock of more than 120,000 wheels to meet any national and international order request in a short time. Recently, in order to cope with ever-increasing production rates, optimise the use of resources, and be able to supply national and international customers with alloy wheels with an even higher quality and aesthetic level, it turned to Silvi & Co. S.r.l. for the design of a new, extremely flexible coating plant capable of meeting all the requirements of this industry. After careful analysis, this plant engineering company based in Lesmo (Monza e Brianza, Italy) developed three automatic lines for the application of both liquid and powder products, which are also suitable for handling small batch sizes.

MAK: unique design style as a distinctive element MAK was founded in Carpenedolo in 1991 as a result of the collaboration started the year before by two well-established firms in the province of © MAK

Brescia – Fonderie Cervati (Gussago), a metallurgical company operating in the metal casting sector and

The loading area with the monorail conveyor supplied by Futura Convogliatori Aerei.

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© Silvi Srl

© Silvi Srl

Wheels at the entrance to the pre-treatment tunnel.

in particular in aluminium processing, and Magri Gomme/Yokohama,

Digital transformation is the defining element of this historical period,

a leader in the field of tyre distribution – that decided to combine their

so we have invested in a B2B platform where our customers can place

technological and commercial know-how to create a new manufacturing

orders 24/7 and we have integrated our warehouse flows with those

business that could stand out in the light alloy wheel market. “The first

of our partners. In addition, a few years ago we activated a system that

few years were the most delicate, as it was not easy to find the right

guarantees the shipment of wheels throughout Europe within 72 hours

positioning and penetrate an established market where well-known and

of ordering. At the same time, we also continue our activity in designing

more structured competitors were already operating. The key was to

wheels for niche supercars. On the occasion of our thirtieth anniversary,

focus on the MAK brand and give it a precise identity related to originality

we decided to produce our SPECIAL 23-inch wheel, an ideal solution for

in design, attention to detail, and reliable after-sales service,” states

the needs of drivers of top premium brands such as Lamborghini, Aston

Gualtiero Cervati, the Managing Director of MAK.

Martin, and Porsche, with their Urus, DBX, and Cayenne Coupé super

The company thus quickly became one of the most important suppliers

SUVs,” notes Cervati.

in the European automotive aftermarket, exporting its products to over fifty countries in Europe and Asia. This result enabled the Group, with

The production of customised alloy wheels

a turnover of around 50 million Euros per year, to continue to invest

MAK is therefore a customer-oriented company that aims at customer

in innovation and design and to maintain a constant level of growth.

satisfaction in many respects: supply of high-quality products with

“Inspired by the Lean Thinking philosophy, we place great importance

innovative design, pre and after-sales service guaranteed by highly

on reducing waste, improving our internal processes, and constantly

qualified personnel, fast and reliable daily shipping, and flexible order

striving for high efficiency and quality through synergy and teamwork in

planning. Always focused on the aftermarket sector – where a high degree

all production phases of our alloy wheels. We have also always paid close

of customisation is required even on small quantity batches – and not the

attention to the demands of niche markets as well as macroeconomic

original equipment one, the production technologies it utilises reflect this

trends.

precise positioning strategy.

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FOCUS ON TECHNOLOGY

“We take care of the production of each wheel in its entirety. Our

© MAK

sales agents listen to and analyse market demands, whereas a partner design studio defines the aesthetics of products and the shape of the required moulds. The research, design, and development phases are carried out entirely in Italy even for wheels produced abroad, thanks to five engineers fully dedicated to these activities and a completely automated, Industry 4.0-oriented foundry implementing integrated remote control of all data. After manufacturing, we apply for homologation first in Germany, then in other European countries, and finally in Italy, since different requirements have to be met,” illustrates Cervati.

MAK produces 1,300 wheels per day from cakes made according to a formulation developed entirely in-house, which requires the supply of an alloy with specific quantities of aluminium, copper, and magnesium. In the moulds, also produced according to drawings provided by MAK to best suit this alloy, a gravity casting

© MAK

process takes place to form one-piece blanks within an upper male die, a lower male die, and the two cheeks forming a ring.

The next steps include machining, turning, drilling, and milling to optimise the inside and outside of channels and valve bores using numerically controlled machines. The wheels are then subjected to manual deburring and surface preparation.

The importance of the aesthetic factor “A product quality check follows each production step so that any defects can be identified and promptly corrected. Choosing MAK means relying on a top-quality manufacturer that combines innovation, style, and functionality,” states Cervati. “The surface finishing of our wheels is therefore one of the most important steps in our production cycle.”

“We previously had a vertical chain coating plant with an overhead crane for the immersion pre-treatment cycle. We had built it in© ipcm

house with the help of an external metalwork company over thirty years ago. Although we had been upgrading it over the years, for example by adding a 10-stage pre-treatment tunnel, it was no longer able to cope with our increasing production rates and meet new market demands”, notes Leonardo Pintossi, the design consultant for MAK’s paint shop.

From top: - Alloy wheels in the Nordson pressurised booth for primer powder application.

- The powder management unit.

international PAINT&COATING magazine - MAY/JUNE 2023 - N. 81

69

SPECIAL ISSUE ON AUTOMOTIVE

© ipcm

“We therefore analysed the offers of several plant engineering

booths for the application of dark and light primers, using a powder

companies and talked with the management of other firms with painting

feeding and spraying system with Nordson dense phase pumps. The

requirements similar to ours, and eventually we chose Silvi’s solution: a

choice of these technologies and the use of a clean room are due to

4.0 coating cycle including spray pre-treatment and the application of an

the need to guarantee the application of the required thicknesses while

epoxy-polyester powder primer, a solvent-based base coat, and a liquid

avoiding external contamination. Following gelling, curing at 200 °C for

or powder clear coat depending on customer requirements.”

40 minutes, and forced cooling, the wheels are automatically transferred

The coating plant designed by Silvi

to a third line with an inverted conveyor for manual sanding and base coat application in the required colour (including metallic ones) inside a

“For MAK, we have designed a multi-purpose coating plant capable of

pressurised booth.

performing different cycles according to production needs even with

“For maximum flexibility, a drying oven has been added after the flash-

small batch sizes, controlled in a simple and user-friendly way via a PLC.

off station, in case MAK needs to use water-based liquid paint products

In one hour, it can paint over three hundred wheels in batches of as few

as coloured base coats. Subsequently, the wheels are taken to a further

as five units,” explains Silvi CEO Daniele Fumagalli.

pressurised booth equipped with an infrared shape detection system

In the loading area, the operators place the alloy wheels on a monorail

for clear coat application. The line also has another booth specifically

overhead conveyor provided by Futura Convogliatori Aerei (Robecco

designed for the application of any acrylic, polyester, or epoxy-polyester

Pavese, Pavia, Italy). This takes them along a 12-stage spray pre-

powder clear coats. The parts finally pass through the last flash-off,

treatment tunnel (strong alkaline phosphodegreasing, weak alkaline

drying, and forced cooling stations and they are finally ready to be

phosphodegreasing, mains water rinsing, deoxidation, demineralised

picked up and packed by MAK’s operators,” says Fumagalli. “Thanks

water rinsing, and final passivation with a no-rinse nanotechnology

to the large number of coating booths and baking ovens operating at

product), followed by a drying oven.

different temperatures, MAK has achieved maximum flexibility in the

The wheels are then transferred manually onto a line with an inverted

management of its operations, thus being able to offer different types of

conveyor and a pressurised clean room equipped with two coating

finishes within a short time.”

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FOCUS ON TECHNOLOGY

Maximum efficiency in powder coating

© MAK

The plant is completed by two demineralisers for water recirculation connected to the pre-treatment tunnel, a physical-chemical waste water purifier, and an afterburner for the treatment of oven fumes.

High ROI For MAK, looking ahead means continuing to invest in production technologies, design, and complementary products, taking advantage of both its know-how and a strong network of collaborators. “We are now working to meet some new market trends and, in particular, creating a dedicated line to equip hybrid and electric cars while maintaining the high degree of aesthetic quality and production flexibility that sets us apart. In addition, we are considering automating our various manual wheel handling steps to further optimise our results, which are already more than satisfactory anyway,” indicates Pintossi.

Nordson HDLV dense-phase technology – everything under control The heart of Nordson HDLV ® technology is patented High Density, Low Velocity (HDLV) Encore HD® pumps delivering exceptional powder coating results.

Significant powder savings and productivity gains from: higher application efficiency, uniform coating thickness, faster color change and minimum maintenance downtime.

Explore the unique features of our powder coating systems online or get in contact with us today for more information!

From the left: - The floor conveyor.

- Automated application of solvent-based liquid paint.

www.nordson.com/hdlv

SPECIAL ISSUE ON AUTOMOTIVE

“We were lucky enough to have the expertise to fully manage our coating

experience and expertise. In July 2021, we commissioned the coating

operation in-house for over thirty years, from the plant concept phase

plant and acquired the factory hall that would house it, expanding it.

to the selection of the most suitable application technologies. With the

We also added an area dedicated to packaging and diamond dressing,

rise of new requirements, however, we chose to rely on a partner that

a process that is applied to more than half of our products. The plant

could analyse our situation and identify the technologies and equipment

became fully operational at the beginning of 2023, but the resulting

needed to achieve our target results.

improvements are already evident. Both our production rates and the

The relationship created with Silvi was both professional and personal,

quality of our finishes have improved dramatically and we expect to

as its technicians were willing to listen to our needs, our concerns,

achieve a return on investment within a short time,” Cervati concludes

and even our ideas on possible solutions, integrating them with their

with satisfaction.

© Silvi Srl

© ipcm

The inside of the drying oven.

© ipcm

The IR gelling phase.

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From left to right: Angelo Ronco from Spray Center, Daniele Fumagalli from Silvi with Gualtiero Cervati, Federico Marini and Laura Scalvini from MAK.

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

rolls and panels of synthetic fiber

accumulatore vernice “Columbus”

paint accumulator “Columbus”

filtri “Andreae”

“Andreae” filters

cartucce filtranti

filtering cartridges

filtri assoluti applicazioni speciali

absolute filters special application

FILTRO ALVEOLARE MAX PAINT distributori esclusivi per l’Italia

massima efficienza massimo accumulo di vernice massima durata

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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

?

HOW IT’S COATED

SPECIAL ISSUE ON AUTOMOTIVE

© Porsche Deutschland

Long-Standing Porsche Lover Has a Colour Named After Him Nadine Toberer Porsche Deutschland – Ostfildern, Germany

nadine.toberer@porsche.de

For the first time, Porsche has implemented a customer-specific Paint to Sample Plus colour in a new process.

G

uards Red, Racing Yellow, Carrara White Metallic – just a

and most recently a 911 GT3 Touring (992). Sons Mike and Stefan

few of the familiar names for colours from the Porsche Car

Essmann compete successfully in the Porsche Sports Cup, with racing

Configurator. Now a brilliantly rich green will join the palette.

cars naturally, these also displaying Essmanngreen accents on the

Michael Essmann, a longstanding Porsche lover and Managing Director

bodies.

of family business Elektro Essmann, has had his very own individual

“My very first Porsche was a 911 SC in 1978 with which I also graduated

colour made within the scope of the Paint to Sample Plus range. As part

from the Sport Driving School,” recalls Michael Essmann. “It was painted

of the model year R Paint to Sample range, starting in March 2023 the

Opal Metallic. It was only later that I had the idea of using the colour of

exterior colour Essmanngreen, colour code 24C, will also be available

our family business for my private cars too. But every time I pick up a

through the Car Configurator for customers of the 911, 718 and Taycan

new Porsche in this very special colour it’s a great feeling. And to know

model lines.

that I’m the originator of this colour named after me.”

As far back as 1992, Michael Essmann had a 911 Carrera RS 3.6 (964) painted in the company colour of the master workshop for electrical

Highest quality and perfect colour matching

installations and photovoltaic systems – the first Porsche model in

While the Custom Colour of the 964 was blended in the After Sales

Essmanngreen. Other cars followed, including a 911 GT3 RS 4.0 (997)

painting process that was standard at the time 30 years ago, the current

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HOW IT’S COATED

SPECIAL ISSUE ON AUTOMOTIVE

© Porsche Deutschland

Essmann Porsche benefits from Porsche professionalising the range of

Type 992 because it was last used successfully in the old paint shop for

special exterior colours in 2021 and significantly expanding its capacity.

Type 997.

A new colour-mixing bench has been put into operation at the main

“Unusual paint finishes are part of the history of our brand and are

plant in Zuffenhausen, where paint specialists blend several dozen

an important differentiating feature,” says Alexander Fabig, Head

ingredients down to the last milligram to achieve the desired shade.

of Individualisation and Classic. “The intelligent combination of the

When the binding agents and additives are included, the recipe for

production process and its industrialisation is unique. Our customers

Essmanngreen contains over 100 ingredients.

thus enjoy a very wide range of available colours and many custom paint

Each batch is divided into two paint pots for bodywork and add-on parts.

finishes that meet the highest standards. Every colour must be deemed

The areas to be painted on the vehicle consist largely of aluminium,

suitable for many different surfaces and materials – perfect colour

plastics and carbon/fibreglass composites. This mix of materials and the

matching is what is wanted.”

different application methods and drying temperatures require slightly different paint compositions, depending on the component. A test body

170 additional colours across all model series

and so-called batch comparison plates are painted and used as a colour

Porsche has extended its colour range while simultaneously

reference for the final acceptance of the car.

restructuring it. “Paint to Sample” used to be known as “Custom Colour”.

These completely new processes designed for high quality with the

This category includes predefined colours that have already been

combination of craftsmanship and industrialisation required the re-

technically approved by the paint specialists at Porsche.

development, testing and approval of all colours, some of which had

For especially individual colour requests, Porsche Exclusive Manufaktur

already been used successfully in the past in the old paint shop. This

goes a step further: “Paint to Sample Plus” allows almost complete

is why it was necessary to develop a paint recipe for Essmanngreen on

freedom in selecting the paintwork based on a sample submitted by

international PAINT&COATING magazine - MAY/JUNE 2023 - N. 81

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HOW IT’S COATED

SPECIAL ISSUE ON AUTOMOTIVE

the customer. Thus, the Essmanngreen colour on Michael Essmann’s

In the interior, the seats were customised. Based on the 964 RS, the seat

911 GT3 Touring was first created as a “Paint to Sample Plus”. After

centres have a graduated colour design in Slate Grey and Crayon. Trim

technical approval, the Porsche paint specialists then added the

made of carbon enhances the dashboards. The “touring” logo is stitched

colour to the “Paint to Sample” programme. There, Essmanngreen can

into the headrests of the full bucket seats in red thread. This fits in with

now be selected from anyone who is interested via the Porsche Car

the overall concept as Elektro Essmann also uses red as a contrasting

Configurator. The process was started by Porsche Exclusive Manufaktur,

colour.

who painted a brand-new 911 GT3 RS (992) in this colour for exhibition

A sports car as individual as your own fingerprint, as unmistakable

purposes.

as your own lifestyle: Porsche Exclusive Manufaktur in Zuffenhausen

The overall range of “Colours of Choice” is very big. For the 911 and

creates very personal customer vehicles through a combination of

718 model series, there are currently 115 additional paint colours to

perfect craftsmanship and a high-tech approach. Highly qualified

choose from, For the Taycan there are currently 108 such options, while

employees with decades of expertise devote their full attention to every

for the Panamera and the Macan the number is 59, with the Cayenne

detail and enhance it through hand craftsmanship.

offering a choice of 52 different colours. Taking into account a number

The experts can draw on a wide range of visual and technical

of overlaps, there are 170 additional colours for all model series

customisation options for the exterior and interior of Porsche cars.

combined.

Visible examples include Sport Design packages, custom rim designs

Personal design even in the interior

and interior trims, as well as the comprehensive “Paint to Sample” range for all Porsche models. Porsche Exclusive Manufaktur fulfils the

Michael Essmann selected not only “Paint to Sample Plus” but also

highest demands with regard to materials and craftsmanship. Alongside

further custom options from the Sonderwunsch programme of Porsche

individual customer vehicles, Porsche Exclusive Manufaktur also

Exclusive Manufaktur. For example, his very personal 911 GT3 Touring

produces limited small series and editions. High-quality materials are

(992) has a Porsche logo on the side whose look is based on the

combined with modern production technologies to create a harmonious

Porsche Heritage Design models.

overall concept.

© Porsche Deutschland

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Since 1964

s i l v i srl.it info@silvisrl.it

design and manufacture of complete lines for painting, e-coat, cleaning and thermal stripping

ADVANCEMENTS

SPECIAL ISSUE ON AUTOMOTIVE

How to Specify E-coats More Sustainably Konstantinos Markou Laboratory Manager Industrial E-coats at Axalta Coating Systems

color-solutions-center@axalta.com

AquaECTM, the latest range of e-coat solutions developed by Axalta Coating Systems, meets the sustainability needs increasingly required by today’s manufacturing industry.

T

he e-coatings industry has undergone a profound shift in recent

The requirement for high performing e-coats remains as strong as ever,

years. Regardless of where coating solutions are being deployed,

however, increased scrutiny around sustainability issues introduces an

whether in automotive applications, white goods, or agricultural,

additional hurdle for specifiers. Although e-coats have historically been

construction and earth-moving equipment, they play a vital role in

regarded as more environmentally friendly than their powder and liquid

maintaining optimal performance, by eliminating or substantially

counterparts, it is fair to say that they have not always been entirely

mitigating degradation that occurs as a result of harsh operating

above reproach from an ecological standpoint. That said, advancements

conditions.

in e-coat technology are continuing to gather pace, allowing job coaters

© AdobeStock

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ADVANCEMENTS

and surface coating professionals to achieve

an e-coat, the more durable and robust the surface

the required level of protection while meeting

will be over the long term, in theory.

increasingly stringent sustainability criteria.

One of the crucial and sometimes overlooked

Performance and sustainability are not mutually

considerations when selecting an e-coat solution

exclusive, and in this article, we explore the key

is the degree of edge protection it provides. Not

considerations that will enable decision makers to

all e-coats are created equal in this regard, since

strike an effective balance between the two.

the formulation of certain ones makes them more

Transitioning away from tin-based catalysts

susceptible to shrinkage during the curing process than others.

There is some inevitable variance in e-coat film

While e-coats have been in use for decades, they

thickness at different points within a surface,

have come a long way since the first generation of

however this is most pronounced on the edges,

solutions, which were made using lead catalysts. The

where thickness of coating is often lower. Because of

environmental and health consequences of lead

shrinkage, the level of protection can be lower across

are well documented, and despite the fact that lead

surface edges, leaving this point of the surface

is no longer in use, we are continuing to see some

vulnerable to degradation and premature decline,

of the same negative impact from catalysts based

undermining the overall quality of the product and

on tin compounds. These substances are known to

its appeal within a competitive marketplace.

have carcinogenic properties and have the potential

Selecting an e-coat product with proven edge

to cause significant damage to marine life as well as

protection is therefore a positive step towards

the wider ecosystem.

helping safeguard the longevity of your surface.

The ecological drawbacks of using tin-based

Understanding how the coating thickness of

catalysts are no secret, making it somewhat

your e-coat can vary around surface edges when

questionable that they remain in use. The reasons

subjected to test conditions provides a useful

for this are, above all, economic since the initial cost

indication of performance.

of setting up a new line with a more environmentally friendly choice of material – financially and in terms

Low cure = reduced energy expenditure

of lost productivity – can be prohibitive, acting as a

The chemistry of your e-coat solution can affect

barrier to positive change.

multiple variables, one of which is the required

For sustainability-minded businesses, however,

curing temperature. This is determined by the

we would recommend adopting e-coat solutions

composition of the backbone resin and crosslinker,

which use a non-toxic catalyst material such as

which must be exposed to high levels of heat to

Bismuth, helping to overcome the environmental

remove blocking agents, at which point a chemical

consequences associated with the materials.

reaction can take place.

Compliance with legislation is always an important

Historically, this process has been highly energy

consideration and while current legislation does not

intensive, requiring, in some cases, temperatures

outright prohibit the use of tin-based catalysts, this

reaching 180°C. If we think of this in terms of energy

is likely to change at some point, hence, it is worth

requirements and carbon emissions, the true

fast tracking the transition away from tin-based

environmental impact becomes clear. Following

catalysts before being legally required to do so.

this logic, e-coat solutions requiring a lower curing

Never underestimate the power of edge protection

temperature, in some cases in the region of 150°C, offer a significant sustainability benefit and can be a great way to increase overall ecological performance.

In order to yield the maximum sustainability benefit

In the context of the mounting cost of energy, opting

from a product or component, it is vital to prioritise

for a low cure e-coat solution can also yield sizeable

longevity. The better the protective characteristics of

cost savings - all while respecting the planet.

SPECIAL ISSUE ON AUTOMOTIVE

© Axalta Coating Systems

Prioritise e-coats based on organic materials

AquaECTM

There is a widespread recognition that more must be done to reduce

Informed by decades of experience of producing e-coat solutions

our dependence on crude oil. Not only is this a finite resource, it is also

for automotive manufacturers and a whole host of other demanding

a major contributor to carbon emissions.

industrial environments, our latest range of e-coat solutions,

While crude oil once accounted for a large portion of the make-

AquaECTM, addresses both the rigorous sustainability and performance

up of e-coats, this is fortunately no longer the case. Indeed, many

specification requirements of such customers.

manufacturers are now deriving the necessary raw materials from

Developed with the use of a tin-free catalyst, and with lower curing

alternative, bio-friendly sources.

temperatures than any other solutions currently available in the market,

While such oils must undergo a higher degree of purification than crude

these can be used to produce components and parts more sustainably.

oils, it could be argued that this is a small but necessary price to pay in

The AquaECTM also delivers demonstrable longevity benefits, and is

the interests of protecting the planet and its resources, and conducting

ideally suited to parts with complex geometries thanks to its ground

business in a responsible and sustainable manner.

breaking edge corrosion protection characteristics.

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Flash to see the Paintsave video

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© Walther Spritz- und Lackiersysteme GmbH

Painting line with primed railroad wheels. In the background on the left: automatic top coat painting booth.

To the right of the wheel track: paint supply room for primer application.

FOCUS ON TECHNOLOGY

SPECIAL ISSUE ON AUTOMOTIVE

Resource-saving Coating Technology for Wheels of Rail Vehicles Torsten Bröker Walther Spritz- und Lackiersysteme GmbH – Wuppertal, Germany t.broeker@walther-pilot.de

Walther Spritz- und Lackiersysteme GmbH, together with J. Wagner GmbH, provided the site of Bochumer Verein Verkehrstechnik (BVV) with a new coating line in order to treat the wheels for rail vehicles as efficiently and sustainably as possible.

A

t the site of Bochumer Verein Verkehrstechnik (BVV), founded

This included a modern, highly efficient coating line. More specifically,

in 1842, wheels for rail vehicles are forged and combined to

a solution for single-wheel coating for primer and top coat application

form complete wheelset systems. In order to adapt to the

that can be easily integrated into the complex production process.

increasing demand in rail transport, the production plant was gradually

BVV attached great importance to sustainable and resource-saving

modernized in 2022.

production.

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FOCUS ON TECHNOLOGY

More efficient production processes thanks to new coating system

conditions of the factory hall: The exhaust air pipes were laid over a

Walther Spritz- und Lackiersysteme GmbH, together with J. Wagner

particularly necessary to meet emission control requirements. The new

GmbH - both companies of the WAGNER Group - made it possible to

coating plant has regenerative cross-flow heat exchangers, whereby up

install such a custom-fit solution.

to 50% of the energy is recovered from the exhaust air.

To meet the different requirements, the new coating line is divided into

long distance under the hall ceiling and led out above the roof. This was

two segments. In the first segment, the rail wheels are masked manually

Material supply as centre

and primed with the WAGNER AirCoat GM 4700AC manual gun. In the

Individual components such as pressure vessels, agitators, automatic

second step, a robot applies the top coat fully automatically with the

lid-lifting devices, drip pans and pneumatic control components have

WAGNER AirCoat gun GA 4000AC.

been combined into high-performance systems by Walther Spritz- und

Both guns enable excellent atomization, efficient paint application with

Lackiersysteme GmbH. The material to be processed is conveyed from

very low overspray and uniform coating thicknesses. Ideal, therefore, for

different delivery containers. Overfill safety, best possible residual

BVV’s requirements: the company can expand its production capacities

emptying, ease of operation, requirements of the Water Resources Act

while saving considerable application material. In addition, the guns are

(WHG) and operational constraints were essential parameters in the

very compact and easy to operate.

project planning. Thanks to its economical use of resources, the new

Inlet and exhaust air supply with heat recovery saves energy

system enables BVV to reduce material consumption and cut costs, especially for paint disposal.

• Primer:

The modernization of the plant was carried out during ongoing

- Paint booth

production. The inlet and exhaust air supply had to be adapted to the

- Ventilation unit with gas surface burner and thermal energy recovery

MADE IN ITALY

IMPIANTI

we design, build and install plants for the surface treatment of metals pre-treatment | anodizing | wet paint application | powder coating plastic coating | EDP (electrophoresis) | enamelling systems

visaimpianti.it

SPECIAL ISSUE ON AUTOMOTIVE

- Paint supply room - Material supply for two solvent-based primers from 30-liter containers - Air powered agitators on pneumatic drum lid lifters - Pneumatic piston pumps Leopard 35-70 - Piping to the paint booth with automatic shutoff - AirCoat manual gun GM 4700AC - GM 1030G for small touch-ups - Exhaust air output is throttled when the spray guns are not in use and is automatically shut off after a certain time has elapsed.

• Top coat: - Paint booth - Ventilation unit with gas surface burner and © Walther Spritz- und Lackiersysteme GmbH

thermal energy recovery - Paint supply room

© Walther Spritz- und Lackiersysteme GmbH

© Walther Spritz- und Lackiersysteme GmbH

- Material supply for two solvent-based and two water-based top coats from 30-liter containers plus corresponding cleaners - Electric agitators and level limit switches on pneumatic drum lid lifters - Leopard 35-70 pneumatic piston pumps for the coatings, Puma 28-40 for the cleaners - Fully automatic application by robot with AirCoat automatic gun GA 4000AC - GM 1030G for small touch-ups - Fire detection system.

Primer paint booth.

Hand application of the primer with the GM 4700AC AirCoat manual gun.

Supply/exhaust air unit with cross-flow heat exchanger and gas surface burner.

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RESEARCH BREAKTHROUGH

Electric Vehicle Batteries Could Get Big Boost with New Polymer Coating Theresa Duque Lawrence Berkeley National Laboratory – Berkeley, USA

media@lbl.gov

Scientists have developed the conductive polymer coating HOS-PFM which enables to manufacture longer lasting and more powerful lithium-ion batteries, that might result in the increased availability of entry-level electric vehicles.

T

he scientists from the Lawrence Berkeley National Laboratory

“The advance opens up a new approach to developing EV batteries that

(CA, USA) have developed a conductive polymer coating called

are more affordable and easier to manufacture,” has stated Gao Liu, a

HOS-PFM that could enable longer lasting and more powerful

senior scientist in the Energy Technologies Area of Berkeley Lab who

lithium-ion batteries for electric vehicles.

led the development of the material.

© Topuria Design/Shutterstock

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RESEARCH BREAKTHROUGH

© Gao Liu/Berkeley Lab. Courtesy of Nature Energy

Scanning electron microscope images of aluminum on a copper bilayer device before battery cycling (Figure A) and after (Figure B).

Figure C shows a copper tri-layer device with HOS-PFM coating after battery cycling.

The HOS-PFM conductive binder is made of a

materials quickly wear down after multiple charge/

nontoxic polymer that transforms at the atomic

discharge cycles.

level in response to heat. At room temperature

During experiments at the Advanced Light Source

(20° C), alkyl end-chains on the PFM polymer chain

and the Molecular Foundry (DOE Office of Science

limit the movement of lithium ions. When heated

user facilities at Berkeley Lab), the researchers

to about 450° C (842° F), the alkyl end-chains melt

demonstrated that the HOS-PFM coating significantly

away, creating vacant “sticky” sites that “grab” onto

prevents silicon- and aluminum-based electrodes

silicon or aluminum materials at the atomic level.

from degrading during battery cycling while

PFM’s polymer chains then self-assemble into

delivering high battery capacity over 300 cycles, a

spaghetti-like strands called “hierarchically ordered

performance rate that’s on par with today’s state-of-

structures” or HOS. Like an atomic expressway, the

the-art electrodes.

HOS-PFM strands allow lithium ions to hitch a ride

“The results are impressive,” has commented Liu,

with electrons. These lithium ions and electrons

“because silicon-based lithium-ion cells typically last

move in synchronicity along the aligned conductive

for a limited number of charge/discharge cycles and

polymer chains.The HOS-PFM coating conducts both

calendar life.”

electrons and ions at the same time. This ensures

Berkeley Lab researchers demonstrated that the

battery stability and high charge/discharge rates

HOS-PFM coating significantly prevents aluminum-

while enhancing battery life. The coating also shows

based electrodes from degrading during battery

promise, as a battery adhesive that could extend the

cycling while delivering high battery capacity over 300

lifetime of a lithium-ion battery from an average of 10

cycles.

years to about 15 years.

The HOS-PFM coating could allow the use of

To demonstrate HOS-PFM’s superior conductive

electrodes containing as much as 80% silicon. Such

and adhesive properties, Liu and his team coated

high silicon content could increase the energy

aluminium and silicon electrodes with HOS-PFM and

density of lithium-ion batteries by at least 30%, Liu

tested their performance in a lithium-ion battery

said. And because silicon is cheaper than graphite,

setup.

the standard material for electrodes today, cheaper

Silicon and aluminum are promising electrode

batteries could significantly increase the availability of

materials for lithium-ion batteries because of

entry-level electric vehicles, he added. The team next

their potentially high energy storage capacity and

plans to work with companies to scale up HOS-PFM

lightweight profiles. But these cheap and abundant

for mass manufacturing.

COMPLETE SOLUTIONS FOR HANGING AND MASKING

www.rostirolla.it

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© BMW Group

© BMW Group

Expansion of E-Component Production in Leipzig: First Cell Coating Line for Battery Modules Goes on Stream The BMW Group has launched the first of its five cell coating line in the Leipzig plant, that will be able to run a complete high-voltage battery production process for the fully electric MINI Countryman by 2024.

T

he first cell coating line in the Leipzig (Germany) plant of the

where production was phased out in the summer of last year. Straight

BMW Group has gone into series operation as e-component

afterwards the space was converted for e-component manufacturing in

production at the site continues to gain momentum. By 2024, the

less than six months and associates underwent the relevant training.

two existing module assembly lines will be complemented by a third, as

The new coating line can handle more than 10 million cells a year, or

well as four more cell coating lines and two more high-voltage battery

over 2,300 an hour. The coated cells are then used on the battery

assembly lines. The four coating lines will enter series operation during

module production line in Leipzig, to make modules for the fully electric

the course of this year, at roughly two-month intervals.

BMW i4* and BMW iX1*. A further line at the facility is producing battery

“From 2024 our plant here in Leipzig will be able to run the entire

modules for the BMW iX*.

process chain for high-voltage battery production. So, we will be making an important contribution to the transformation to electromobility,” has

From cell coating to high-voltage battery

stated Markus Fallböhmer, the head of Battery Production at the BMW

High-voltage battery production happens in three stages: cell coating,

Group. To meet its goal of fully electric vehicles accounting for at least

module production and assembly of the battery itself. The processes are

half of all sales by 2030, the BMW Group is investing more than €800

highly automated.

million to establish and develop e-component production at BMW Plant

The BMW Group sources its cells from partners who manufacture them

Leipzig.

exactly to specification. The type that is used depends on the vehicle

More than 2,000 coated cells an hour

concerned and is chosen to ensure the best possible characteristics.

Coating lithium-ion cells consists first of pre-treating and patterning their

Covering 2,300 m2, the new cell coating system at the BMW plant

surfaces with a laser. This involves the laser beam “chiseling” a texture

in Leipzig is located in the former production hall of the BMW i3,

into the outside of the uncoated cell to increase its surface area and

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reduce the surface tension of the aluminium casing. Next, the cells are

connect them to the vehicle. The size and shape of the housing and the

plasma-cleansed to remove any dirt particles and oxides. Together,

number of modules inside depends on the vehicle variant. That way,

these two processes improve the adhesiveness of the surface, ready

each car receives the most suitable high-voltage battery.

for the coating to be applied. It is administered by a specially developed machine that coats the cells in two layers, which are then hardened

A secure future for BMW Group Plant Leipzig

by UV and offer the best possible insulation for the cells. Finally, a fully

The continued expansion of Plant Leipzig is very much driven by

automated three-stage quality control process is carried out in which

e-component production, which will take up some 150,000 m2 of

the thickness and surface quality of the coating are inspected.

manufacturing space in the future.

A high-voltage test is conducted to ensure the coating is completely free

“This is a long-term investment in the future of the Leipzig plant,” has

from defects.

emphasised Petra Peterhänsel, the director of the pòant, adding that

The cell coating used at the BMW Group is blue, which was deliberately

the expansion of the plant would not only safeguard current jobs but

chosen for its important role in the positioning of electric BMW i

also create new ones. “At present, more than 800 employees work in

vehicles and as the signal colour of the range. Within the BMW Group

e-component production at our Leipzig site. By 2024 there will be more

production network, Plant Leipzig is a pioneer in electromobility, having

than 1,000.”

produced the company’s first fully electric model, the BMW i3, from

The next great milestone for Plant Leipzig will be production of the MINI

2013 to 2022.

Countryman successor, which will roll off the production lines from

Once coated, the battery cells are assembled into larger units known as

the end of this year. The crossover will be available with a choice of

modules. When completed, these are fitted into an aluminium housing

combustion engines or a fully electric drive – powered by high-voltage

along with the control and cooling units and the connectors that will

batteries made in Leipzig.

We create chemistry that makes lines love curves.

Coatings give a car more than just long-lasting protection.

Brilliant gloss and innovative colors transform contours into dynamics and design into emotion. Lines and curves are united and edges and contours are brought to life. When color and shape come together, and paint evokes passion, it’s because at BASF, we create chemistry. www.basf-coatings.com

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L.T.E. Lift Truck Equipment: Two Industry 4.0-Oriented Automatic Coating Plants to Optimise Production, Achieve High Quality, and Reduce Consumption Ilaria Paolomelo, ipcm®

Continuous improvement and technological innovation – the winning combination that enables L.T.E. Lift Truck Equipment, a Toyota Group company, to consistently optimise performance and achieve excellent quality. This is also thanks to its partnership with Visa Impianti, which has recently provided it with a liquid painting plant for the production of lift cylinders and a powder coating line for masts and fork carriages. © L.T.E. Lift Truck Equipment

FOCUS ON TECHNOLOGY

© L.T.E. Lift Truck Equipment

© L.T.E. Lift Truck Equipment

Aerial photo of the Toyota L.T.E. plant located in the SIPRO area in San Giovanni di Ostellato (Ferrara, Italy).

Overview of the cylinder coating system supplied by Visa Impianti.

K

aizen is a Japanese word that combines the terms Kai, meaning

and Visa Impianti, a company active in the design, production, and

“change”, and Zen, meaning “towards the best”. Masaaki Imai

installation of coating systems based in Triuggio (Monza e Brianza, Italy).

coined this word in 1986 to disseminate the fundamentals of

This collaboration has culminated in the supply of an automatic liquid

the Toyota philosophy of continuous process improvement beyond the Japanese borders and up to the West, so that it could be adopted by

painting line for lift cylinders and a powder coating plant for masts.

each and every company, not only in Japan or within the Toyota world.

About L.T.E.

However, the concept of Kaizen originated much earlier with Toyoda

L.T.E. Lift Truck Equipment S.p.A. was founded as a manufacturer of

Sakichi and it was later spread by Kiichiro and Taichi Ohno.

special lifting units for forklift trucks in 1976 in Milan and later moved

It is still one of the key values of the Toyota Way, a set of core

to the SIPRO production area in San Giovanni di Ostellato, in the

principles underpinning Toyota’s production system, better known

province of Ferrara. Since its beginnings, it has always been considered

as TPS - Toyota Production System, which promotes and encourages

a partner of excellence both for the design and manufacture of masts

continuous improvement through the active participation of all

and for its ability to produce special masts while achieving the same

company functions, the relentless pursuit of quality, and the reduction

quality standards as mass-producing companies. Now, it is an original

of waste.

equipment manufacturer (OEM) fully recognised by all major forklift

Deeply embedded in this Japanese multinational’s history, the Kaizen

producers.

philosophy has been leading all the Group’s companies to always

December 2005 was a landmark moment for L.T.E., as it was acquired

implement cutting-edge technologies and processes and enter into

by TMHG (Toyota Material Handling Group), becoming part of the

partnerships with suppliers that share this same way of working. It was

world’s leading forklift manufacturer. In 2006, it also adopted Toyota’s

based on these premises that a synergy was born in 2008 between

production system, thus progressively expanding its production capacity

Lift Truck Equipment, a manufacturer of lifting units and equipment

as well as its product portfolio, which now includes masts, lift cylinders,

for forklift trucks based in San Giovanni di Ostellato (Ferrara, Italy),

and fork carriages.

international PAINT&COATING magazine - MAY/JUNE 2023 - N. 81

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SPECIAL ISSUE ON AUTOMOTIVE

© L.T.E. Lift Truck Equipment

© L.T.E. Lift Truck Equipment

© L.T.E. Lift Truck Equipment

From left to right: The cylinder finishing cycle begins with the pre-treatment phase; Components inside the drying oven; The 3D scanner at the entrance to the coating booth.

Vertically integrated make-to-order production flow

high performance degree of our paint shop. Combined with constant

Currently employing around 665 people, the L.T.E. plant in Ostellato is

growth at the factory level, this has contributed to the reduction of our

mainly dedicated to make-to-order production, manufacturing around

production lead times, which used to be 6 days, whereas today it is just

30,000 2 to 9-tonnes masts and over 182,000 cylinders exclusively

over 2 days; at the same time, there is still room for improvement and

for other TMHE (Toyota Material Handling Europe) Group companies.

some already-planned activities will enable us to further reduce this time

Its production process is vertically integrated and organised in three

frame. This is the result of the excellent work of our engineering staff

business units devoted to the production of cylinders, masts, and fork

with the support of the Visa technical team, which has always provided

carriages respectively.

us with significant insights in terms of technological improvements,”

The lift cylinders’ production cycle begins with the machining of rods

states L.T.E.’s operations director.

and barrels, followed assembly and testing, liquid finishing (painting), packaging, and shipping. The metal profiles used to manufacture

The reasons for a choice

masts and carriages, on the other hand, undergo different machining

The coating process plays an extremely important role for L.T.E., as

processes, which include cutting, milling, drilling, and welding before

it allows manufacturing high quality products that meet the required

powder coating and assembly operations.

parameters and specifications, including salt spray resistance, while at

“Our collaboration with Visa Impianti started in 2008 and led to the

the same time being aesthetically appealing. The importance placed

installation of our two coating plants, which are the beating heart of

on finishing explains L.T.E.’s decision to install a powder coating plant

L.T.E.’s production department, as they help regulate its manufacturing

in 2008 and an automatic liquid coating system in 2017. “Looking at

rate. Technological excellence and continuous technical improvements

the timeline of our company’s history, 2014 certainly stands out as a

achieved by co-designing with our supplier have guaranteed the

year in which we defined numerous new projects and goals. In fact,

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in 2014, we doubled the capacity of our factory with the strategic

After pre-treatment, masts and fork carriages are taken to the

objective of becoming the R&D hub for all the Group’s products

automatic powder application booth and then to a manual touch-

intended for the European market. At the same time, we launched

up one. The parts are then transferred to a curing oven for 80

TOSO (meaning “painting” in Japanese), a project aimed at standardising

minutes and finally subjected to forced cooling in an air-conditioned

our coating process and monitoring its related parameters on a daily

environment. The loading and unloading operations take place by

basis to guarantee a high quality degree and reduce paint costs and

means of automatic lowerators that facilitate the operator’s work,

consumption,” states Rudy Zaramella.

provided by Futura Convogliatori Aerei (Robecco Pavese, Pavia, Italy) as

Powder coating of masts and fork carriages

both Power&Free overhead conveyors.

“At the moment, this system is used to treat both masts and carriages,

The collaboration between Visa Impianti and Toyota L.T.E. began

but we are currently building a third coating plant dedicated exclusively

with the installation of a powder coating plant, whose cycle starts

to the latter, again in cooperation with Visa. Indeed, fork carriages

with a mechanical pre-treatment phase consisting of a sandblasting/

are characterised by a few accessories (e.g. oversized latches and

shot blasting operation. “In 2008, the year in which this first line was

side components) whose separate treatment would greatly optimise

installed, the cycle also included a chemical pre-treatment phase

our process. This is why, in order to achieve consistently high quality

(degreasing, rinsing, and rinsing with demineralised water) after shot

standards and improve traceability, we have decided to separate

blasting, but that was eliminated over the years in favour of using shot

these two products, creating a business unit entirely devoted to

blasting alone and higher-performance powders supplied by Inver1

the manufacture of carriages, which will be using the new system.

(Bologna, Italy),” illustrates Paolo Massari, the owner of Visa Impianti.

Already at an advanced design stage, this plant is going to integrate machine learning and predictive maintenance with sustainability, as it

A brand of The Sherwin-Williams Company.

1

is designed to be a zero impact line: in particular, it should be powered

SPECIAL ISSUE ON AUTOMOTIVE

© L.T.E. Lift Truck Equipment

The primer is applied with reciprocators supplied by CMA Robotics.

© L.T.E. Lift Truck Equipment

The filters inside the booth.

exclusively by electricity from renewable sources and equipped with a

Varese, Italy), which includes the following stages:

bell oven for greater energy saving,” says Zaramella.

• Degreasing;

Liquid coating of lift cylinders

• 2 rinses with mains water; • 1 rinse with demineralised water;

Again with a view to growth, in 2017 L.T.E. acquired an area of over

• No-rinse nanotechnology passivation.

40,000 m and inaugurated its business unit devoted to lift cylinders. It

After drying, the components are transported to the coating booth,

relied once more on Visa Impianti for the installation of a new coating

where each load bar is 3D scanned to automatically generate the primer

line, this time applying liquid paint. “The decision to use powder or liquid

and polyester top coat application programme. The cycle ends with

products depends on the technical characteristics of our parts: cylinders

polymerisation and forced cooling in an air-conditioned environment.

are painted after the test phase and can therefore not exceed

The plant is also equipped with a booth for manual application, which is

70-80 °C in the drying oven; masts, on the other hand, require longer

only used to paint cylinders with non-standard shapes.

curing times, approximately 75-90 minutes at 200 °C,” explains the

Every single phase of the coating process is monitored through

operations director of L.T.E.

management software for greater efficiency and traceability. In 2017,

“Our cylinder coating plant has the peculiarity of being fully automatic,

together with Visa Impianti and the University of Ferrara, L.T.E. also

with robots supplied by CMA Robotics (Pavia di Udine, Udine, Italy)

developed predictive maintenance software and carried out a series of

to carry out paint application,” explains VISA Impianti owner Paolo

tests that led to the design of a neural network eliminating false error

Massari. Here, the finishing cycle begins with a pre-treatment phase

signals, which was then also implemented to resolve possible issues in

using chemical products developed by Condoroil Chemical (Casale Litta,

the welding department’s work flow. The company is now continuing

2

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FOCUS ON TECHNOLOGY

to invest in the predictive maintenance aspects of its paint shop by

GLOBAL SOLUTIONS FOR WATER TREATMENT

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

focussing on special sensors and artificial intelligence systems: at the moment, the painting line has 56 predictive sensors and 15 more will be installed soon, for a total of 71. In addition, for even better quality and sustainability, a zero-liquid discharge purification plant with a thermocompression evaporator-concentrator, designed by Visa and Ecoteam Spa (Scandicci, Florence, Italy), is going to be installed by the summer of 2023. This will allow recovering process water and reducing the waste water generated by the pre-treatment tunnel and the duplex system for demineralised water.

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

© L.T.E. Lift Truck Equipment

srl

The application of the paint product using guns with Gema’s dense phase technology.

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

SPECIAL ISSUE ON AUTOMOTIVE

A long-lasting, successful partnership “Kaizen, or continuous improvement, is a priority for our company, which is why we rely on partners and suppliers who share our vision and goals. Our relationship with Visa Impianti is one that goes beyond the suppliercustomer dichotomy, a true partnership where both companies share their knowledge in order to achieve constant technological and performance improvements,” states Zaramella.

“A completely make-to-order production means that we do not keep any stock. Meeting orders and individual customer requirements in a timely manner can therefore be very difficult, as a breakdown or any other problem could lead to a temporary halt in production.

However, the plant solution provided by Visa has enabled us to halve our system’s takt time from year to year, which is currently 4.5 minutes, as well as to quickly solve any issues on our coating line, always restoring and restarting it in less than an hour,” he adds.

This forklift component manufacturer’s © L.T.E. Lift Truck Equipment

collaboration with Visa Impianti has also enabled it to win some prestigious awards

The forced cooling phase in an air-conditioned environment.

in the competitions organised by the Toyota Group each year to reward the most interesting innovations and best practices.

In particular, in 2019 L.T.E. won an Award of Excellence for achieving an “improvement in operational availability through the introduction of a new method of data analysis in predictive maintenance”, whereas last year it was awarded for increasing its “capacity and productivity by reducing process time and downtime in cylinder testing and painting operations.”

© ipcm

From left to right: Visa Impianti owner Paolo Massari, Toyota L.T.E. operation director Rudy Zaramella, Ilaria Paolomelo from ipcm®, L.T.E plant process engineer Francesco Cavedagna, and L.T.E. maintenance engineer Nicolò Righini.

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www.infragas.com

INFRARED RADIANT GAS SYSTEMS FOR THERMAL TREATMENTS

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SPECIAL ISSUE ON AUTOMOTIVE

MANTA Group: Flexibility and Speed of Production Guaranteed by Automation and Digitalisation of the Commercial Vehicle Engines Coating Phase Edited by MANTA Group

Flexibility. Automation. Digitalisation. Respect for the environment. These criteria guided MANTA Group in its project for the installation of a new automatic engine coating line that combined the expertise of Gaiotto, Graco, Savim, and CM Automazione to meet Iveco Group’s aesthetic and performance requirements.

© ipcm

With its new automatic coating plant, MANTA Group paints up to 370 engines per day for FPT Industrial.

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A thirty-years history in the assembly and coating of aerospace and automotive components

line featuring our first two articulated robots supplied by Gaiotto. In

The story of MANTA Group began in 1986 in Orsara di Puglia (Foggia,

agricultural machines to be produced in Foggia. In order to cope with

Italy) from the ambition of a family of entrepreneurs determined to

this task, MANTA invested in a new painting plant identifying a pool of

manufacture reliable and innovative products.

suppliers that have cooperated to create a painting line which is fully

In 1989 began the production of some parts for the Foggia plant of

digital, automated, flexible and fast with an installed capacity of 85,000

Alitalia, now Leonardo.

engines per year”.

“In 1996, my father bought TMC, a company specialising in the

2021, MANTA Group was entrusted with the painting of engines for

manufacture of components in composite materials for the rotor wing

Over 700 engine variants

industry,” says Michele Frisoli, the current CEO of MANTA Group. “In

“The finishing of engines for agricultural applications has long-lasting

2007, MANTA Group acquired the final assembly of complex structural

aesthetic and functional requirements to be satisfied,” emphasises

axles for fixed-wing aircraft. When FPT Industrial (the brand of Iveco

Matteo Sforza, Procurement, Sales & Special Projects at MANTA Group.

Group specialising in powertrains) also started producing engines for

“By leveraging the skills acquired and involving in the project experts

the Japanese market in its Foggia plant, we were entrusted with the

of the field and universities departments with specific expertise,

application of the corrosion protection treatment (a liquid clear coat)

we designed with Gaiotto, Savim and CM Automazione the plant

thanks to the painting experience we had gained in the aerospace

engineering aspects, and with Graco the application ones to develop

sector. To this purpose, in 2009 we installed an automatic painting

a finishing line that is highly flexible and fully Industry 4.0 compliant.

© ipcm

The loading and unloading area of the automatic plant designed by Savim (Arbizzano, Verona) with a conveyor supplied by CM Automazione (Giussano, Monza e Brianza).

international PAINT&COATING magazine - MAY/JUNE 2023 - N. 81

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© ipcm

This system is complex not only for the over 700 engine variants with four different colours, but also for its full digital integration with our company’s management system. This enables us to monitor the process stage reached by each engine and the fulfilment of the quality requirements.”

“The water-based one-coat paint system applied on the engines was validated and homologated by an external laboratory (CRF) before the start of the production. The plant manages the incoming engine variant identifying the masking needed and the colour to be applied. The integration and digitalisation of this line were a challenge that required the collaboration of all our suppliers, also because our commissioning schedule was very tight. Eventually, we hit the mark and we are very satisfied with this pool of technology providers,” notes Sforza.

The XD45/59 step-by-step conveyor provided by CM Automazione houses up to 116 handling units equipped with a ring-gear idler swivel hook.

Technical characteristics of the line The painting plant built by Savim (Arbizzano, Verona, Italy) and equipped with Gaiotto robot © ipcm

paints 370 engines/day. It is equipped with an XD45/59 step-by-step conveyor designed and provided by CM Automazione (Giussano, Monza e Brianza, Italy). This accommodates up to 116 handling units with a maximum load capacity of 850 kg each, featuring a ring-gear idler swivel hook, normally locked in a unique position for safe part handling.

From the loading area, the transport units proceed across the pre-treatment and drying tunnel until the masking area with a step-bystep movement and a pitch of 2000 mm; their transfer time is less than one minute. In the coating area with two application booths the main conveyor (TR1) transfers the task to a dedicated conveyor (TR2), which also operates with a step-by-step flow and a pitch of 3200 mm, maintaining the correct spacing of the parts. The two coating booths feature rotation systems of the transport units to allow the

The pick-to-light system that monitors the correct execution of the engine masking operations before pre-treatment and then before coating.

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completion of the painting operations in case of a robot malfunction. Inside the baking oven,

FOCUS ON TECHNOLOGY

© ipcm

  The pre-treatment tunnel.

CM Automazione has positioned four drive units that allow for the storage of the handling units.

For the supply of the paint feeding and application equipment and the colour change system, MANTA relied on Graco and on the technical expertise of its integrator Comaind (San Giovanni Lupatoto, Verona, Italy), whose collaboration was fundamental in one of the most critical phases of this project. All the operations are performed in-line, except for the incoming and recording of the engines.

The first station is the masking one, to protect sensitive surface areas against water ingress during the pre-treatment phase. A pick-to-light system borrowed from Toyota reads the type of engine matched with the incoming load bar and a screen displays the image of the engine and all the different masking devices required.

Station no. 2 is devoted to the 3-stage chemical pre-treatment with phosphodegreasing, cleaning with demineralised water, and drying in three steps: pre-drying tunnel (station no. 3), robotic blow-off with two Gaiotto robots (station no. 4), and an oven at 90 °C (station no. 5). The engines then pass through a cooling area (station no.

6) before entering station no. 7, masking 2, also with a pick-to-light control system where about 100 masking devices are applied.

The cycle proceeds with the application of the liquid paint in two pressurised, temperature and humidity-controlled water curtain booths, supplied by Savim, each with a Gaiotto articulated robot rotating 180° that paints one side of the engine. The minimum thickness applied is 50 microns. A third manual booth is used for touch-ups. The line ends with a flash-off tunnel and an oven that accommodates 50 engines at 100 °C for 1 hour and 30 minutes. The

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



SPECIAL ISSUE ON AUTOMOTIVE

engines then proceed to an in-line quality gate for final approval. A demineralisation system and a Hydro Italia dirt separator complement the plant.

The application and automation system “We designed the paint feeding and application system together with Gaiotto to handle the four colours applied by MANTA,” states Davide Galvani of Comaind. “The most used one is grey, which accounts for almost 90% of the production. The other three colours (yellow, perkins grey, and transparent) are wildcard tints for the remaining 10% of the volumes. Since coating planning is not done on a batch basis but rather by individual engines, we designed a very quick colour change system taking a time equal to that needed to move a load bar by one pitch, i.e. 30 seconds. © ipcm

The paint management unit is equipped with a Automatic spraying with the Gaiotto GA2000 robot and the Graco AirPro gun.

1000 kg container for the black colour and 200 l drums for the other tints. The paint is kept agitated by an ATEX-certified electric agitator with expandable vanes and a refill system linked to a 100 l tank where a Graco Endura-Flo pump circulates the paint at a pressure of 2.5-3 bar. This tank pre-feeds the PD1K machine equipped with four separate pumps, one for each colour, to guarantee maximum colour change speed on board the robot.”

“60-mesh filtration is performed on the recirculated product,” adds Galvani. “The PD1K device also has its own filtration unit at the gun’s outlet. The two coating robots are equipped with two automatic Graco AirPro compliant-technology guns each: one gun only handles grey paint, whereas the other is fed by colour change valves positioned about 40-50 cm from the gun, almost on the robot’s wrist; one valve is for flushing the circuit, the other three are for the wildcard colours. The paint management unit also pre-feeds the touch-up

© ipcm

The Graco PD1K mixing machine with four separate pumps for each colour, installed by Comaind (San Giovanni Lupatoto, Verona).

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booth where there is a gun available for each colour that is activated with the correct colour

FOCUS ON TECHNOLOGY

depending on the incoming engine.”

“We selected the PD1K machine together with Gaiotto with the aim of controlling the paint flow directly at the gun and adjusting it according to the movement of the robot during the painting stage. In addition, this unit allows analysing the technical/production parameters and also interfaces with the line’s 4.0 system. For the latter, Gaiotto designed the master control of all the machines in the line, then MANTA extrapolated data from it to interpolate them with its own management system for engine advancement and plant remote control,” concludes Davide Galvani from Comaind.

In addition to installing four self-learning 6-axis robots, two for blow-off and two for coating operations, Gaiotto also worked on the identification numbers management system (e.g. the date and time of the entry of each © ipcm

engine on the line, the end of each phase and the departure of the load bar from individual stations, the programme used by the robots,

The paint management unit set up by Comaind with Graco Endura-Flo pumps.

the colour used in the first coating station and the amount of paint used, and so on).

At the loading station, based on each part’s identification number, the MES communicates to the Gaiotto master the colour and ITEM with which the engine is to be processed on the line. The system thus defines the following parameters: • Masking: at each of the two masking islands, a drawing of the engine is displayed illustrating the specific surface areas to be masked. The pick-to-light systems indicate to the operator the type and quantity of caps to be picked; • Oil filling: for engines that require oil filling, the MES communicates the amount of oil to be filled into the engine based on its identification number. The filling system feeds the amount of oil tracked; • Blow-off: in addition to drying, two blow-off robots remove any cleaning water remaining inside the holes with a specific programme managed by the system according to the variants;

© ipcm

Hydro Italia’s sludge separator treating the water coming from the coating booth’s overspray collection curtains.

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© ipcm

© ipcm

These painted engines leave the drying oven and head for the unloading station.

From left to right, Michele Frisoli, Matteo Sforza, Luigi Vitobello, and Antonio Lafaenza from MANTA Group, Roxanne Conings from Graco, Davide Galvani from Comaind, and Marco Caporello from Graco.

• Coating: performed in two booths equipped with GA2000 robots

programs were not optimised yet, whereas today with the production

with a programme selected by the identification number management

ramp up moving forward, the manual process has been progressively

system. If required, the colour change is performed with a 30-second

reduced. The start-up phase involved a learning process, especially

downtime during the load bar change.

when it came to handling water-based paint, which is much more liquid

• Touch-up: performed in a manual booth where the operator is shown

than its solvent-based. Our choice of suppliers proved to be a winning

the colour to be used by a light switching above the four spray guns.

one: we started by turning to a long-standing partner – Gaiotto, with

Reliability and technological expertise: the criteria for choosing the right suppliers

which we had previously worked on the automation of our old coating line and in whose products, we had found reliability and solidity – and we then built the whole companies pool together with its team,

“Production on this line started at the end of 2022” indicates Michele

selecting Savim among three other possible suppliers and Graco for

Frisoli. “With the new plant and especially thanks to the automation

the quality and technological content of its systems. Ultimately, we are

and application systems supplied by Gaiotto and Graco respectively,

very satisfied because we managed to realise a very complex system in

we immediately saw a high-quality level. In the beginning, manual

a short time.”

retouching was required more frequently because the robots’ painting

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Unparalleled Efficiency with Paint Shop and Final Assembly Systems for Electric Vehicles from Dürr Togg, the first smart and connected electric vehicle manufacturer in Turkey, has relied on an environmentally-friendly complete solution for its paint shop and final assembly line provided by Dürr.

P

roduction is underway at Togg’s new Technology Campus.

by 2030. The turnkey paint shop project was awarded to Dürr in 2020

Turkey’s global technology brand and first smart and

and a second order for the final assembly system followed in 2021.

connected EV manufacturer has an ambitious target for its

Together, they covered all plant engineering, application technology

Togg Technology Campus for electric vehicles: to be one of the most

and marriage, including fully automatic screwdriving stations and

environmentally-friendly plants in Europe. Dürr planned and built

inspection equipment. “The pre-treatment and cathodic electrocoating

the paint shop as a general contractor and supplied systems for the

systems are already rated for the final expansion stage, while the plans

final assembly process. NEXT.assembly, Dürr’s bundled technology

include provision for doubling up of all other power units in the layout.

spectrum for final assembly as a complete solution was used for the

Therefore, Togg can react quickly if the capacity requirements increase,

first time, enabling Togg to achieve unparalleled efficiency in vehicle

for example, by adding a second oven or an entire line,” explains Bruno

assembly.

Welsch, CEO & President Paint and Final Assembly at Dürr Systems

175.000 units smart and connected EVs are to roll off the production

AG. Production started in the paint shop only recently, with the final

line annually at the Gemlik Togg Technology Campus in western Turkey

assembly system set to be commissioned shortly.

© Togg

The seven-axis painting robot EcoRP E043i equipped with most recent application technology ensures highest coating quality.

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© Dürr

The EcoDryScrubber dry separation system saves up to 60% of energy and stands for sustainable coating.

Cutting water, electricity and heat consumption

Latest technology for high-colour brilliance

Togg initially opted for a lean painting process to minimize energy

Togg insists on high standards not only for environmental friendliness

demand. The base coat and clear coat of the internal and external

but also for coating quality. Next-generation Dürr robots apply the paint,

paint finish are applied in a single topcoat line with integrated primer

including the seven-axis EcoRP E043i, which is mobile enough to paint

application, eliminating one drying phase. The solvent-based paints

doors from the inside and open tailgates. A unique technical feature is

contain 30 to 35 percent more solid content than standard paints

the EcoBell 3 atomizers equipped with two main needles, which apply

to achieve the required layer thicknesses with lower discharge rates.

colored clear coats for particularly shiny surfaces. The second main

The EcoDryScrubber dry separation system concentrates the solvents

needle eliminates the time-consuming rinse cycles previously required,

released into the exhaust air fully automatically and separates the

reducing detergent consumption and ensuring the fastest color changes

overspray - saving resources in many ways. The system requires

within the required cycle time.

virtually no water and very little energy for air conditioning, which is usually one of the highest energy consumption processes in painting.

A new way of looking at final assembly

Spray booth air recirculation of up to 95 percent means that heat and

Togg benefits from NEXT.assembly in the final assembly area. Whereas

electricity consumption is reduced by up to 80 percent and 50 percent,

individual components were previously the focus, the final assembly

respectively. This reduction also pays off economically, with energy

system is now considered a whole unit to make vehicle assembly as

consumption reduced by up to 60 percent. Togg goes well beyond

efficient as possible. NEXT.assembly bundles all of Dürr’s technology

the legal requirements with one additional measure to protect the

and consulting portfolio for maximum efficiency in the vehicle assembly

environment. The Oxi.X, a regenerative thermal oxidizer (RTO) that can

process. The result is the most comprehensive final assembly portfolio

be operated auto thermally – in other words, without a primary energy

on the market to-date. It is available as a complete solution or in

supply for the burner – disposes of the booth exhaust air.

individual modular parts. “Togg is the first car manufacturer to choose

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SUCCESS STORIES

a complete solution from our final assembly offering. We developed a highly customized, resource-conscious solution that results in high synergy and efficiency at all levels along the whole line with precisely coordinated processes,” reports Andreas Hohmann, Vice President Consulting & NEXT.assembly.

Modern conveyor technology for doors and bodies Dürr’s overhead conveyors ensure efficient processes. A total of 57 lightweight overhead conveyors transport the vehicle doors to a separate door pre-assembly line. Another 50 heavy overhead conveyors are provided for transporting the bodies. With the potential for future digitization, subsequent process integration or maintenance analysis tools is © Dürr

possible.

Window gluing as part of line tracking One way to save material in pre-assembly is through precise dosing with the EcoShot Meter, which is suitable for almost all thick matter for sealing and gluing. The dosing unit, which is suitable for 1K and 2K applications, can also apply PU adhesives for window gluing.

At Togg, these are used in the fully automatic gluing of windows and panoramic glass roofs.

The automated process happens while the body is being conveyed (line tracking), making it much more efficient than the previous stopand-go process where the vehicle conveyor had to be stopped for installation.

From top: At the x-wheel wheel alignment stand, vehicles are tested and adjusted using the latest sensor technology. © Dürr

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The x-DASalign test stand calibrates the driver assistance systems at the end of line.

SPECIAL ISSUE ON AUTOMOTIVE

Flexible marriage process thanks to automation Togg is ideally equipped for the specific marriage process for electric vehicles with a line divided into seven individual stations, including the fully automatic x-bolt screwdriving station with six individual spindles. They fasten the front-axle module, the battery, and the rear-axle module automatically with a total of 30 screwing points. A downstream manual screwdriving station fastens another 14 screwing points, which can be easily automated in the future.

Next generation of filling The ProLine Cube guarantees faster and more high-quality filling for all media. As the technological core of the filling system, the fourth Somac adapter generation – the ergonomic G4 Blue Adapter – determines the fill quality and process time.

Exact 3D axle geometry measurements

C

The battery-powered vehicles are inspected and aligned in

M

two complete end-of-line systems by the wheel alignment

Y

stands x-wheel, among others. They are equipped with the

CM

new x-3Dsurface sensors. These provide 3D measurements of

MY

axle geometries and align them with an extremely high level of precision and reliability. The wheel alignment stands are combined with the headlight measurement and adjustment systems x-light as well as the complicated ADAS calibration systems x-DASalign,

CY

CMY

K

which are used for calibrating the SVC (Surround View Camera), FLC (Forward Looking Camera), and FLR (Forward Looking Radar).

The roll/brake/ABS test stands x-road for dynamic roll, brake, and ABS testing complete the end-of-line system.

“As the principal supplier, we work closely with Togg to meet high environmental and quality requirements,” says Bruno Welsch.

The service offering is rounded out by the Turkey-based Dürr team, which will take over the ongoing servicing of the system in the future.

Wherever paint matters!

ART WITHIN SURFACES

SPECIAL ISSUE ON AUTOMOTIVE

Alfa Romeo F1 Team Stake x BOOGIE: a New Artistic Project to Bring Fans Closer to the Team Alfa Romeo F1 Team Stake has launched a collaboration with world-renowned artist, BOOGIE, to create an artistic project aimed at bringing fans closer to the team and celebrate the start of the 2023 season.

B

OOGIE took his spray cans to the bodywork of one of the team’s

alpine backdrop playing as big a part in the composition as brushes

cars to create a unique piece of art, which was unveiled in the

and paint. The design of this artistic project is not a simple PR stunt,

stunning setting of Waldhaus Flims, in the Swiss Alps.

however, but the beginning of a campaign to bring fans closer to the

BOOGIE, a German-born graffiti artist, designer and illustrator living in

team. Alfa Romeo F1 Team Stake partners, JigSpace1, created a bespoke

Switzerland, boasts an artistic career that took him to creating content

3D model of the car, in its distinctive livery, which will be available for

in more than 40 countries, with some of the biggest brands in the world

fans to enjoy in augmented reality (AR) from the comfort of their homes.

and some of the most accomplished artists of his generation.

The Art Car was also accessible in real life, as it traveled to London for

Based in Basel, BOOGIE embodies the spirit of Alfa Romeo F1 Team

an appearance at the Stake stand at the 2023 ICE London, the Global

Stake: both international and proudly local, ready to engage with

Gaming Hub staged at the ExCel on February 7-9, in a showcase of

different cultures and places without forgetting where it comes from.

the team’s partnership and the latest technologies; in addition, further

Designed for a team that, since its beginnings, has been challenging the status quo, the Art Car is born in the Swiss mountains, the incredible

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https://link.jig.space/lg6dS6UCRrb

ART WITHIN SURFACES

appearances in Zurich, to invite the local community to experience the car, and at Grand Prix destination cities, are in the plans and yet to be unveiled.

Fans are at the heart of everything the team does, and Alfa Romeo F1 Team Stake aims to get them as close to this project as possible: a group of the most loyal followers of the team will be invited to the team’s Hinwil headquarters to see the Art Car and meet BOOGIE: and to highlight how the Art Car project is a living one, fans will work with the artist to add their own touch to the detail.

Finally, following a year-long campaign, the Art Car by BOOGIE will be auctioned by Memento Exclusives through F1 Authentics, to raise funds for Alfa Romeo F1 Team Stake’s charity partner, Save the Children – giving back to the community even further.

This project will bring Alfa Romeo F1 Team Stake closer to the fans in each phase of its development. It’s an exciting, ground-breaking journey the team is proud to undertake, alongside trusted partners and an inspiring artist. This is the team’s first ever Art Car: with his distinctive, clean, comic-style look, BOOGIE put his signature on a unique project.

Alessandro Alunni Bravi, Managing Director of Sauber Group and Team Representative: “We are proud to bring this project to life together with an incredible artist such as BOOGIE. He is like us, the embodiment of talent who came to call Switzerland home and evolved a unique style and way of doing things. Like BOOGIE, we are not afraid to challenge the way things are done and the Art

BE WASTEWATER FREE

Car project is the best example of this. Most importantly, we don’t want the Art Car to remain closed in our HQ: it’s a project for our community, for our fans, to get closer to the team – first through the JigSpace AR experience, then in person – and feel what drives us. I am excited about seeing this project grow and I can’t wait for the next few months.”

BOOGIE, artist: “The opportunity to paint a Formula One car doesn’t come every day – it’s a once in a lifetime chance, and to do it for a team based in Switzerland has a special meaning for me. With my design, I have tried to convey the spirit of this team: the letters all coming together to form the art symbolise all the people, partners and organisations that contribute to create this car. Alfa Romeo F1 Team Stake is a team – that goes beyond its name: it’s a group of people with a vision that is more than the sum of its parts.”

Scan or click the QR Code to see the art car painted by BOOGIE

ZLD SINCE 1984 www.eco-techno.it sales@eco-techno.it

SUCCESS STORIES

Revamping a ZLD Waste Water Treatment Plant Hydro Italia pursued the zero liquid-discharge objective by revamping Dana’s pre-treatment water purification plant.

H

ydro Italia recently built and tested the entire water treatment

paint pre-treatment tunnel, thus creating a zero liquid-discharge water

section of the pre-treatment line operating at the Rovereto

cycle. In addition, a 500 l/h reverse osmosis system had been installed

plant of multinational company Dana, which specialises in the

for refilling low-salinity water (conductivity < 10 µS/cm) into the pre-

manufacture of axles and transmission shafts and mechatronics for

treatment line. As the pre-treatment section had to be adapted to an

commercial and non-commercial vehicles.

increase in production of more than 30%, a revamping project of the

Already a long-standing partner of Dana, in the past Hydro Italia had

existing water treatment system was also developed.

successfully installed a Hydrofloty 24M sludge separation system for

The aim was to integrate plant improvements and new solutions, always

treating the water flowing from the factory’s two coating booths and a

continuing to pursue the goal of zero liquid-discharge – a philosophy

6 m³/day vacuum evaporator for purifying and recirculating the cleaning

that over the years has always distinguished Hydro Italia in the field of

water and the phospho-degreasing baths’ liquid collected from the

water treatments for the coating sector.

© Hydro Italia

The Hydrofloty 24M sludge separation system.

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© Hydro Italia

Engineering specialized in the supply of systems for surface treatment, painting and coating

The new oil separator.

Specifically, Hydro Italia installed a new ion exchange resin-based

E-COAT SYSTEMS

demineralisation plant with a nominal capacity of 5,000 l/h for the last cleaning stage of the pre-treatment tunnel. In order to ensure 24/7

LIQUID PAINTING SYSTEMS

continuity, the system has a duplex configuration. Also with a view to the ZLD goal, a new vacuum evaporator was added to treat the waste water generated by the demineraliser’s resin regeneration process, as

POWDER COATING SYSTEMS

well as bath concentrates that are not treated by the main evaporator.

The revamping project was completed with the installation of a new oil

SELF-LEARNING ROBOTS FOR AUTOMATED PAINTING

separator to replace an old machine that was undersized compared to current needs. Indeed, keeping the phospho-degreasing tanks free of oil residues results in better efficiency in the subsequent stages.

The new oil separator automatically works alternately on the two tanks by means of two floating suction units located inside the phosphodegreasing tanks themselves.

The installation of the new equipment was completed in November 2022 and the testing and start-up phase was conducted at the beginning of January 2023, in conjunction with the restart of the coating line. The preliminary and preparatory work for the construction site has been carried out in the summer, including, for example, moving the existing treatment plants (the evaporator and the osmosis system) to the new area devoted to water treatment.

SYSTEMS FOR THE TREATMENT OF VOCs EMISSIONS

FOCUS ON TECHNOLOGY

ENOLGASiTech Reduced Energy Consumption by 25% through Low-Cure Polyester Powder Coatings Gabriele Lazzari, ipcm®

Intending to optimise energy consumption and reduce energy-related costs and the environmental impact of its production, ENOLGASiTech applies Antartica, the new high-tech low-cure polyester powders of STARDUST Powder Coatings, which enable it to cure its finishes at an oven temperature of 140 to 160 °C, thus reducing gas consumption by 25%.

I

n the current context, in which concerns for the environment and the need to adopt sustainable practices have become top priorities, the industry is faced with

a crucial challenge: reconciling production efficiency with environmental protection. Rack cabinet manufacturer ENOLGASiTech (Sale Marasino, Brescia, Italy) is among the companies that have managed to combine these two elements at best. For more than two decades, it has been coating its products in-house through the application of 15,000 kilograms of powders per year to eliminate the use of toxic solvents, significantly reduce the emission of volatile organic compounds, and reuse excess powder that has not adhered to the metal substrates, thus reducing waste and optimising the use of resources while ensuring high finishing quality and excellent wear, abrasion, and weathering resistance.

Over twelve years, ENOLGASiTech has been able to triple its turnover to €3.2 million in 2022 thanks to major technological investments. To continue along this path and further reduce energy consumption and energy-related costs in this historical period characterised by high price increases, it has decided to switch to Antartica, the low temperature curing polyester powders supplied by Stardust Powder Coatings to maintain the aesthetics, properties, and performance degree of its finishes while curing them at a temperature between 140 and 160 °C.

The high quality of Antartica powder coating applied on ENOLGASiTech’s rack cabinets.

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© Enolgas

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© Enolgas

© Enolgas

FOCUS ON TECHNOLOGY

A Balzac series wall-mounted cabinet with a black finish and a Hegel series floor-standing cabinet with a white finish.

An international industrial group with an all-Italian craftsmanship soul

wall-mounted cabinets, uprights, extensions, cable ducts, plinths,

ENOLGASiTech Srl was created in 2009 with the acquisition of

optical boxes, legs, power strips, and castors. 30% of production is

Carpenteria Turelli Srl, a metalworking firm specialising in rack

intended for the Bonomi Group itself and the rest is sent to Italian

cabinets, by ENOLGAS Bonomi, a company for which the former

distributors and foreign dealers. “We design, control, and manage the

used to also produce valves and boxes for the heating and plumbing

entire production chain of both standard rack cabinets and optional

plates, cable management units, shelves, panels, ventilation units,

fixtures sector. Covering an area of 4,000 m , it is equipped with state-

non-active components such as high-tech optical cassettes of the

of-the-art machinery that enables it to maintain constant production in

highest quality and functionality. All of our products are certified and

three shifts. “Led by chairman Sandro Bonomi, our international Group

guaranteed for durability and performance, so that they can meet the

consists of five highly structured businesses and has sales offices in

highest demands. They are in fact used in server rooms and other

Germany, India, and the United States of America and production sites

large professional spaces, but also to enhance smaller areas thanks

in Brazil and Italy. However, it needed a site capable of manufacturing

to the high aesthetic level conferred by our technical-creative design

lightweight metal parts and structures for its rack cabinets intended

team, with a focus not only on technology and energy savings but also

for structured wiring and telecommunication technologies,” explains

on ergonomic modularity, in line with our company’s philosophy,” adds

ENOLGASiTech managing director Flavio Bonomi. “Therefore, when

Bonomi.

Turelli Srl’s founder decided to sell his business, Sandro Bonomi

“Despite heavy technological investments in machinery and

decided to acquire it to have an all-Italian manufacturing workshop

production facilities, we have maintained our craftsmanship quality,

that could quickly meet his company’s production needs.”

which enables us to always go the extra mile for our customers.

The Group’s product range currently includes floor-standing and

We not only produce functional cabinets, but we also equip them

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© Enolgas

The various coated components.

with culture, history, and a soul. This is also why all our products are

Therefore, our production is very flexible, so that we can respond

customisable and adaptable to every customer’s needs.”

quickly to any specific customer request also in terms of insulation

From carbon steel to finished structures

and conductivity, for proper earthing and for avoiding the build-up of electrostatic charges,” indicates Flavio Paris, the production manager of

ENOLGASiTech guarantees maximum flexibility and speed while

ENOLGASiTech.

supporting its customers at all stages, from design, feasibility analysis,

These machining phases are followed by powder coating with Stardust

cost analysis, and sample development to approval and production.

low-cure Antartica products, an essential step in ensuring protection

To meet all market demands, it carries out every production stage

against corrosion and chemicals, as well as enhancing the aesthetic

in-house. The process starts with the procurement of raw material, i.e.

value of products. Manual assembly and final quality control then take

CE carbon steel sheets in different thicknesses and types (galvanised,

place, followed by packaging and storage in the internally managed

polished, ground, etc.), which undergo various mechanical processes

logistics warehouse, enabling the company to guarantee fast delivery

through multiple CNC machining centres: laser cutting, punching,

times.

shearing, manual or robotised press-bending, welding, and panelling.

“We draw on the twenty years’ experience in the world of metalwork

The automatic powder coating plant

fabrications of our specialised operators. Over the last few years, we

In its finishing department, ENOLGASiTech has an automatic,

have also structured our staff and equipped ourselves with latest-

continuous-flow powder coating plant equipped with two booths

generation industrial automatic machines so as to achieve the necessary

featuring four automatic guns and two reciprocators each, as well as

flexibility level to range from standard production to the manufacture

pre and post-finishing stations. This gives it the necessary flexibility to

of customised parts. Using 3D CAD systems, our technical department

apply powders in the different RAL colours required by customers, even

takes care of the development, drawing, and design of our rack cabinets

for small-sized batches and individual units, or to carry out sampling

and their semi-active components, which contain the active components

operations without slowing down standard production, which therefore

that need to be shielded.

can take place at the same time.

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© ipcm

Rack cabinets ready for packaging and shipping.

The importance of finishing and environmental sustainability

© ipcm

The booth applying Stardust’s low temperature curing powder coatings.

reduce energy consumption and speed up production. “Whereas it would usually take an hour and a half to bring a 20-millimetre thick steel beam up to temperature, with this solution it is possible to

“The finishing step is of great importance in our production process

cure the paint product in just forty minutes. As a result, this solution

because our rack cabinets can also be placed in domestic environments

offers a twofold advantage: by decreasing the operating temperature

and, therefore, they must meet high quality and aesthetic standards. For

but keeping the drying time constant, energy consumption and

ENOLGASiTech products, we mainly use four RAL colours: 9010 smooth

energy-related costs are lowered; on the other hand, by keeping the

glossy white, 9005 wrinkled semi-matte black, 7016 wrinkled semi-

temperature at 180 °C, the parts’ dwell time in the oven is reduced

matte grey, and 7035 textured glossy grey. However, with the support

and production is sped up,” states Guido Pozzoli, the president and

of Stardust, we are able to offer our customers an unlimited colour

managing director of Stardust. “Of course, the innovative Antartica

chart, including the NCS range,” emphasises Paris. “We use Stardust’s

low-cure powders have the same chemical and mechanical resistance

low-cure polyester powders to obtain a thickness of 80 to 100 microns

characteristics as their counterparts, they have the same grain size, and

because, although rack cabinets are generally placed indoors, we still

they are applied in the same way.”

want to guarantee resistance to ultraviolet rays and to oils, greases, and corrosive and harmful chemicals. Moreover, as we have embraced the

Quick delivery even of small batches

low environmental impact culture, they enable us to reduce the waste of

Given the current period, characterised by high costs for gas and

energy resources.”

other energy resources, ENOLGASiTech decided to keep faith with its

Low cure powder coatings

green soul by experimenting with new solutions that would enable it to maintain the high quality level of its rack cabinets and components

Stardust’s low temperature curing polyester powders can be applied on

while decreasing gas consumption, reducing polluting emissions, and

iron, steel, cast iron, and aluminium. They start to cross-link at

saving on their associated costs. “We decided to make an investment

120 °C, reaching full cure between 140 and 150 °C. This is why they

that would allow us to improve the environmental sustainability of our

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processes. We analysed different market offers and finally chose

© ipcm

to rely on Stardust after talking to sales consultant Vincenzo Domante. Their strength is their ability to also supply small batches, even a single box of paint, very quickly. This enables us to maintain our own strengths, namely flexibility and speed of delivery,” says Paris. “They can supply us with polyester, and hybrid powder coatings with smooth, matte, glossy, wrinkled, textured, metallic, and even super gloss finishes in any colour.”

“ENOLGASiTech approached us to test our paints at the beginning of 2023. I worked with them to prepare samples and demonstrate the potential of our products. In addition, Stardust can provide specific research papers on the savings achievable with the low temperature curing technology, with or without our products; they analyse the kilowatts consumed depending on the types of metal substrate, the geometry of parts, and the thicknesses applied. This enabled ENOLGASiTech to evaluate the costs and benefits of our offer and decide to test our paints. © ipcm

© ipcm

By applying them, they were able to see the finishing quality obtained with our powders and therefore chose to continue working with Stardust,” explains Alessandro Argiolas, technical sales expert at Stardust.

Energy consumption reduced by 25% “We have only been working with Stardust for three months, but the results are already evident. Managing to reduce the temperature of a curing oven by 40 °C is an exponential gain.

Although we have not sacrificed any chemical, mechanical, film distension, or gloss property, we have reduced energy consumption by 25%. Both Guido Pozzoli and the entire Stardust team have very innovative ideas and can think outside the box.

We are totally satisfied. In fact, after the initial tests, we have decided to paint 30% of our production with Antartica coatings and we are soon going to employ low-cure powders on 90% of our components, as our prospects for savings are excellent,” states Paris.

The control modules of the paint nozzles; the film thickness control phase; ENOLGASiTech production manager Flavio Paris.

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EVOLUTION TO E-MOBILITY C O AT I N G

I M P R E G N AT I O N

CLEANING

Our 70 years experience in Surface Treatment is ready for the E-Mobility market.

Research, innovation, development.

In 70 years, our vision towards the future has never stopped.

Today, Tecnofirma provides quality to the electric market which is the most evolving technology in the automotive industry.

Our impregnation, cleaning and painting plants are the result of the constant commitment to offer cutting-edge solutions and products anytime, anywhere.

TECNOFIRMA SpA - V.le Elvezia, 35 - 20900 Monza (MB) - Tel. +39 039.23601 - Fax +39 039.324283 - tecnofirma@tecnofirma.com - www.tecnofirma.com

BRAND-NEW

© VULKAN INOX GmbG

VULKAN INOX to Present Sustainable Abrasives for Surface Finishing at GIFA 2023 The new energy-efficient production of reusable stainless steel blasting media from VULKAN INOX reduces carbon footprint.

T

he manufacturer of highly efficient, durable and reusable

cycle. So, the CHRONITAL and GRITTAL blasting abrasives improve the

stainless-steel abrasives VULKAN INOX GmbH has recently

eco-balance of the customers, because the media has a significantly

announced that it will showcase the sustainable CHRONITAL and

smaller CO2 footprint.

GRITTAL blasting media at GIFA, the international trade fair dedicated

“The customers are making great efforts to reduce their own footprint.

to foundry that will take place from 12 to 16 June 2023 in Düsseldorf

So, we have made many adjustments: as a starting material, we

(Germany).

deliberately buy secondary input materials with a low CO2 footprint.

th

th

The high dimensional stability of the individual stainless-steel grains

Since 2022, we have been operating our induction furnaces with

prevents the formation of dust and noticeably improves working and

electricity generated from renewable sources and implementing waste

visibility conditions. In addition, their use reduces the amount of waste

heat recovery to power the drying process. Overall, we have reduced

and the cost of disposal. In the induction furnaces, the stainless-steel

CO2 emissions from our own and third-party energy sources (Scope

is melted and then atomised to create the spherical blasting abrasive

1 and 2) by 87% since 2018. This means we are conserving valuable

CHRONITAL, that is mainly suitable for cleaning, deburring and edge

resources. Our goal is to convert the entire process so that gas will no

rounding. The angular blasting media GRITTAL, on the other hand, is

longer be required,” has stated Christian Hoffmann, the sales manager

formed by crushing the granules.

of VULKAN INOX.

The reusable stainless steel blasting abrasives, which are produced

VULKAN INOX will be at booth n. G09 in hall 16.

exclusively with renewable energy since 2022, are manufactured starting from melted steel scrap and are completely recycled back into the metal

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For further information: www.vulkan-inox.de/en

BRAND-NEW

Election of New President and Change in the KANSAI HELIOS Group Management Board The new Management of KANSAI HELIOS will expand the “Good to Great” strategy of the company group.

K

ANSAI HELIOS has recently announced that it has appointed

team there and to take on new assignments and professional challenges.

Dietmar Jost as new president of the company, which has also

Bastian Krauss, the current executive director, will instead become

elected a new management board. The new Group Management

executive vice-president, continuing to manage the group-wide

Board will continue to strengthen and enforce the global “Good to Great”

production and operations areas, as well as the further integration and

strategy of KANSAI PAINT in Europe.

development of the powder coatings segment.

Dietmar Jost is currently the executive director of the business and will

Taking turns with Kajima, also Yoshihiro Tanaka from KANSAI PAINT Japan

serve as new president from 1st April 2023. He was selected based on his

will join the management board as executive director after his relocation

deep and extensive understanding and leadership in sales and research

to Austria while Mitsuru Masunaga, dispatched from Mitsui & Co., Ltd.,

and development, so he is expected to further expand the system

continues to serve in his position with a new focus on corporate functions,

supplier strategy.

including compliance and M&A.

The current president Junichi Kajima, on the other hand, has been invited back to KANSAI PAINT Japan in order to strengthen the management

For further information: www.kansai-helios.eu

YOUR SYSTEM SUPPLIER FOR INDUSTRIAL COATINGS

ADHESIVES/ SEALANTS

POWDER COATINGS LIQUID COATINGS

E-COAT GELCOAT

www.helios-coatings.it

BRAND-NEW

Trasmetal Has Acquired Shares of the Plant Engineering Firm Varnish Tech Trasmetal became part of the shareholding structure of Varnish Tech, a first step towards a subsequent merger.

O

n 13th April 2023, the Trasmetal Group concluded the

field of robotics applied to surface treatment processes for general

purchase of part of the shares of Varnish Tech S.r.l as part

industry, aluminium, plastics, porcelain enamel, electrophoresis and the

of a business combination process which will strengthen its

automotive sector.

financial structure and allow it to provide a complete service to the

The exchange between the professional figures will allow installers

customer, guaranteeing the best ROI for tailor-made coating plant

to get to know the whole system (structural calculations, hydraulics,

projects.

electronics, fluid dynamics, aeraulics and robotics).

With the aim of becoming an important player on the European and

The company will also house internal activities such as engineering,

global territory, after some collaborations on individually acquired

carpentry, software development, electronic switchboards and robotic

orders, Varnish Tech and Trasmetal – which is close to turn 70 – have

integration.

therefore decided to join forces and become one unique player.

Through the aggregation will therefore be created a solid corporate

From its headquarters in Galliate (Italy), Varnish Tech analyses, designs,

structure capable of responding to customer requests both in terms

builds and installs automatic coating plants for both small and large

of mechanical-plant engineering and in terms of documentation (e.g.,

volumes all over the world.

performance reporting, compliance with regulations, manuals, etc.).

The Milanese plant engineering firm Trasmetal therefore adds to its portfolio further production technologies and expertise in the

© Adobe Stock

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For further information: www.trasmetal.net

HIGHLIGHT OF THE MONTH

Euroimpianti Polska Opens Its Doors From an interview with Gianluca Baruffaldi,CEO of Euroimpianti, and Iwona Laskowska, managing director of Euroimpianti Polska

T

he history of Euroimpianti, one of Italy’s leading manufacturers

Headquartered in Biłgoraj, a city in South-Eastern Poland, Euroimpianti

of automatic, manual, and semi-automatic coating systems for

Polska will help strengthen the company’s presence in a key, highly

the application of liquid and powder paints, has been marked by

industrialised territory, offering greater technical support and proximity

several major successes that have allowed it to position itself among

to customers in Eastern Europe. ipcm® interviewed Euroimpianti CEO

the world’s leading plant producers in the manufacturing industry in

Gianluca Baruffaldi and Euroimpianti Polska managing director Iwona

general and in the aluminium sector in particular. Founded in 1976

Laskowska to find out more about the birth of this project and the

in Villafranca di Verona and then relocated to Valeggio sul Mincio

commercial objectives of the newly founded firm.

(Verona), Euroimpianti began producing and distributing its systems first on the Italian market and then throughout Europe since 1980,

How important is the Polish market for Euroimpianti?

gradually strengthening its presence at the international level. Over

“The Polish market is a target of great interest for Italian manufacturers

the past ten years, it has steadily expanded by opening sales and

of surface treatment technologies and systems for several reasons.

operations offices in several strategic markets: in Brazil in 2012, in

First of all, Poland has a booming and constantly growing market,

Spain in 2016, in the US in 2018, and in Germany in 2021. Two years

also thanks to the significant support of the European Union, which is

later, Euroimpianti now continues its expansion all over the continent

providing funds to help local businesses invest in painting and industrial

by opening Euroimpianti Polska.

automation systems. In addition, the Polish market is full of important

© ipcm

Gianluca Baruffaldi, CEO of Euroimpianti, and Iwona Laskowska, managing director of Euroimpianti Polska.

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HIGHLIGHT OF THE MONTH

companies working in the aluminium and iron sector, producing components for various industrial sectors in which the painting phase plays a fundamental role,” explains Gianluca Baruffaldi.

“Euroimpianti has been exploring the Polish market for the past twenty years. In fact, before embarking on this ambitious project, we collaborated with a local distributor and supplied over eighty companies in the area with our machines. However, the need to provide our customers with an all-round technical and assistance service led us to the decision to open a new branch in Biłgoraj, relying on the expertise and experience of Iwona Laskowska, who has been working with our company for about seventeen years.”

“When Gianluca told me about this new project, I immediately showed great interest as I have in-depth knowledge of the market, the different technologies, and the types of systems, and because I already am the main spokesperson for many current and potential customers in this country,” states Iwona Laskowska.

What added value is Euroimpianti Polska going to offer?

“The new branch is not only a sales representative office, but it also has a technical and service department, an equipment assembly area, and a spare parts warehouse, which will enable us to offer an efficient and timely service to all customers in this region.

Euroimpianti Polska also boasts a highly specialised and qualified technical team,” adds Baruffaldi.

“Offering technical assistance to our customers is a priority for us. This is the main reason that has led us to open several representative offices around the world over the years. With a view to the expansion and growth of the Euroimpianti brand, we could not overlook such an important and flourishing market as Poland. The metal coating sector, especially for aluminium and iron, is of major importance here as there are numerous companies operating in the production of components for cars, agricultural vehicles, bicycles, furniture accessories, and architectural profiles, all sectors in which painting is essential for both product functionality and aesthetics. Euroimpianti’s product range, which includes manual, automatic, and semi-automatic lines for liquid and powder coating of workpieces of all sizes, is perfectly suited to the needs of the Polish market. Following an in-depth market analysis, we estimate that our system that best meets the needs of local companies is Euro 90, a fully automated powder coating plant for metal semi-finished and finished parts, especially suitable for mass productions. At present, the aluminium finishing sector is still a niche market, but one with significant growth potential,” concludes Laskowska.

© Pasturi

The headquarters of Pasturi in Cigole (Brescia).

FOCUS ON TECHNOLOGY

Pasturi’s Green Soul: 2-Megawatt Photovoltaic Panels and a Zero Liquid-Discharge Pre-Treatment Water Purification Plant Gabriele Lazzari, ipcm®

Pasturi is an aluminium profiles extruding company that stands out in the market for the flexibility and speed with which it applies high-quality, customised finishes for architecture and design thanks to its in-house powder coating department. At the same time, it is also characterised by its focus on environmental sustainability, as demonstrated by the photovoltaic panels laid on its factory’s entire roof and the custom-made water purification and recirculation system for pre-treatment water installed recently with the help of SAITA.

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FOCUS ON TECHNOLOGY

© ipcm

Aluminium profiles being loaded into the vertical coating system.

“P

asturi has always paid particular attention to the issue

an innovative closed-loop purification plant supplied by SAITA (Limena,

of environmental sustainability, as proved by both the

Padua, Italy) and specifically developed to avoid wasting water and

photovoltaic panels installed on the roof of our plant and the

recycle it for increased environmental friendliness.

production technologies we have chosen over time.” These were the

Constant investment and innovation

words of Simone Pasturi, the manager of his family business’ coating department, at the end of the previous reportage carried out by ipcm

Gian Mario Pasturi established Pasturi Srl as a commercial warehouse

at the premises of Pasturi (Cigole, Brescia, Italy), which had decided to

in 2001. The firm then evolved into a well-established business devoted

invest in a new vertical powder coating plant for aluminium profiles with

to the extrusion of aluminium profiles for the architectural, furnishing

cutting-edge technologies aimed at improving the quality of its finishes

(curtain systems, door and window frames, etc.), and design sectors. Its

and shorten its delivery times.

first 1,800-tonne extrusion line was gradually joined by a 3.250-tonne

Four years later, Pasturi has further shown its green soul by expanding

one and a further 1,800-tonne one, able to extrude profiles up to

the 1.5-megawatt photovoltaic system already installed on the roof of its

12,000 millimetres in length handled with automated systems. It also

headquarters and starting work on an additional ground-mounted solar

equipped itself with a machining department (precision cutting, drilling,

farm to self-produce more than half of its energy needs. In addition,

milling, shearing, threading, punching, slotting, welding, velcroing, rolling,

in order to be able to recirculate the liquid used for its pre-treatment

drawing, bending, tumbling, and assembly), a coating department, and

cycle prior to the aluminium profile coating stage, it has also installed

a machine for in-line profile packaging directly in the paint shop, the

®1

company’s most recent investment.

“Insourcing Coating Processes in the Architectural Aluminium Profile Industry: Pasturi’s History” by I. Paolomelo, in ipcm_International Paint&Coating Magazine no.

59, pp. 120-126.

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© Pasturi

© Pasturi

The profiles proceed to the spray pre-treatment tunnel.

The outside of the pre-treatment tunnel with the water storage tanks.

© ipcm

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FOCUS ON TECHNOLOGY

It now has 120 employees and processes 30,000 tonnes of aluminium per year in two-shift production. It can quickly provide a complete service to meet any customer requirement through its technical department, which analyses every request to design and draw the required dies, and its new logistics hub opened in 2022, complete with a photovoltaic plant already in operation and its own fleet of vehicles for the delivery of the machined, finished, and packaged profiles to end customers.

“Thanks to his pragmatism and thirty years’ experience in the aluminium sector, first as a press foreman and then as a commercial agent, our founder has been able to interpret and anticipate the demands of an ever-changing market, making his firm differentiate from competition with innovative solutions and timely responses,” states Letizia Roggero, the Managing Director of Pasturi. “Foresight, targeted continuous investment, and in-depth knowledge of aluminium are the main characteristics of our management. This has also enabled us to expand the geographical area in which we operate and enter the American market last year. Photovoltaics is certainly among the sectors on which we focus the most, acting as both a user and a producer: we manufacture in-house the profiles for attaching solar panels on our own roof and we have a line of pre-cut and machined profiles for the supporting structures of photovoltaic systems.”

Fast, flexible, and environmentally friendly powder coating Pasturi’s in-house department devoted to polyester powder coating (Qualicoat class 1 and class 2) has enabled it to increase its delivery speed and improve the customisation degree it can offer, no longer only in terms of extrusion or packaging methods, but also of its finishes’ colours and styles. In addition to such flexibility, reduced energy and water consumption are achieved through the new zero liquid-discharge system for pre-treatment water. “Besides applying standard colours, we can interface with powder coating suppliers to carry out trials with new tints or coat profiles with customised hues, even when working with just five or six profiles.

Whereas we still outsource anodic oxidation, insourcing our coating operations thanks to the powder application plant supplied by Euroimpianti (Valeggio sul Mincio, Verona, Italy) has allowed us to position ourselves on the market as a fast, flexible, and reliable partner. Moreover, the several application technologies we have at our disposal and SAITA’s waste water treatment plant have not only increased the quality of our finishes but also contributed to improving the environmental sustainability of our operations, a key element of our company’s mission,” says Pasturi.

Find out more...

www.freilacke.com

© ipcm

The importance of sustainability for Pasturi

drought. Therefore, avoiding wasting process water has become an

“State incentives have enabled the photovoltaic market to expand in

essential requirement,” indicates Roggero.

recent years, but actually we have always considered it as fundamental,” notes Pasturi. “Sustainability is a must for us, both in terms of energy

SAITA’s zero liquid-discharge water treatment plant

consumption and production.” Euroimpianti’s Eurovertical powder

Pasturi’s powder coating cycle begins with a pre-treatment phase

coating plant, which was commissioned at the end of 2018 and became

consisting of a chrome-free cascade cleaning process including acid

fully operational at the end of 2019, is in fact perfectly in line with the

degreasing with Alfideox 101 and Alfisid 14 and an acid attack with the

firm’s philosophy, as it is equipped with solutions aimed at minimising

alkaline product Alfideox to remove any impurities from the aluminium

electricity consumption and thermal energy expenditure. The ovens

profiles, a double rinse with water filtered and purified by SAITA’s plant,

are equipped with mechanical seals to minimise heat loss and maintain

and a no-rinse passivation stage with Alficoat 748/3. This pre-treatment

stable temperature and ventilation, the pre-treatment tunnel cleans the

operation enables the company to achieve Qualicoat-compliant results

profiles with a special low-pressure cascade system, and the tunnel’s

in a wide range of conditions through automated, simple, and safe

tanks are insulated. In addition, it now features an automatic bath

dosage management of chlorine chemicals, all supplied by Alufinish

management and maintenance system and a water purification and

Italia.

recycling plant designed by SAITA, in which the waste liquid produced

“The coating plant is complemented by a ZLD water treatment and

in the aluminium profiles pre-treatment stage is treated and then

purification system,” explains Carlo Enrico Martini, Marketing Manager

recirculated within a closed loop depuration system, avoiding water

at SAITA. “Initially, Pasturi had approached us for a traditional chemical-

waste. “Recently, our region has experienced prolonged periods of

physical purification plant, i.e. without water recycling. However, with

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FOCUS ON TECHNOLOGY

© ipcm

© Pasturi

the aim of meeting its water-saving and environmental friendliness

system, thus also simplifying the bureaucracy related to discharge

needs, we worked together to conceive and develop a state-of-the-art

authorisations. Electricity consumption is also reduced, as there are only

system. Pasturi is now able to completely reuse the cleaning liquid

centrifugal pumps for recycling demineralised water, and maintenance

flowing from its pre-treatment tunnel’s tanks thanks to demineralisation

needs are minimised, because activated carbon only needs to be

systems complete with filtration columns using activated carbon and

replaced once a year,” adds Pasturi.

regenerable ion-exchange resins, which remove any pollutants present

“With a traditional chemical-physical system the operators dedicated to

in the waste water and send purified water back to the plant. These

managing the system would perform more tasks. In contrast, the ZLD

continuously filter and recirculate the liquid to guarantee a constant

solution provided by SAITA is fully automated and unmanned,” confirms

flow of high-purity demineralised water in the last stages of the tunnel,

Martini.

using a system of communicating vessels. This allows a low conductivity value to be maintained in the cleaning tanks, eliminating any problem of contamination and staining due to salt deposits on the profiles.”

SAITA’s water purification plant enables Pasturi to save 4,000 litres of water per hour, which would otherwise have to be disposed through the sewage or external authorised centres.

“Recirculation is very easy to manage and does not require the presence of an operator, as the process is automatic. Moreover, thanks to this system, it is not necessary to connect the drains to the sewage

From left to right: - The inside of the storage tanks.

- The ZLD pre-treatment water purification plant supplied by SAITA.

international PAINT&COATING magazine - MAY/JUNE 2023 - N. 81

131

85% water saving “The decision to install SAITA’s water treatment and purification plant coincided with the choice to insource powder coating, which we made as a result of the exponential growth in the demand for finished profiles.

When we calculated that more than 20% of the aluminium profiles in our production had to be painted, we realised that the time was right to take this step. Its layout had to be specifically adapted to our space requirements, due to the particular geography of the area in which our factory is located – as it was not possible to dig the pits normally necessary for plant installation – and to the height of our factory – which was not initially conceived to accommodate a plant with a height of over 10 metres,” illustrates Pasturi.

“Fortunately, SAITA turned out to be more than just a

© ipcm

technology supplier, but rather a strategic partner that tailor-made the perfect solution for us. After listening to our requirements, it used its experience and expertise to develop a zero liquid-discharge, closed-loop water treatment and recirculation plant in close cooperation with the other partners involved, in order to perfectly integrate all the required technologies and meet our technical needs.

“SAITA was our first and only choice, as we were already aware of the professionalism and helpfulness of its technicians and the results we would be able to achieve.

Thanks to its water purification plant, we now use only 150,000 litres of water per year (just under 4,000 litres per week), compared with the 4,000 litres per hour normally required for a plant without this technology. Using mains water even to regenerate the resins, the simplicity

© ipcm

of its management has also reduced the number of authorisations required. This project certainly required a lot of work, but we are absolutely satisfied with the results,” concludes Roggero.

From top to bottom: The filtration columns using activated carbon and ion-exchange resins and the storage tanks. © ipcm

132

The panel for displaying process parameters.

N. 81 - MAY/JUNE 2023 - international PAINT&COATING magazine

FASTRIP S, our stripping solution for the automotive industry FASTRIP S is a vertical spray system for the chemical stripping of metals, a new and innovative machine that speeds up the stripping process and reduces consumption and environmental impact, as well as guaranteeing excellent quality results. It is suitable for stripping metal, iron, and light alloys workpieces without damaging their surfaces. The parts to be treated are arranged in baskets that can be custom designed according to their intended use like automotive moldings, alloy wheels, etc.. In order to ensure homogeneous treatment, the platform on which the baskets are loaded rotates and the spray jet creates a cascade effect. Fastrip S operates with high temperature stripping cycles, which are fully adjustable according to the combination of materials and coating used. We recommend to use the METALSTRIP chemical products series by ALIT TECHNOLOGIES in order to get an optimized result.

www.alit-tech.com

GREEN

ENERGY SAVING

MODULAR

ALIT Technologies Srl - San Bonifacio, Italy +39 045.245.6638 - info@alit-tech.com

STURDY

PROVEN EFFECTIVENESS

4.0

FOCUS ON TECHNOLOGY

RI-ME’s New 4.0 Coating Line Embraces Virtual Reality with the New VR-Tracking System for Robot Self-Learning Monica Fumagalli, ipcm®

RI-ME Srl (Fontaniva, Padua, Italy) has been offering contract heat treatment, mechanical surface preparation, and powder and liquid coating services on heavy metalwork fabrications for thirty years. It was among the first companies to integrate a new Industry 4.0-oriented line with a system that uses virtual reality simulations to train a robot for the most complex painting operations.

© ipcm

RI-ME was among the first companies to use the innovative VR-Tracking system for robot self-learning.

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© ipcm

RI-ME Srl specialises in heat treatment, metal and quartz sandblasting, and powder and liquid coating of components of all sizes.

V

© ipcm

A section of the power&free overhead conveyor in the parts loading area.

irtual reality is a computer technology capable of simulating a

our production, which serves the most diverse sectors, from ACE to oil

real situation through a PC and/or specially developed devices.

& gas and from machine tools to the amusement park industry, with

Within the scope of the possibilities offered by Industry 4.0, it

the latter in good recovery after the slowdown due to the pandemic.”

represents an opportunity in terms of vocational training, machine control, and industrial product design, with the aim of making the

RI-ME: extreme care in controls

manufacturing process more efficient and effective even in complex

RI-ME has two production facilities with a total area of 21,500 m2 and a

production systems such as those including coating lines.

specialised workforce of around 50 employees.

“The state incentives for the digital transition,” explains Giovanni

“We are equipped with two heat treatment furnaces, different types of

Zambon, the president of RI-ME Srl, a company specialising in heat

metal and quartz shot blasting machines, and two coating plants for

treatment, mechanical surface preparation, and powder and liquid

the application of liquid and powder paints, one with a continuous-

coating of heavy metalwork fabrications for thirty years, “pushed us to

flow one-rail handling system and the most recent one with a

decide to realise the project for a new coating line that we had already

continuous-flow, step-by-step conveyor supplied by CM Automazione

planned but intended to implement later on. This was an opportunity

at the end of 2022.

we could not miss, and I am convinced that all SME entrepreneurs

“One of our flagships is our analysis department, which performs the

like me should seize it. At the same time, we went a step further by

necessary measurements for the quality certification of the services we

integrating this new line with a latest-generation robot supplied by

provide. It carries out all the necessary tests for pre- and post-painting

CMA Robotics Spa (Pavia di Udine, Udine, Italy), capable of simulating

verifications following international quality standard regulations.

the operations “virtually taught” by our coaters. Designed and installed

Checks relating to surface preparation before coating include

by Sartec Srl in partnership with CM Automazione Srl, the supplier

verification of environmental parameters and of surface cleanliness

of its Power&Free conveyor, this new system fits perfectly with the

and tests for roughness, surface salts, and dustiness. During painting,

parameters of Industry 4.0. We use it for painting medium and small-

we check different environmental parameters and wet film thicknesses.

size parts and relatively small batches compared with the standards of

After application, we assess dry film thickness and adhesion values

international PAINT&COATING magazine - MAY/JUNE 2023 - N. 81

135

and we perform cross-cut, pull-off, and porosity tests. Our team

© ipcm

also includes a NACE-certified technician who guarantees the very high quality of our corrosion protection tests.”

From shot blasting to coating: a varied service portfolio 90% of the material treated by RI-ME undergoes mechanical pretreatment and the remaining 10% chemical pre-treatment. The mechanical preparation technologies used are different: “Shot blasting,” explains Zambon, “is a mechanical process by which the most superficial part of a material is removed by abrasion caused by a jet of grit and air. We use metal grit on carbon steel, aluminium, and cast iron products. Our plants are equipped to perform both manual and automatic shot blasting treatments with tunnel and tumble belt systems, as well as with two hoist

© ipcm

systems with a load capacity of 8 and 10 tonnes respectively, with a maximum length of 18,000 mm. We also perform a quartz shot blasting process to remove any layer of impurities, such as rust and old paint, by abrasion: the treated surfaces appear clean and slightly rough, suitable for the subsequent application of coatings, adhesives, and other substances”.

As far as chemical pre-treatment is concerned, on the other hand, the factory is equipped with an off-line 5-stage tunnel. “From here, the parts are taken to our new coating line, where they are dried in an air stream oven also used for baking after liquid painting.”

Industry 4.0 and virtual reality In terms of coating operations, RI-ME’s main requirements were to relieve its main plant of the treatment of small batches and to optimise handling, painting, and drying operations. “This resulted in the need for a system specifically designed to optimise the © ipcm

automatic handling of small lots,” indicates Zambon. “Therefore, we implemented a powder and liquid coating line that allows interconnecting all the functional devices involved in the painting process, from the conveyor to the pumps and from the robot to the ovens, in full compliance with the Industry 4.0 parameters.

From top to bottom: The robot self-learning booth, which is also used for coating non-standard parts.

The operator teaches the robot by performing a normal painting operation.

The coater’s movement is recorded by sensors connected to a laser tracking system, and then converted into the robot’s pattern.

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© ipcm

The 6-axis articulated robot from CMA Robotics’ 6100 series mounted on the ceiling.

© ipcm

The robot’s control system interfaces perfectly with the company’s management system.

“Each of the conveyor’s load bars is equipped with a magnetic TAG that

The VR-Tracking system can be easily integrated into an existing coating

ensures the exchange of information with the management system and

line: an operator can manually paint the first component of each series

enables the tracking of every part’s route through each stage of the

and the robot can take care of the following ones. Especially compared

coating cycle. The TAG is also associated with the part’s drawing and the

with the method requiring moving the entire robot arm during teaching,

painting programme to be communicated to the robot when entering

this new technology brings significant simplification.”

the booth. For the creation of the programmes that the CMA Robotics

Therefore, Sartec created for RI-ME a pilot plant equipped with two

6100 6-axis articulated robot has to follow, we have chosen two different

coating booths. The first one is an in-line booth divided into two identical

methods: with simpler parts, they are created automatically thanks to

areas (6,000 x 3,000 mm) by opposing grids where the ceiling-mounted

the two optical barriers that 2D-scan the shape of the component; in the

robot can work front and back applying two different products (powder

case of parts with particular and complex geometries, the operator uses

or liquid). The second one is an off-line booth to be used for the robot’s

the VR-tracking system to virtually teach the robot how to paint them.

self-learning operations with the VR-Tracking system and for painting

This is the latest innovation in the field of robot self-learning systems.”

non-standard parts.

VR-Tracking: the robot learns from the coater

The advantages of the new system

“The VR-Tracking system,” illustrates Marco Zanor, sales director at CMA

Giovanni Zambon confirms that he was immediately impressed by

Robotics, “is the evolution of the self-learning system in which the robot

the new system. “First of all, compared with traditional self-learning

has to be moved manually. With this technology, an operator “virtually

technologies, setting a painting programme only takes the technical time

teaches” the robot the required orientation and movement using a

required for the application operation, thus streamlining the previously

special joystick on which the spray gun is fixed. The coater’s movement

time-consuming and laborious programming phase. Secondly, the new

is recorded by sensors connected to a laser tracking system, and then

offline software package enables to modify any self-learnt trajectories

converted into the robot’s pattern. This also allows optimising and

to optimise the final results. Other advantages are related to logistics

subsequently modifying both individual points and entire sequences.

and the characteristics of the robot: manual self-learning, in which the

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operator guides the mechanical arm, does not allow

© ipcm

constructing devices beyond a certain size due to the limitations imposed by the need for lightness and physical reach during programming; with the VR-Tracking system, on the other hand, the robot can have the size and weight best suited to every application requirement.

Finally, the operator does not have to stand in front of the robot to create the programme, but they can work in another area of the department, as in this case, or even in another location. Initially, the plant’s layout was conceived as a more linear loop circuit, but this solution was soon replaced by a more complex layout developed

by Sartec that, however, resulted in a more functional coating department in which the off-line booth for the robot’s self-learning operations was easily integrated.”

© ipcm

The many challenges of the project “RI-ME needed a semi-automated plant to handle smaller batches compared with its production standards and lots with limited amounts of parts,” states Federico Martellato, the sales manager of Sartec, the company headquartered in Padua that designed and installed the new coating line. “The main challenge was related to the limited space we had available to place all the functional devices for processing the largest number of components possible. This resulted in a long search for the most appropriate layout, which was revised several times before devising the current configuration.

We were assisted in this study by a trusted partner, CM Automazione (Giussano, Monza and Brianza, Italy), which took care of the design and supply of a conveyor that

© ipcm

was not easy to realise, given these space limitations in combination with another critical issue that emerged during the design phase: RI-ME’s need to also paint with multi-coat systems involving the application of powder layers followed by liquid layers and vice versa.

From top to bottom: The control display developed by Sartec with the plant layout.

The lowerator for loading and unloading heavy workpieces.

Each load bar has a maximum capacity of 300 kg.

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FOCUS ON TECHNOLOGY

The solution was found in the installation of an XD37/45 type two-rail overhead conveyor with a continuous-flow, step-by-step operation, featuring 30 load bars with a maximum load capacity of 300 kg each for transporting parts with a length of 4 m, a height of 2.5 m, and variable depth. The handling units move with a 600-mm pitch.

CM Automazione created a bypass from the powder coating booth to the liquid coating one to solve the problem of multi-coat systems. If two powder layers are needed, the chain makes two turns.”

At the three booths (i.e. the one dedicated to selflearning, the powder application one, and the liquid application one), the conveyor is equipped with three devices for the rotation of the handling units. It is also equipped with an oiling station for automatic lubrication, as well as a lowerator for loading and unloading heavy parts. Finally, the line includes three storage buffers © ipcm

before and after the lowerator and one at the bypass point between liquid and powder application.

The curing oven installed by Sartec.

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The coating systems

two with a dimension of 18,000 mm x

Liquid painting is carried out according

5,000 mm x 5,000 mm and one with

to customer specifications and RI-ME

a dimension of 18,000 mm x 9,000

can apply marine-quality systems,

mm x 5,000 mm. The liquid painting

inorganic galvanising paint, epoxy

booth is equipped with fibreglass and

products, food-grade paint, and so on.

Columbus paint stop filters, whereas

The process begins with the picking

the powder booth features a cartridge

up of the parts from the warehouse

filter and a cyclone.”

and the setting of the conveyor parameters. The conveyor is equipped

Conclusions

with the various devices designed for

“I totally relied on the Sartec team for

the best possible arrangement of the

the selection of the right conveyor,”

material to be treated. The operators then prepare the paint and set the hardware and software aspects of

indicates Zambon, “and I was indeed

© ipcm

The WAGNER liquid paint management unit.

the systems. The blanks are checked

advised in the best way possible because, in addition to excellent plant engineering skills, CM Automazione

after pre-treatment: if they do not conform they are discarded or

has an uncommon ability in troubleshooting, which was not to be

reworked, otherwise they are loaded onto the equipment or hooked

taken for granted with such a complex line. For the choice of the robot,

directly to the conveyor. “The raw material,” says Zambon, “then enters

on the other hand, I personally selected CMA Robotics among other

an automatically controlled deionising chamber, after which the

suppliers because I was impressed by the VR-Tracking system they

actual painting phase starts. After application of the liquid primer with

developed, a true innovation in the panorama of AI applied to robotics

manually guided guns or by the self-learning programmed robot, the

that I am considering integrating into the other plant as well. I also had

workpieces pass into a flash-off chamber and are then subjected to

free rein when it came to the application system and therefore I turned

top coat application. This is followed by a further flash-off phase in a

to our long-standing supplier WAGNER, as I already knew the quality

pre-oven and drying in an oven at 80 °C. Finally, the parts are unloaded,

of its equipment. Another task – again not an easy one – that Sartec

checked, packed, and labelled. “For our powder coating operations, we

performed excellently was ensuring that the entire plant with all its

use polyester and epoxy products applied with Venturi pumps both

individual devices interfaced properly with our company’s management

for mass-produced parts with a size of 4,000 × 2,000 mm and a weight

system, in full compliance with the Industry 4.0 parameters. Thanks to

of 150 kg and for non-standard fabrications with lengths up to 12,000

this new painting concept including the VR-Tracking system developed

mm, heights up to 2,500 mm, and widths up to 1,600 mm. The powders

by CMA Robotics, RI-ME has now taken a step forward by projecting

are cured in a second oven that reaches a maximum temperature of

itself into a production reality in which virtual simulation is becoming

220 °C in the combustion chamber.”

an indispensable tool not only for training machines and personnel,

The department is completed by 150-m2 and 300-m2 floor suction

but also for speeding up and further simplifying the manufacturing

systems, connected with three controlled-temperature suction booths:

process.”

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FOCUS ON TECHNOLOGY

An Infrared RHT Radiant Gelling Plant Halves A.P.M.’s Two-Coat Application Time Monica Fumagalli, ipcm®

The use of infrared technology in the industry has led to significant process efficiency improvements in various sectors: in the coating sector, its application has speeded up cycle times by optimising the primer gelling phase in two-coat application processes and the pre-curing operation. This case study focuses on A.P.M. Srl, a shot blasting and coating contractor for the heavy industry and construction sectors that has chosen Infragas Srl as its partner for the supply of infrared panels.

I

n 1800, physicist William Herschel placed a mercury thermometer in the colour spectrum produced by a glass prism to measure the warmth of the different coloured bands of light. He thus discovered

that the volume of mercury in the capillary tube increased even after moving beyond the red edge of the spectrum, where there was no more visible light. This was the first experiment that demonstrated that heat could be transmitted by an invisible form of infrared energy (from the Latin for “under red”, as red is the visible colour with the lowest frequency wave). Since then, the use of infrared rays has been further developed and applied to the most diverse sectors, from manufacturing to home automation, from LED lighting to medicine and aerospace exploration.

A.P.M. installed an IR RHT radiant plant supplied by Infragas for primer gelling in the application of two-coat systems.

FOCUS ON TECHNOLOGY

In the field of industrial coating, infrared radiation (IR) is now widely employed to pre-heat workpieces before applying a second layer of paint in two-coat systems or before curing. “This technology brings clear advantages in terms of both cycle time reduction and return on investment,” emphasises Giovanni Gagliardi, the owner of A.P.M. Srl (San Marco Evangelista, Caserta, Italy), an anticorrosion powder coating contractor treating light, medium and heavy metalwork fabrications for the construction, engineering and furniture industries, as well as the automotive, railway, and white goods markets. “The integration of an IR oven into a coating line is a solution that many contractors prefer not to pursue in order to avoid modifying their systems’ structures. Personally, I think that, in addition to offering the obvious advantage of reducing production times by up to half, this technology also offers limited footprint solutions that are easy to integrate into any plant layout.

© ipcm

For example, in the case of A.P.M., what triggered this investment was the redesign of our paint shop, which we have been constantly updating with state-of-the-art equipment since 1993.”

A.P.M.’s shot blasting and coating plants The A.P.M. factory is equipped with three shot blasting machines supplied by Turbotecnica Srl (Legnano, Milan, Italy) and two coating plants. “We believe that a great mechanical surface treatment is essential for a high-quality coating, therefore we have 3 automatic shot blasting machines which allow us to adequately treat the material in very short times: 2 machines are integrated into the coating line, the third treats semi-finished products with a dimension of 3x3x13 m and a maximum weight of 8,000 kg to an SA 2½ degree finish.” All parts that do not undergo this mechanical pre-treatment phase are cleaned in the new stainless steel tunnel recently installed by M.I. Due Srl (Monza e Brianza), the company

© ipcm

that designed and built A.P.M.’s first plant in 1993. “Today, we use that line to process parts with a dimension of 6x1x2 m and a maximum weight of 500 kg, whereas the static plant installed in 2020 is devoted to large-size parts with a dimension of 12x3x3 m and a maximum weight of 2,000 kg.

“We apply two-coat epoxy, polyester, epoxy-polyester, and polyurethane paints. Before the installation of the gelling oven

From top: On leaving the drying oven after pre-treatment, the parts are primed first on one side and then on the other in the two Gema Open booths.

On the left, the IR oven built by Avin Srl with Infragas RHT panels and, on the right, the GRT booth for the top coat application.

© ipcm

international PAINT&COATING magazine - MAY/JUNE 2023 - N. 81

143

© ipcm

© ipcm

into our automated system, the primed parts had to pass through the curing oven, move all around the plant, and then return to the oven again for final curing after the application of the top coat, thus travelling twice along the whole line. When in 2019 we decided to modify our conveyor, making it suitable for transporting parts up to 6 m long, and replace our booth with a new one, we also made space to install a 3 m-long IR oven built by Avin Srl (San Martino al Tagliamento, Pordenone, Italy) with 10 RHT infrared panels supplied by Infragas Srl (Mappano, Turin, Italy). The booth of the Superior line, built by GRT (Modena, Italy) has an air flow rate of 20,000 m3/h and is equipped with reciprocators, vertical and horizontal detection system, an automatic system for cleaning the bottom of the booth and the guns, as well as of six automatic and two manual powder guns supplied by Gema.

Therefore, the coating cycle performed on our automatic plant now includes as follows:

© ipcm

mechanical or chemical pre-treatment; blow-off or drying; manual application of the primer in two Gema Open cartridge booths, one for each side of the part to be treated; oven gelling; manual application of the top coat in the quick colour-change booth equipped with dense phase technology; and curing in the oven with a final cooling station for immediate handling of the component.

Integrating the line with a gelling system has made this new process possible while halving our coating cycle time.”

RHT gas radiant burners “The installed gelling oven,” indicates Francesca Marabotti, Infragas Srl’s Business Development Manager, “is equipped with 6 From top left clockwise: - Primer gelling in the IR oven.

- The gelling oven has 10 RHT infrared heaters, i.e. 3 on each side and 4 tilted forward (2 at the top and 2 at the bottom).

- The top coat application booth with Gema’s OptiCenter powder centre.

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side RHT 6C panels (3 per side) and 4 RHT 5C panels (2 at the top and 2 at the bottom, tilted forward), with a total power of 560 kW, suitable for gelling the high thicknesses required by the heavy metalwork fabrications handled by A.P.M. These

FOCUS ON TECHNOLOGY

Radiant High Temperature (RHT) panels are high-temperature

© ipcm

infrared burners ideal for heat treatment of materials subjected to high process speeds and needed of a high power density.

They emit shortwave infrared radiation, they can be adjusted by up to 50% of their nominal power, and they are ready for installation. Complete with a control unit that manages air-gas mixing, flame control, and power regulation, they are CE certified and available in different configurations. Our team developed this technology to meet the needs of all end users that need innovative solutions to speed up their production cycle without losing sight of coating quality, such as A.P.M., which was one of the first companies to recognise its advantages.”

“Thanks to this investment, we were able to redesign the layout of our line, which used to present a risk of contamination of the painted parts, reversing the conveyor’s route and streamlining the coating cycle,” confirms Gagliardi.

Giovanni Gagliardi, owner of A.P.M., and Francesca Marabotti, Infragas Srl’s Business Development Manager.

© eosmarketing

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From top left clockwise: on the left, the pre-treatment tunnel and, on the right, the curing oven; The recently installed static system; the static plant treats parts that are up to 12 m long.

The choice of the right power supply source for heating

machinery every year. Costs are significant, but this equipment

“To reach the kW power required for primer gelling,” adds Gagliardi, “I

enables us to run very efficient production cycles. Today, we can

personally chose gas instead of electricity, because the latter would have

provide durable, high-quality coatings in compliance with ISO 12944

forced us to install a power plant and face the risk of longer lead times

requirements for all atmospheric corrosion classes, including C5 indoor

for reaching the right temperature.”

and C5-I and C5-M outdoor classes, combining process efficiency with

“RHT burners are a safe and reliable source of heat,” explains

fast delivery times.

Marabotti, “generated by the combustion of natural gas or propane and

During the pandemic, one of the factors that increased the risk of

transmitted through short-wavelength infrared rays. The gas premixed

surface corrosion on structures was the block of container ships

with the air from the control group is transformed into infrared energy

outside the world’s major ports. One of our most important customers

in an environmentally friendly and absolutely safe manner. The front

had sent 30,000 kg of heavy metalwork fabrications coated by A.P.M.

fiber is made by sintered and high temperature resistant material: It

by sea to the port of Los Angeles. For none of these products, which

has to be considered that it reaches up to 950 °C at maximum power.

remained in the bay for several days, did we receive any complaints

Finally, the structure of the RHT panels is made of stainless steel,

related to traces of corrosion: this is a point of pride for my staff, my

maintaining its robustness over time.”

company, and myself. We have reached this quality degree thanks to

A forward-looking investment

the forward-looking investments we have made and our ability to take advantage of them in the best possible way. This also applies to the

“I have always believed in the need to invest in quality,” states Gagliardi.

RHT technology of our gelling plant, in the use of which we have been a

“This is why A.P.M. invests in state-of-the-art surface treatment

pioneering company.”

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N. 81 - MAY/JUNE 2023 - international PAINT&COATING magazine

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ROAD TO 2050

New Interpon Initiative Helps Customer Reduce their Energy Consumption Interpon powder coating is launching a brand new initiative, to help coaters and manufactures save on overheads and tackle energy consumption to meet future sustainability targets.

A

kzoNobel is launching a new initiative to help manufacturers

consumed. lt also shows how different products are being innovated to

and coaters using lnterpon powder coatings to better manage

support a more efficient powder coating operation.

and reduce the amount of energy they consume to tackle rising

At the heart of the initiative is an energy savings calculator to give

energy costs and meet future sustainability targets.

customers a first indication of the potential energy savings and carbon

The initiative explores how even small changes in the powder coatings

footprint reductions they can make.

process can make a big difference on the value and volume of energy

The calculator is supported by an energy savings tips document

© AkzoNobel

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EPISTOLIO EPISTOLIO towards the future

that shows how simple measures such as checking for leakages in compressed air systems, improving insulation, and ensuring all process equipment is regularly serviced and maintained can all

SOLUZIONI ROBOTIZZATE DI ROBOTIC PAINTING SOLUTIONS VERNICIATURA

contribute to greater efficiency. ln addition, it features a number of lnterpon products that can contribute to even more energy efficiency - through low temperature curing properties (e.g. lnterpon 610 Low-E, lnterpon ACE Low-E, and lnterpon 700 HR) or single layer coating options (e.g. lnterpon Redox One Coat).

The initiative similarly demonstrates how lnterpon solutions go beyond the powder in the box. Through expert knowledge and service built over more than 50 years, and access to lnterpon’s Technical Service teams who can audit and advise on line set-up and recommend process improvements, customers can reduce their energy consumption to drive a more sustainable business - a key factor in customer buying trends.

Remco Maassen van den Brink, Marketing Director AkzoNobel Powder Coatings, says that many businesses want to reduce energy, but need support in taking the first steps: “Sustainability is criticai for all of us and helping our customers to reduce energy is one of the many ways we can work with, and for, our customers in meeting our shared ambitions. AkzoNobel’s own journey has already started in reducing our carbon emissions across our full value chain by 50% by 2030.”

For further information: www.akzonobel.com/en/about-us/sustainability

© AkzoNobel

Epistolio Srl.

Publierre_Milano

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

HIGHLIGHT OF THE MONTH

Claudio Minelli Appointed as the Honorary President of Verind after a Fifty-Six Year Long Career Edited by ipcm®

The Verind shareholders’ meeting appointed its new board of directors, president and honorary president, and general managers. After a fifty-six year long career in the coating industry, Claudio Minelli became the honorary president of the company founded by his mother in 1958. support of Mario Camozzi, Pietro Pizzamiglio, and Adolfo Bax. These were the founders of Olpi, a firm specialising in the construction of coating systems for the automotive sector that purchased paint application equipment in the USA, Germany, and France. They thus had the idea to create a direct import company that was separate from Olpi but able to support it in its work in the automotive sector, while also selling the same products to all potential customers of the industrial market. The three founding partners entrusted their young and capable employee, Maria Berera Minelli, with this challenge. Verind’s success actually owes much to her character, drive, and ambition, but also to the economic boom of the 1960s, the simultaneous development of several small and medium-sized Italian companies needing to improve their products’ finishes with new techniques, and then Claudio Minelli’s From the left: Alessandro Molé, Lars Friedrich, Claudio Minelli, Marco Pizzamiglio, Matteo Minelli and Thomas Hohmann

V

great ability to lead the company into the 21st century.

A lifelong career “My professional history has been long but linear. I have only had one

erind S.p.A., an international company belonging to the Dürr

job!” says Claudio Minelli, interviewed by ipcm® on the occasion of his

Group and specialising in the industrial coating, surface

appointment as Verind’s honorary president. “I started my career in

protection, ultrafiltration, and water treatment fields, celebrated

1967 at Olpi, which would later become Olpidürr, as an assistant to

its 65 anniversary on Wednesday, 26 April 2023. At the same time, its

Pietro Pizzamiglio, one of its founders. For a long time, Pietro’s son

shareholders met to appoint the company’s new board of directors,

Roberto formed a historical pair in the painting world with my father,

Lars Friedrich as the new president, and Thomas Hohmann, Marco

who was the technical director of Olpi back then. It was thanks to the

Pizzamiglio, and Matteo Minelli as directors. They also appointed Claudio

involvement of Roberto Pizzamiglio in the company that Olpi entered

Minelli, the company’s former president and CEO, as its honorary

the car coating sector and began its industrial development, also

president, thanking him for his outstanding work over more than fifty

through numerous collaborations with foreign firms. For example, in

years in Verind’s management. On the same day, the new board of

the middle of the 1960s, it initiated contact with a German company

directors resolved to appoint Matteo Minelli and Alessandro Molè as the

that had invented a coating technology using current, electrophoresis,

new general managers.

thus replacing the old flow coating system. From those years, I

Founded in 1958 by Maria Berera Minelli, a prominent figure in the

remember the long evenings spent talking with Pizzamiglio to invent a

Italian coating industry who has been at the helm of Verind together

control system for managing the cost of each of the coating plants we

with her son Claudio for over sixty years, this company started out

sold, as it was not possible to know their actual costs until months after

by marketing pneumatic pumps and electrostatic guns thanks to the

start-up! There were not many books to help us, so we invented the

th

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HIGHLIGHT OF THE MONTH

first industrial cost accounting system for defining the cost of each order and checking its progress week by week.”

With this first success in the technical-managerial field, the first part of Claudio Minelli’s career came to an end when he joined his mother Maria’s company in 1970.

“In the 1970s, the automotive industry’s need for industrial partners capable of supplying, assembling, installing, and starting complete systems represented a turning point for Verind,” indicates Claudio Minelli. “In the same period, my mother had the great idea to implement the profit centre concept into her company, assigning each manager a different sector and each sector a cost and revenue account. These were years of great development, very dynamic but also very hard. At the time, the automotive sector – that was assigned to me - in Italy was composed of numerous factories all over the nation and I was always travelling among customers. In the early 1980s, we started selling high-speed rotary atomisers mounted on Cartesian machines for painting car bodies. We worked for a long time with German company Behr, a manufacturer of bell plants, until its owner decided to sell his business to German company Dürr. That was the beginning of our fruitful collaboration with Dürr and also of my professional growth, as I first became the general manager of Verind, then in the late 1990s its managing director, and finally the president of its board of directors, holding this position for more than 20 years.”

www.cmautomazione.com

Since the 1990s, when the partnership with the Dürr Group began, this also gradually entered Verind’s shareholding structure up to its current 50% share. In the meantime, Claudio Minelli led Verind from the economic boom of the 1980s to the 2000s, when the family’s third generation began taking over its management. “After twentyfour years at the helm of the company, I have become its honorary president. I will continue to work here, but with a supporting role, the same role my mother played until the end,” states Claudio Minelli. “I would like to help others in a silent and reassuring manner.

Employees see me as a symbol of continuity and closeness, especially those who have been with Verind for a long time. My professional path has been linear but, during these fifty-six years of my career, I have witnessed beautiful periods of technological and commercial innovations and revolutions in the automotive world. I realise that today there are no longer the conditions for a company to have such a rapid and intense development trajectory as Verind’s one. Over the years, we have also been lucky enough to come across many partners that have offered us outstanding technological support and great development opportunities. Now, I cannot wait to find out what the future holds for us at technological level.”

CM AUTOMAZIONE s.r.l.

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

SUCCESS STORIES

A Quality-Conscious Approach to Purchasing Powders: Colortec’s Philosophy Alessia Venturi, ipcm®

Colortec (Volpiano, Turin, Italy) is one of the most exclusive coating contractors in the Piedmont region.

With two modern coating lines, one automatic and one manual, Colortec applies two-coat outdoor protective finishing cycles for a wide range of industries in which the aesthetic and functional quality of coatings is strategic. These excellent operating results are also achieved thanks to its partnership with TIGER Drylac Italia, Colortec’s main paint supplier, which guarantees constant high powder quality and above all colour consistency and stability from one batch to another.

“T

he impact of the cost of powder on a coating operation is not

Piedmont region that does not only paint the metalwork fabrications

so high as to justify the choice of using poor-quality, budget

necessary for the construction of Eurotherm plants and all the Group’s

products instead of aiming at a higher yield, reduced waste

machines, but also applies high-quality finishes, two-coat coating

and rework, lower consumption, and above all better finishes – and

systems, and corrosion protection powders for a wide variety of

therefore increased customer satisfaction – through high-quality,

industrial sectors.

although more expensive paints.”

“Thanks to the advanced management control system that we have

These are the words of Paolo Ghiazza, the general manager of

implemented, we have calculated that powder accounts for less than

Eurotherm Spa, a company designing, building, and installing coating

12% of total process costs. This is why we have chosen to start a

systems, and Colortec Srl (Volpiano), a leading coating contractor in the

long-term collaboration with TIGER Drylac Italia, which over the years

Metal parts coated with TIGER powders at Colortec’s site in Volpiano. © ipcm

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SUCCESS STORIES

has become our largest supplier of powder coatings – meaning that TIGER is always our first choice when an end customer does not include a different manufacturer in its specifications,” Ghiazza adds.

“The advantages brought by TIGER coatings in terms of coverage, finish, product yield, and consumption, but also of waste reduction, in total deliver more value to us when comparing to other offerings, also considering that they lower our overall process costs and therefore increase our competitiveness in a difficult market such as the contracting one.”

Paint quality consistency from batch to batch Founded in 1930, TIGER Coatings is now a globally operating family-

© ipcm

owned business with 8 production sites, 3 R&D centres, and a sales network in over 50 countries. It is the world’s sixth largest manufacturer of powder coatings and its range of products is used in a variety of industries from automotive to architecture. It is also the ideal partner for coating contractors with a focus on quality and performance, thanks to its profitable solutions that increase productivity and the added value of finished products. “The Italian manufacturing industry is known for the quality and beauty of the products it creates: the “dress” of these products should also live up to such a high design and production quality. Both aesthetic factors such as paint distension, tactile effect, and hue saturation, and technical aspects including ease of application, optimum coverage, transfer efficiency, and chemical and weathering resistance are at the heart of TIGER’s product policy,” explains Alberto Zancan, the Sales Manager of TIGER Drylac Italia. © ipcm

“Our partnership with Colortec, a benchmark company in the Piedmontese contract coating sector, is a testimony to this: Colortec is a fully digitalised company, with full management control and traceability of painting parameters that allow measuring in practice the operational benefits of using TIGER powders. The higher product yield achieved, for example, is guaranteed by the high engineering degree of our paint, which has such a particle size consistency that the product recovered after application is fully reusable. In TIGER’s headquarters in Wels (Austria), constant fine-tuning of machine settings and production control ensures consistent quality and colour uniformity even among different batches. The formulation consistency of our powders also helps us achieve this result, guaranteed by the fact that we produce the required resins in-house. In the coming years, we are actually going to expand our resin production capacity to meet the growing demand for

© ipcm

TIGER powders.”

“There is no doubt that the operational benefits of high-quality powders can only be appreciated when implementing optimal paint management control,” emphasises Paolo Ghiazza. “Still too many coating contractors rely on chance in the planning and management of day-to-day operations and this does not help them assess the real impact of their

From top to bottom: - From left to right, Ilaria Paolomelo from ipcm®, Luigi Sacco from Colortec, and Marzia Brambilla and Alberto Zancan from TIGER Drylac Italia.

- A TIGER metallic finish applied on aluminium fan cover plates.

- Automatic spraying of epoxy primer.

international PAINT&COATING magazine - MAY/JUNE 2023 - N. 81

153

SUCCESS STORIES

Gelling of the first powder layer in the IR oven with RHT gas radiant burners supplied

by Infragas Srl.

© ipcm

The automatic top coat application booth with a manual post-finishing station.

Some parts before and after powder curing.

© ipcm

© ipcm

costs. Better understanding on the part of coaters would be needed to

metallic effect products,” notes Alberto Zancan. “Finally, one of TIGER’s

support powder manufacturers offering high-quality products.”

services that we value most is the development of customised colours,”

Customised, stable, and durable colours

says Paolo Ghiazza. “In particular, we tested this with Eurotherm’s colours: we needed to match the blue of the paint with the blue of the

“TIGER provides us with both standard and Qualicoat-approved

silicone we use to insulate our machines. The latter has a shade that

polyesters, epoxy primers for two-coat systems, and hybrid powders,”

is close to RAL 5002, but the standard powder colours did not match

explains Luigi Sacco, paint shop manager at Colortec. “Within

well: TIGER therefore developed a special Eurotherm blue that perfectly

their finishes’ range, we particularly appreciate the textured ones,

matched the silicone’s hue!”

which have a very nice, homogeneous, and fine tactile effect. Both the tint and finishing performance of TIGER’s products are very

Service implementation

stable over time and outdoor colour retention is excellent. Stability

“To support our industrial customers, particularly coating contractors,

and homogeneity among different production batches are also

TIGER Drylac Italia’s strategic goals include the further improvement

appreciable: we consider this a major advantage because some

of our services with medium-term objectives,” says Marzia Alessandra

batches of powder might be stored and then used after a long time.

Brambilla from Tiger’s Business Development & Marketing department.

Finally, their ease of application ensures excellent results even with

“TIGER has a great development potential and there is still a lot of room

metallic paints.” “TIGER uses a second-generation bonderisation

for growth in the Italian market. Product quality in particular is certainly

system that guarantees ease of application and consistent,

our main strength, as it guarantees undoubted process savings to

homogenous coating results, avoiding the typical surface defects of

users.”

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Free of APEs, P, F, B and hydrochloric and nitric acid

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Superior paint quality for multi-metal applications

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UniPrep® AC products can operate at a mild to near-neutral pH and are free of alkylphenol ethoxylates (APE), phosphorus and boron as well as phosphoric, hydrofluoric, hydrochloric and nitric acids, satisfying many customer and regulatory requirements.

Enhanced paint performance Improves safety Saves time and money Near neutral pH Spray or immersion processes

Atotech an MKS Brand info @atotech.com

www.atotech.com

© Stelma Paint

FOCUS ON TECHNOLOGY

Stelma Paint Invests in a New Powder Coating Plant with a Cutting-Edge Application System to Perform over 80 Colour Changes per Week Gabriele Lazzari, ipcm®

Stelma Paint is a powder coating contractor that aims at providing its customers with the highest possible degree of flexibility and production speed. Thanks to its new plant designed and built by Avin and to the application technologies supplied by Gema, it has been able not only to increase the quality of its finishes but also to improve its production flow, as it can now perform more than 80 colour change operations per week.

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© ipcm

The loading area of the new coating line designed and built by Avin.

B

© ipcm

A component to be coated, loaded onto the one-rail overhead conveyor supplied by Se.Po. Italia.

esides aesthetic quality and corrosion, chemical, impact, and

From stagnation to expansion in a new headquarters

scratch resistance properties conferred on the parts they treat,

Massimo Stella founded Stelma Paint Srl in Vidor (Treviso, Italy) in

coating contractors normally need to achieve a high degree

2008 by taking over the company of his previous employers, who had

of operational flexibility and production speed to quickly serve their

intended to close it down as a consequence of the global economic

customers operating in the most diverse industrial sectors.

crisis of the previous year. Despite the initial difficulties and problems,

Leveraging its founder’s thirty years of experience in surface finishing,

Stelma Paint has gradually grown, moving to Pieve di Soligo (Treviso,

Stelma Paint has positioned itself as a strategic partner by offering

Italy) and expanding and optimising the coating technologies at its

advanced technical expertise, specialised resources, and state-of-

disposal. The positive results of these investments have allowed the

the-art equipment to guarantee optimal painting results. Its constant

company to expand even further, up to acquiring a plot of land in to

search for innovative solutions to update its available technologies,

build its current headquarters in Follina, improving the quality of the

improve its offer, and anticipate its customers’ quality demands

finishes offered to its customers and increasing its production volumes

has been rewarded by the market, enabling it to expand into a new

at the same time.

headquarters and increase its production volumes. Its most recent

“Although I was already at an advanced age, I was sad to see the firm I

investment, in particular, was a new powder coating plant supplied by

had worked in for over thirty years close. So, I decided to take over the

Avin Finishing Solutions (San Martino al Tagliamento, Pordenone, Italy)

business and, thanks to the great professionals working with me and to

with a MagicCompact EquiFlow BA04 booth and a 0C06 OptiCenter®

our innovative spirit, we are now a very solid local business employing

All-In-One powder centre supplied by Gema. This has enabled Stelma

twelve people,” says Massimo Stella, who runs the company together

Paint to improve its production flow and handle up to 80 colour change

with his daughter Mayra while waiting for his other son to enter into the

operations per week while continuing to guarantee a high finishing

family business. “Initially, we only had a small line and served our local

quality level.

market within a radius of about fifty kilometres. Over the years, we have

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© ipcm

© ipcm

Parts at the entrance to the spray pre-treatment tunnel.

Load bars exiting the pre-treatment tunnel.

added new technologies, such as a static drying oven installed after the

After drying in a 30-metre-long air stream oven at 120 °C, the parts are

pre-treatment tunnel, which have enabled us to improve our offer and

gathered in a storage buffer to cool down naturally. The load bars then

grow. Today, we are able to perform between 50 and 80 colour changes

proceed to the Gema MagicCompact EquiFlow BA04 booth. Afterwards,

per week, because we want to ensure maximum delivery speed. In this

the coating is cured at 180 °C in a 60 metre-long, “U”-shaped oven with

way, we can serve a variety of both local and international customers

two combustion chambers but with modular burners, in order to avoid

in a wide range of sectors: from interior design to light metalwork

temperature peaks. Finally, the parts are cooled in a second storage

fabrications and from automotive to transport.” The growth of Stelma

buffer.

Paint also required the replacement of the previous powder coating

“Our previous experience led us to opt for drying and curing processes

plant with a new solution that would allow the company to increase its

that would not waste heat: this is why we asked Avin to design the

production volumes while maintaining high operational flexibility and

coating plant so that the two tunnels were installed side by side,”

finishing quality.

explains Stella. Morgan Infanti, the General Manager of Avin, confirms:

Avin’s plant customised for Stelma Paint’s needs

“We had to modify the structure of the curing oven and of the drying tunnel located after pre-treatment, placing the tunnel’s entrance in

The old static painting line is still used to treat special batches, but the

conjunction with the oven’s inlet and outlet doors to allow for heat

Pieve di Soligo site is now also operating an automatic powder coating

recovery.”

plant for iron and aluminium components designed, built, and installed

by Avin, which enables it to process parts with a maximum size of 1.5 x

Gema’s application technologies

3 x 0.8 metres and a maximum weight of 100 kilograms. The new plant

The plant designed by Avin, therefore, integrates a booth and

has a line speed of 2 metres per minute and it is served by a one-rail

application technologies provided by Gema, which have enabled Stelma

overhead conveyor built by Se.Po. Italia (Olginate, Lecco, Italy).

Paint to increase production speed and finishing quality by achieving

First, this leads the load bars from the loading area to the multi-

optimal penetration of the polyester powder paint, greater coverage of

metal spray pre-treatment tunnel where the parts undergo an initial

the entire parts’ surfaces, maximum coating homogeneity, and excellent

phosphodegreasing phase at 55° C, two rinses with mains water, a

impact and scratch resistance properties. The equipment provided

further rinse with demineralised water, and a final passivation stage.

includes the rectangular MagicCompact EquiFlow BA04 booth with

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FOCUS ON TECHNOLOGY

a cyclone, the 0C06 OptiCenter® All-In-One powder centre for quick

setting the required film thickness and changing it when different parts

colour change operations, two reciprocators with four OptiGun GA03

need to be coated.

dispensing guns each, and the MagicControl 4.0 plant control unit.

The booth is also equipped with the GemaConnect app to read data and

The OptiCenter® All-In-One system

constantly checking eventual maintenance operations. So, it is possible

The peculiarity of the equipment delivered to Stelma Paint by Gema

to ensure the efficiency of the booth and a quick supply of the wear

lies in the 0C06 OptiCenter® All-In-One multifunctional powder centre,

materials.

whose compact design effectively saves space within the plant thanks

The non-conductive plastic structure of the booth, in combination with

to the absence of gun control modules, and whose OptiSpeeder tank

the EquiFlow extraction technology, prevents powder from accumulating

optimally fluidises the paint and has a large slanted opening allowing for

on the bottom and adhering to the walls, while its “H”-shaped floor

quick and easy access to the powder container. This system monitors

ensures excellent air distribution and balanced suction, as the three slits

and controls the air flow and electrical parameters more accurately,

in the bottom guarantee optimal powder containment and ventilation

thus enabling greater atomisation efficiency. Being integrated within the

in the manual application area. This creates a uniform air flow that

electronic board, its motors manage the air flow and the powder feeding

ensures easy control of the application process and outstanding coating

tubes for smooth, precise, and consistent delivery, thus improving

results. The booth is designed for quick colour change operations and

paint flow management and allowing a precise amount of powder to be

automatic cleaning of internal circuits, the float, spray pipes, and spray

dispensed depending on the current application needs.

guns. It is also equipped with an automatic filter emptying function and

“The use of OptiCenter® All-In-One in combination with the coating

two manual guns at the ends of the booth for pre and post-finishing

booth’s EquiFlow technology generates a closed-loop powder

operations. In anticipation of a possible need to further expand

application environment, thus reducing overspray and improving

production, Gema’s booth can be configured differently in terms of size,

efficiency. Electricity consumption is also reduced by 25% and

air intake volume, and number of guns and manual touch-up stations.

compressed air consumption by more than half,” indicates Graziano

The user-friendly interface of the MagicControl 4.0 control unit, with

Scarinci, Gema Europe’s sales representative for the Veneto e Friuli

its convenient icon-based touch screen, can be easily mastered by the

regions.

operators to create standardised programmes for multiple batches by

“Although the number of batches to be coated has increased, our

© ipcm

The plant’s control panel, showing the special “U” shape of the curing oven.

© ipcm

A component coated with Gema’s OptiGun GA03 guns.

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cycle time has been significantly reduced. Gema’s OptiCenter® All-In-One has brought us three advantages right from the outset: powder penetration has increased, film distension has improved, and powder consumption has decreased,” adds Stella.

A successful collaboration Stelma Paint’s collaboration with Avin and Gema was therefore very fruitful, as it provided the coating contractor with the most suitable solution for its processes, enabling it to improve production quality and reduce the time needed for colour changes. In turn, this has increased its turnover, improved the healthiness of its working environment, and decreased its © ipcm

powder consumption. “We decided to rely on Avin and Gema after listening to the testimonials of some fellow coaters and acknowledging the professionalism demonstrated by their technicians in the initial phase of our collaboration. Admittedly, I had some misgivings during this new plant’s analysis and design phase, since our requirements were very peculiar. The special layout of the line aimed at matching the drying and curing ovens’ inlets and the application technology selected were new challenges for us.

“However, we found in Avin and Gema two reliable and flexible partners that listened to our requests, examined our needs, considered our suggestions, and clarified our doubts. In addition, their geographic proximity is a further positive factor, because we know they will quickly intervene if we need spare parts or specialised technical assistance through their local service partner Tecnospray from Pasiano

© ipcm

di Pordenone”, concludes Stella. “In addition to a considerable reduction in powder consumption, which was incidental to our requirements, Gema’s equipment also improved our paint penetration and spreading rates. We are completely satisfied with this investment. The system was installed in March 2023 and it is not fully operational yet, but its quick colour change system has already allowed us to gain a full day’s production per week.”

From top to bottom: The pre-treatment tunnel and the drying and curing ovens installed side by side.

© ipcm

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The MagicCompact EquiFlow BA04 rectangular coating booth and the 0C06 OptiCenter® All-In-One powder centre provided by Gema.

BRAND-NEW

Sole Supplier of Aluminium Anodizing or Painting and Water Purification Plants: The Best Guarantee for the Success of ZLD Process Thanks to the acquisition of the brand CISART, CIE Group is now able to supply a comprehensive system solution for aluminium treatment: anodizing and pre-treatment prior to coating, that belong to CISART know-how, and the related waste water treatment system, a process solution that CIE has been developing since 1980.

C

ISART is a historical name in aluminium

CISART also specialises in high technology

a complete and unique system: surface

surface treatment field (aluminium

processes such as thick anodizing, polishing

treatment line/ depuration system/ chemicals.

anodizing and aluminium coating) as

etc. especially for the aerospace and

This makes the consumer feel reassured and

well as CIE’s name in the depuration of water

automotive industries.

safe from rebound of responsibility.

that comes from those plants.

Recently CIE has acquired CISART brand,

A great example of this integration is the

CISART was founded in 1973 by Dionisio

integrating its technologies with CIE’s waste

realization of Abu Dhabi TALEX anodizing

Cittadini and it counts more than 100 plants

water treatment and ZLD (Zero liquid

plant. In this case, CIE has associated a water

built around the world. In fact, it was the

discharge) technologies and with MST

recycling treatment system to the 2 anodizing

first company in the world to build a vertical

Chemicals’ specialities as well.

lines designed by CISART (one for profiles up

anodizing plant and paint pre-treatment lines.

This integration allows to offer to the client

to 7,5 mt and the other for profiles up to 14,5 mt), reducing water consumption by 50%. This is a process, developed by CIE, called PURALL that makes possible to recycle the water used in the production stage, after a depuration process that removes 90% of pollutants and salts.

The whole surface treatment plant and the PURALL process have been approved by the Ambiental department of Abu Dhabi government, passing the strict limits imposed.

The success was about both the quality of discharges and the amount of water consumed per m2 of treated surface; the water consumed results 50% less than the standard amount used for this kind of production.

For further information: www.cieeng.com

© CIE

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BRAND-NEW

Inauguration of the new Eurotherm France Sales Office On 11 May, the new Eurotherm France sales office in Saint-Quentin-Fallavier (Lyon) was inaugurated with a happy hour offered to business partners.

E

urotherm has been designing and building tailormade systems since 1958 to meet the coating needs of any company, be they small businesses or large

firms, on both the Italian and European markets. From pretreatment operations, such as cleaning and sandblasting, to the application of liquid or powder coatings, Eurotherm’s plants always implement the most efficient technological processes to guarantee excellent results.

After the opening of its representative office in Germany in 2016, having always had a privileged relationship with the French market by tradition and geographical proximity, Eurotherm has now opened a sales and production office in the Lyon area to

© ipcm

support its French dealers.

Eurotherm France’s objectives are to reinforce its service to dealers, to offer technical, commercial, and spare parts assistance, and to support them in projects for more complex markets such as aerospace and automotive, which require highly technical painting equipment.

A strategic location near Lyon and its thriving industrial area, as well as close to major motorway and airport infrastructures, was chosen for the new site, making it very easy to reach. The SaintQuentin-Fallavier offices include a large commercial space with a lounge and a meeting area painted in dusty blue and earthy tones, with a baby blue vintage Fiat 500 car, similar to the one in Eurotherm’s headquarters in Volpiano (Turin, Italy), standing

© ipcm

at the centre. A collage of screens displays videos showing the production stages of Eurotherm’s plants, which are completely manufactured and coated in the Italian factory. There are also several sales offices, whereas the plant including a spare parts warehouse and a production hall is going to be opened soon.

For further information: www.eurotherm.eu

Clara Santos and Mathieu Raudet, Sales Office Manager and CEO of Eurotherm France, respectively.

© ipcm

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BRAND-NEW

Hexion’s Versatic™ Acid 10: A Safer-to-Use Alternative to 2-Ethylhexanoic Acid Hexion’s Versatic™ Acid 10, a proven technology that is safer than 2-ethylhexanoic acid, will help meet the upcoming regulatory changes announced by ECHA.

I

mpending regulatory changes announced by the European Chemicals

regulatory changes,” said Jeroen Jansema, Vice President and General

Agency (ECHA) will favourably position Hexion’s Versatic Acid 10 as a

Manager, Performance Materials (Versatic Acids and Derivatives).

safer-to-use replacement for 2-ethylhexanoic acid (2-EHA). Versatic

“Versatic Acid 10 is just one proven product in Hexion’s Versatic Acid

1

Acid 10, and other Versatics derivatives, are excellent building blocks

portfolio and it delivers a variety of critical performance improvements

that enable the production of high-performance emulsions, high solids

that help customers improve hydrolytic and chemical stability, water

and waterborne resins. They also have the more sustainable attribute

repellency, durability, and adhesion. We have been working with many

of enabling the production of paints and coatings with lower volatile

market leaders as they prepare to transition away from 2-EHA to a

organic compounds (VOC) emissions than before.

higher-performance solution.”

The industry’s move toward alternative products, such as Versatic

Versatic Acid 10 is ideally suited for a variety of applications such

Acid 10, follows the reclassification of 2-EHA and most of its salts as

as dryers for alkyd paints and inks, PVC heat stabilizers, and in the

Reprotoxic Category 1B by the Risk Assessment Committee of ECHA

production of metal-based catalysts for polyurethane applications.

beginning in November 2023. The ECHA 1B rating refers to materials

Its unique performance profile compared to other carboxylic acids

that are presumed to be a human carcinogen (H340), mutagen (H350),

also positions the intermediate as a preferred solution for a variety of

or reproductive toxicant (H360), based on animal studies.

growing applications, including: tire adhesion promoters, fuel additives,

“Versatic Acid 10 is a proven technology that is a high-performance

metal working fluids, antifreeze, bitumen emulsifying agents, esters

alternative for producers who will be impacted by the pending

for solvents or lubricants, cosmetics, personal care, detergents, metal

Safer to use as a non-classified material under Globally Harmonized System of Classification and Labeling of Chemicals (GHS) with no signal word and no known significant HS&E effects or critical hazards.

1

extraction, polymerization initiators, and more.

For further information: www.hexion.com/VA10

© Hexion

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SUCCESS STORIES

Saveral Achieved Unparalleled Improvements in Powder Coating Quality with Its New IPS Coating Centre As reported in the last issue of ipcm®1, Saveral has been an established player in the Italian automotive and industrial part finishing sector for many years, thanks to the flexibility of its coating systems and the high customisation degree it offers. As part of a €1 million investment in 2022 to upgrade its painting equipment, it was among the first Italian companies to install Wagner’s IPS Coating Centre, a unique technology that redefines powder coating and colour change processes while opening up new horizons in terms of plant availability, productivity, and user-friendliness.

1

Gabriele Lazzari, “Saveral: The Italian Powder Coating Pioneer Continues to Innovate Its Plants” in ipcm® 80, Vol. XIV, March-April 2023, pp. 112-116

© Saveral

The IPS Coating System is completely automated, digital and interconnected.

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G

lobalisation and digitisation are increasing competitive pressure in the industry, also in the powder coating field. Plant availability and productivity, therefore, are required to increase. At the

same time, end customers demand increasingly customised products, which entails working with smaller batches and more frequent colour changes. Finally, the shortage of skilled workers is having an impact on performance and quality levels in some countries.

At PaintExpo 2018, Wagner Industrial Solutions launched a revolutionary solution to overcome all these challenges for coaters while maintaining a high efficiency, productivity, and quality degree: IPS Coating Centre.

“The IPS acronym stands for the basic concept behind this new plant: Integrated Powder System. Indeed, only with an integrated approach can productivity and quality be increased and operations streamlined,” explains Marco Spada, Powder Solution Specialist at Wagner. “Combined with a self-cleaning booth, a powder recovery system, guns, and other components, IPS is the first fully automated powder coating system ever configured, a game-changer for all coaters, contractors and others.”

Saveral’s experience with IPS Precisely one of the most important coating contractors in Northern Italy was among the first to invest in IPS. Based in Almenno San Bartolomeo (Bergamo), Saveral is a coating contracting company founded in 1954

by Abele Preda. It was one of the first companies in Italy to include powder coating in its offer and today it counts numerous leading manufacturers in the automotive, metalwork, architecture, furniture, and electromechanical sectors among its customers. Its vocation for technological innovation has enabled it to expand its customer portfolio, the range of parts it coats, and its target markets.

Increasing production volumes and quality demands over the last two years, however, led Saveral to innovate further by becoming one of the first companies in Italy to install a Wagner IPS powder centre in 2022.

“IPS is a 4-in-1 solution: powder preparation, feeding, dosing, and colour change operations are integrated into one fully automatic system that ensures significant improvements in coating quality,” explains Donatella Rota, coating manager at Saveral. “It increases productivity, it ensures consistently high coating quality, it is easy to use, and it guarantees

© ipcm

The Ultrasonic sieve really makes a difference when applying metallic and textured finishes.

short colour change times of 7 minutes on average without operator intervention. Indeed, IPS works completely automatically without human supervision: the operator’s only task is to replace the powder box at each colour change and select the coating programme matched with

“IPS works differently to conventional powder centres,” adds Donatella

the parts entering the booth.”

Rota, “as it operates under a vacuum and without human supervision:

All process steps can be fully automated and centrally controlled.

it weighs the paint, it draws the product from the box corresponding

Powder preparation, feeding, and dosing take place in a closed-loop

to the set programme, it sieves it with ultrasound, it feeds the guns,

system that automatically performs colour changes at the push of a

it cleans the system, and it discharges the recovered powder into the

button.

box automatically. Operator intervention is only required to place the

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SUCCESS STORIES

powder box, select the coating programme

© ipcm

on the control panel, and then remove the box after the colour change and select the subsequent coating programme.”

“The benefits we have experienced since the introduction of IPS could frankly only be guessed at the time of our purchase,” says Amos Pesenti, Saveral’s plant manager. “Its automation level is such that the operator is redundant, which is no small thing at these times of extreme shortage of skilled labour.

The touchscreen user interface is very simple, even simpler than that of the other powder centre in Wagner’s range, SuperCenter, two of which are in use here at our premises.

The IPS machine is connected to Saveral’s management system: it reads the barcode on the powder box, verifies conformity with the tint included in the programme selected by the operator, and starts to draw a new colour independently.”

Combined with a self-cleaning booth, a powder recovery system, guns, and other components, IPS is the first fully automated powder coating system ever configured.

“The cleanliness level at the colour change operations is unparalleled: with the previous system, we used to treat the feeding pipes with glass grit every fifteen days to keep them clean. With IPS, even after two months of

© ipcm

use without treating it with grit, the booth’s suction pipe is still clean,” indicates Pesenti.

“During application, no cloud is formed. On the contrary, the transfer efficiency is so high that the powder in the booth seems to be very little. As a result, the exhaust powder in the final filtre is radically reduced. The ultrasonic sieve really makes a difference when applying metallic and textured finishes since the dynamics of vacuum powder coatings management is completely different (Soft Rain). Finally, another advantage in the assistance service is the option to use the Hololens (AR glasses) with a real time connection, that allows a quick contact and a just as quick and effective response.”

The touchscreen as a very user-friendly interface.

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Integration and automation for high system availability “Many factors ensure the high availability degree of IPS: its SMART BOXER fresh powder system can house two boxes of powder, thus reducing the risk of downtime caused by the plant running out of product. Integrated sensors allow for the automatic recording of paint consumption for each batch. At the core of the system, the IPS MASTER unit, Wagner has integrated a closed-loop powder preparation, feeding, and dosing system, including an ultrasonic sieve as an important element to guarantee a high coating quality.

The system allows changing colours in as less as 5 minutes, depending on the tint. Whereas conventional powder centres have to be cleaned manually by an operator, resulting in their exposure to powder and in the risk of environmental contamination, the IPS machine’s cleaning process is fully automatic,” says Marco Spada while presenting the technical benefits achieved by Saveral.

“Another automatic process is the powder feeding one with Smart Feeding Technology (SFT), using recovered air and an electronically controlled metering valve to create an almost wear-free, highperformance circuit. The advantage is that the parameters no longer have to be adjusted manually – a task that used to require the intervention of experienced personnel. Powder supply is constantly monitored by sensors, which guarantee high process reliability with a pipe length of up to 30 metres. Thanks to this and other technological innovations, the SFT feeding and dosing technology guarantees consistent operating conditions over a long time. Finally, the powder centre can be connected to Wagner’s Internet of Things solution, which, for example, provides real-time monitoring of key aspects via graphic elements and an interface to Wagner’s services.”

“The investment for IPS was certainly significant. However, after less than one year of use, we expect to achieve a return on investment within a shorter than expected time,” concludes Amos Pesenti from Saveral. “In future, we are definitely going to also replace our other powder centres with this technology”.

© Kilometro Rosso SpA

It is not easy to find red buildings in the everyday landscape, probably because of the controversial nature of this colour. The exception is the Kilometro Rosso, the building designed by Jean Nouvel which runs alongside the A4 motorway in the province of Bergamo (Italy).

COLOUR STUDY

The Most Controversial Colour: Red Monica Fumagalli, ipcm®

Used since prehistoric times for the first pictorial drawings, red arouses conflicting emotions by its very nature: loved and hated at different points in history, this primary colour has reached the present day as a protagonist in the most diverse fields, from art to fashion, from astronomy to architecture. f you turn to page 58 of this magazine, you will find a picture of a

I

(FIA)? At the beginning of the 20th century, the federation used to assign

flaming red Ferrari: it is virtually impossible to think of this brand

a different colour to each nation and the Italian car manufacturers

without associating it with the colour red. Did you know, however,

that took part in its first competitions were assigned red (blue went

that this was chosen not because of fashion trends but due to an

to France, green to Great Britain, white and later silver to Germany).

obligation imposed by the Fédération Internationale de l’Automobile

Ferrari’s iconic red is therefore a legacy of the red Alfa Romeo cars with

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COLOUR STUDY

which Enzo Ferrari’s small company raced when it did not produce

In ancient Rome, the most commonly used colour after red ochre was

vehicles of its own yet, in the 1920s, and which went on to become

cinnabar, made of mercury sulphide and, for this reason, considered

rosso corsa (“racing red”) for everyone, normally identified with

toxic. It was so appreciated and valued that it cost even more than

Pantone 185 C.

Egyptian blue3. In classical Rome, the use of red was widespread. The

More in general, red, one of the three primary colours, has always been

Romans attributed a stronger symbolic meaning to it than to other

considered an extreme tint: it is the symbol of passion and excitement,

shades; at the same time, animals with tawny or red fur aroused fear

danger and prohibition, dynamism and energy, luxury and celebration,

and in human beings red hair had such a bad reputation that it was also

fire and hell, anger and battle.

considered a negative sign in the Germanic-Scandinavian world.

1

The origin of the word “red”

The colour of the blood of Christ marked the indissoluble link of red with Christianity, and then with wine and the ecclesiastical world inheriting

The word “red”2 (in Italian “rosso”, in French “rouge”, in Spanish “rojo”, in

Roman purple clothes. As it is well described in an article published in

Portuguese “vermelho”, and in German “rot”) derived from the Indo-

digital magazine Doppiozero4, red soon became a symbol of power and

European root “rudh-” or “reudh-”, which also originated the Latin terms

the Roman aristocracy loved it for fabrics, clothes, ornaments, precious

“rubens”, “ruber”, and “rufus”, the proto-Germanic term “rauthaz” (the

stones, jewellery, decorations, and emblems. “Suddenly, at the height of

English name for this colour, as well as the German and the Dutch

its success, however, a fearsome competitor appeared: blue. Until the

one, “rood”, derived directly from it), and their Slavic, Celtic, Sanskrit

12th-13th century, in all images, Mary had been dressed in black, grey,

counterparts. In the latter case, the word “rudhiram” meant “blood” as

brown, purple, and dark green; now, the Madonna was covered in blue

a noun and “red” as an adjective. This was also the origin of the Greek

and subsequently turquoise. It was an age of success for clothes and

term “éruthros”; in fact, “ereuthophobia” (or “erythrophobia”) is the term

dyers. People moved from the bright, vivid colours of the Middle Ages

for fear of blushing.

to darker shades; red-brown appeared, the most beautiful of colours

Red: the history of a colour that was first loved...

combined with what was seen as the ugliest.”

Red has ancient origins: as mentioned, in some archaic languages

…and then hated

the term “red” was used to refer to blood or even just to describe a

In the 16th century, religious reformers vetoed the use of red because

beautiful or colourful object. The earliest evidence of the use of red

it was associated with the concept of luxury: clothes and dyes in this

pigment from hematite clay dates back to the Stone Age, some 400,000

colour were downgraded due to their excessive cost. However, it

years ago. About 30,000 years ago, in the cave of Altamira in Cantabria

remained the colour of Renaissance painters: in the 16th and 17th

(Spain) or in Lascaux (France), our ancestors painted hunted animals

centuries, red was used to attract the viewer’s attention. The master of

on the rock with red from hematite. In addition, archaeologists in

reds was Titian, who unsurprisingly also gave his name to a particular

Africa have uncovered hundreds of fragments of pigments of various

shade of red and who used to apply many layers of pigment mixed with

colours, consisting mainly of oxides, iron hydroxides, and manganese

a semi-transparent glaze that allowed light to filter through, to make his

hydroxides, which have remarkable technical characteristics in terms of

vermilion colours even brighter.

coverage, colour intensity, and resistance.

“The new science dealt yet another blow to red. By discovering the

Red has had great importance in all ancient civilisations. In China, for

spectrum in 1666, Newton dethroned it. From the centre of the system

example, the first evidence of black and red ceramics can be traced

(white, yellow, red, green, blue, and black), in this English scientist’s

between 5000 and 3000 BC. In Egypt, traces of red ochre were found

classification red was moved to one of the extremes (red, orange,

in Tutankhamun’s tomb and it is widely believed that this was used

yellow, green, blue, indigo, violet)5.” The term “infrared”, coined in the

as a female cosmetic to make up cheeks and lips. In Greece, red was

19th century, refers to the invisible energy emanating below the lowest

combined with black to create vivid and contrasting tints on ceramics,

frequency wave, precisely that of red.

statues, and temples. Traces of coloured pigments have been found in

In the 19th century, red was transformed into a political colour,

the metopes of the Parthenon, the marble sculptural panels originally

becoming the tint of the flag of the Paris Commune in 1871 and of the

located on the outer walls, suggesting that the most important temple

Russian and Chinese revolutions later on, symbolising the socialist and

of the Acropolis was richly coloured, with red and blue as the most

communist parties and therefore subverting the 16th-century concept of

used tints.

the colour red being associated with luxury.

https://www.ipcm.it/en/open/ipcm/2023/80/136.aspx https://shorturl.at/kvQY9 5 Same as above 3

https://shorturl.at/loEIU 2 www.linkedin.com/feed/update/urn:li:activity:7001092899694129152 1

4

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169

© Adobe Stock

In the Cave of Altamira our ancestors painted hunted animals on the rock with red from hematite.

© Wikipedia

The Venus of Urbino painted by Tiziano Vecellio in 1538 (Galleria degli Uffizi in Florence, Italy).

Red in the present day

Planet Mars, not coincidentally called after the Roman god of war, is

Whereas in the West red has such a variety of different and contrasting

nicknamed “the Red Planet” because the regolith that makes up its soil

connotations, in the East it has the meaning of purity (India) and good

is rich in iron oxide. This shade of red is more evident here than on

luck (China): just think of the dresses of Indian brides and the typical

the other planets because when the solar system formed 4.5 billion

colours of the Chinese New Year. But how is this tint utilised on the

years ago, many planets received large quantities of iron forged in the

web? Although most websites are dominated by blue, recalling reliability

hearts of long-dead stars but, whereas most of them saw a gravitational

and solidity, and green, reflecting the current sustainability-related

collapse that concentrated iron in their cores, Mars’ smaller size

trends, red as the colour of communication is found in many corporate

together with its weaker gravity meant that high amounts of this element

logos (including that of the magazine you are reading, for example),

remained in its more superficial layers.

for precisely the same reason it was chosen by Greek sculptors and

Finally, a word on red in architecture: it is not easy to find red buildings

16th-century painters: it is eye-catching and impossible to ignore, it is

in the everyday landscape, probably because of the controversial

the colour of fire, and it recalls energy and dynamism. Its visibility is

nature of this colour. Yet, a building designed by French architect Jean

the reason why it was chosen for fire engines and stop signs to trigger

Nouvel fully reflects its sense of energy and vitality: the scientific and

alarms. It is also often used in the logos of businesses in the food

technological hub named Kilometro Rosso and requested by Alberto

industry because it is thought to stimulate appetite.

Bombassei, the founder of company Brembo, along one of the busiest

Fun facts

motorways in the province of Bergamo (Italy). Its colour was chosen for two reasons: on the one hand, its brightness attracts the attention of

This warm colour also plays a role in fashion, astronomy, and

motorists driving along the road and, on the other hand, it pays homage

architecture. “Valentino red”, for instance, represents its namesake

to the project’s commissioning company, Brembo, which supplies Ferrari

maison. According to a statement, this nuance stemmed from an

and many other F1 car manufacturers with its brakes – which brings us

experience of Valentino himself when, as a young man, he attended

back to Ferrari’s red mentioned at the beginning of this article, like a fil

a performance at the Barcelona Opera House and a woman in the

rouge (!) linking all the nuances of this controversial colour.

audience struck him with her red velvet dress: “Among all the colours worn by the other women, she seemed unique, isolated in her splendour. I have never forgotten her. I think a woman dressed in red is always wonderful, the perfect image of the heroine6.”

6

https://www.tradecommunity.it/2022/05/rosso-valentino-colore-simbolo-maison

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La finitura delle superfici è il nostro DNA

Pallinatura Professionale per automotive Tensioni residue di compressione prima della pallinatura*: 11 MPa una profondità di of 24 μm Granigliatrice a tavola rotante Rösler: la scelta per processi di pallinatura ripetibili

Tensioni residue di compressione dopo la pallinatura*: -1214 MPa ad una profondità di 24 μm

*I valori sono un estratto di una curva di misurazione della tensione residua, materiale 20MnCr5.

Finitura di Massa | Granigliatura | AM Solutions Rösler Italiana S.r.l | Via Elio Vittorini 10/12 | I-20863 Concorezzo (MB) Tel. + 39 039 / 611521 | Fax +39 039 / 6115232 | rosler-it@rosler.com | www.rosler.com

STANDARD & LEGISLATION - UCIF Informs

The New Digital Legislative Pillars and Their Relationship with Finishing Equipment and Mechanics in General UCIF – Italian Surface Treatment Equipment Manufacturers’ Association Milan, Italy

info@ucif.net

T

wo new regulations and directives will soon hit companies

Finally, the Machinery Directive also includes topics related to artificial

in the mechanical engineering sector: the new Machinery

intelligence algorithms for the first time. The Artificial Intelligence

Directive and the Data Act, a part of the European data strategy.

Regulation (AI Act) that will see the light of day in the medium term,

Countless questions, however, remain open and careful analyses are

developed as an independent, cross-sectoral regulation, is going to

going to be required to understand the exact impact of these two

deal with this complex topic from different points of view, namely

standards on firms in the mechanical engineering industry. Through

security, privacy, and ethics, also including any machines integrating

the specific expertise of ANIMA Confindustria’s technical office, UCIF

artificial intelligence algorithms into their “embedded software”. The

seeks to promote knowledge and awareness of the digital issues that

Machinery Directive, on the other hand, deals with AI specifically in

are affecting and will increasingly affect business organisations and

terms of operator safety. In any case, it should be emphasised that

their production at the plant engineering level. This article, therefore,

current IT security management issues, as well as the ever faster-

presents an overview of the two new regulations.

paced development and integration of AI into production processes,

The new Machinery Directive was adopted by the European Parliament

have required and will continue to require specific and increasingly

on 18 April 2023. It is going to enter into force twenty days after its

stricter laws.

publication, expected to take place in July 2023. Then, it is going to be

With the Data Act, the European Union intends to provide itself with

applicable forty-two months after the date of entry into force, thus

common legislation on data and industrial services. The purpose of the

effectively replacing the current Machinery Directive 2006/42/EC.

Data Act is therefore to establish common rules governing the sharing

Although apparently long, companies will have to manage this time frame

of data generated by the use of connected products and their related

at best to be ready when they have to eventually implement both digital

services (e.g. IoT, industrial machines) to ensure fairness. Presented

pillars, the Data Act and the Machinery Directive, which among other

by the Commission in February 2023 and approved by the European

aspects are intended to regulate the digital aspects of industrial products,

Parliament on 14 March, this law primarily aims at encouraging greater

with a particular focus on the “corruption” of on-board systems. The

use of the data collected by connected devices and machines to

ultimate goal is to bring digitally secure products (and thus also plants)

remove barriers to innovation. However, some aspects are still under

onto the market, able to withstand cyber attacks even if connected.

discussion and deserve attention and in-depth analysis. For instance,

In the Machinery Directive, the first that will affect manufacturing

the representatives of the mechanical engineering industry are inclined

companies in terms of time, there are no less than three articles

to support an adequate model to effectively protect any trade secrets

specifically dedicated to regulating the digital security of machines. In

that could objectively and potentially be exposed in the data-sharing

this respect, it introduces new essential health and safety requirements

processes under the Data Act. This needs to be specifically addressed

as well as changes to existing ones. For example, the evolution of a

by the regulatory framework that will soon come into force.

machine’s software package will not be allowed to lead to any decrease

The coming scenarios are therefore going to call for increasing

in the reliability degree of control systems with a safety function. A new

cross-sectoral data awareness and transparency. Data and IT security

requirement that will have to be fulfilled is that of “protection against

are going to be increasingly placed at the centre of every activity,

corruption”, thus raising a specific alert for cyber attacks aimed not

making it crucial to establish safety perimeters, understood as sets of

only at damaging the functioning of machines and systems but also at

boundaries and protocols that define and protect each organisation’s

causing malfunctions that could harm the safety and security of those

digital assets from unauthorised access.

working on the plants themselves.

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AUTOMATIC FEEDING SYSTEMS FOR PAINTING PLANTS

© Adobe Stock

RESEARCH BREAKTHROUGH

Silver as Functional Filler for Protective and Antibacterial Coatings Massimo Calovi, Orietta Massidda and Stefano Rossi University of Trento – Trento, Italy

stefano.rossi@unitn.it

Recently, silver has been widely used as a multifunctional filler in coatings of various kinds. Its additives have the main objective of introducing virucidal features in the layer, to reduce the transmission of bacteria and pathogens. Nevertheless, the use of silver-based additives should be considered with caution, as it is possible to observe undesirable phenomena associated with the degradation of the filler or with the introduction of defects in the coating.

O

ne of the most severe issues in recent decades was

well-being of already frail patients [2]. Surface contamination in public

represented by the SARS-CoV-2 epidemic, which drastically

areas is also a key source of concern, and all touch-on surfaces in

altered people’s routines all across the world. The indirect

train and metro stations, airports, restaurants, and elevators need

spread and transmission of dangerous microbes through surfaces,

to be regularly disinfected [3]. However, continuous surface cleaning

which call for cautious cleaning, have received a significant amount

necessitates significant financial and time investments, and the level of

of media coverage. For instance, the widespread transmission of

user engagement is crucial to its success [4]. As a result, contemporary

bacterial and viral infections in hospital settings [1] and the rise in

scientific research has focused on alternate strategies, designing novel

bacterial drug resistance pose serious problems, especially for the

composite materials with the capacity to withstand both viral and

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RESEARCH BREAKTHROUGH

bacterial contamination. In order to improve the safety of the products,

© University of Trento

widespread usage of disinfectants could be avoided and replaced with a selective preventive strategy.

Designing materials with robust technological capabilities and pleasing aesthetic qualities that should both endure over the course of a product’s life is the true technological challenge. In this perspective, silver could be employed as multifunctional filler in different protective coatings. Due to its potent biocidal activity, which is also present at low concentrations, silver has been one of the finest antimicrobial agents for at least 25 years [5, 6]. Silver ions are believed to be the primary agent responsible for the antibacterial activity because they can adhere to the cell wall and change its permeability, deactivate respiratory enzymes, and prevent DNA replication [7]. Today, silver nanoparticles are employed in a variety of delicate applications requiring the highest level of hygiene, such as restorative dentistry, polymer implants, artificial implants, and surgical equipment [8].

They are used in the food and textile industries in addition to health purposes [9]. Following the SARS-CoV-2 pandemic, different synthetic experiments on silver and silver oxide were conducted in order to

Figure 1: SEM micrograph of silver products entrapped in the alumina layer.

examine their antibacterial characteristics [10], cytotoxic activities [11], and bioactive properties [12]. One of the most interesting fields of application of silver is associated with the world of multifunctional

highlights the morphology of the silver products deposited during the

protective coatings.

anodization process.

Silver in anodised aluminium surfaces

Also, the surfaces of aluminium oxide layers were stressed exposing them to adverse circumstances, including sulphur dioxide atmosphere,

Silver-based additives can be applied to the major types of coatings,

UV radiation, and thermal fluctuations. Staphylococcus aureus and

to obtain intrinsically antibacterial layers. An interesting example is

Escherichia coli were employed as representatives of Gram-positive

represented by the anodised aluminium surfaces, highly employed

and Gram-negative bacteria, respectively, to assess the antibacterial

in the construction of components for public spaces [13]. The first

activity of the surface. This process guaranteed also antiviral protection

experiments on the deposition of silver on anodised aluminium

from SARS-CoV-2, and played a significant role as an indicator of the

surface appeared around 20 years ago. At the time, anodised

efficiency of the chosen preventive approach for health protection.

aluminium’s antibacterial activity emerged to be enhanced by the

Lastly, cytotoxicity resulting from prolonged exposure of healthy

electrodeposition of silver [14], opening the door to new kinds of

and diseased human cells to anodised aluminium surfaces with and

antimicrobial surfaces. Silver has been formed on the anodised layer

without silver was investigated in order to assess potential toxicity

in recent years using both the electroless deposition method [15, 16]

brought on by contact with the surfaces. In conclusion, these studies

and other approaches such hydrothermal deposition and the photo-

present a quick and efficient way for adding silver to anodised

reduction deposition technique [17]. Nonetheless, other researchers

aluminium layers, which is a great candidate for use in public areas

created a straightforward method for co-depositing alumina and silver

due to its high durability, antibacterial performance, and lack of

powder during the anodizing stage [18]. Some recent works [19, 20]

cytotoxicity activity.

aim to propose a viable method for producing anodised aluminium layers with antibacterial properties, by means of a single co-deposition

Silver in vitreous enamel coatings

step with silver nitrate. The studies were particularly concerned with

Similarly, vitreous enamel coatings are excellent choices for

assessing the impact the silver-based filler had on the alumina layer’s

applications in high-traffic areas since they’re made of materials that

durability. In order to assess how silver influences the protective

are extremely durable [21]. Due to their excellent resistance, vitreous

features of the anodised layer after exposure to hostile settings

enamel coatings are particularly appealing for use in situations

simulating human touch and disinfection processes, the morphology

that need high durability, such as public areas and healthcare

of the Al2O3-Ag composite coating was thoroughly examined. Fig. 1

facilities where cleaning and disinfection are routinely performed

international PAINT&COATING magazine - MAY/JUNE 2023 - N. 81

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© University of Trento

Silver protective paints Among the various methods to protect a component and increase its durability, the application of organic coatings and paints is still the most widely used. Similarly with the other sectors of the coatings industry, the use of silver-based fillers into organic coatings is a current trend issue [26, 27], to get antibacterial paints [28]. For example, silver nanoparticles were added in glossy paint [29] and acrylic water-based paint [30], evaluating their efficiency, while other studies aim at assessing the effect of silver-based filler into PVA films [31], polyurethane coatings [32] and emulsion paints [33]. Moreover, a recent study investigated the effect of colloidal silver on the durability of acrylic cataphoretic coatings [34], valuating the effect of the amount of silver on both corrosion resistance performance and behaviour in the aggressive environment of the composite layers. Fig. 3 shows the morphology of the colloidal silver powders, acquired by SEM

Figure 2: Optical micrographs of the enamel cross sections.

observations.

The addition of colloidal silver into the cataphoretic solution resulted in a radical alteration of the coating’s visual aspects and generated

[22]. Moreover, porcelain enamels have a surface that is pretty

discontinuities that promoted the acrylic matrix’s permeability,

smooth, free of open porosities, and naturally prevents the growth of

weakening its protective capabilities. Furthermore, the samples’

microorganisms. Considering the important advantages these coatings

exposure to UV-B radiation provoked the silver-based fillers’ quick

have over other materials, the development of antimicrobial enamels

oxidation, with consequent layer darkening. Yet, in certain quantities,

then represents a frontier of particular interest.

colloidal silver can also enhance the protective characteristics of the

Some recent works address the study of the deposition of antibacterial

composite coating, but excessive concentrations of the silver-based

enamels, by means of silver-based additives [23, 24]. Fig. 2 shows the

additives can cause discontinuities in the acrylic matrix, lowering its

optical cross-sectional micrographs of these enamel coatings, made of

durability. Thus, colloidal silver represents a good multifunctional filler

three specific layers (ground, intermediate and top layers).

for cataphoretic deposition processes, but it needs to be used with

The antibacterial effectiveness of the composite coatings was

care and in the necessary proportions to avoid damaging the coating’s

evaluated both after the manufacture of samples and following tests

lifetime.

of surface deterioration. The selected surface degradation tests were

Similarly, silver is also finding wide use in wood paints. Due to the

representative of the operando circumstances that these coatings are

widespread use of wood, numerous research has recently concentrated

typically put through, i.e., after mechanical and chemical deterioration.

on the use of nanofillers to enhance various wood coating performance

Moreover, the enamel coatings with silver-based additives were

[35]. The prevention of the proliferation of microorganisms is one of

also tested against Candida albicans, as a model organism for

the most important factors in the improvement of wood coatings.

fungal pathogens in hospital settings [25]. 1 wt% AgNO3 additive

Several studies [36-38] have specifically examined how to preserve

concentration in the enamel formulation was effective in preventing the

wood coatings against fungus and bacteria. The effectiveness of silver

proliferation of both E. coli and S. aureus before and after degradation

nanoparticles as an antibacterial agent in transparent wood paints

of the sample surfaces. The studies demonstrated that silver-based

for outdoor applications was previously evaluated by two years of

enamel coatings can be produced using a concise deposition technique

natural weathering [39]. However, recent studies [40, 41] have verified

employing a small amount of silver. These silver-based enamelled

the antibacterial capabilities of silver in organic coatings for wood

coatings may eventually be evaluated against other nosocomial clinical

applications. The majority of studies on the antibacterial properties

isolates with multi-drug resistance (MDR). Silver-based enamelled

of wood coatings with silver additions, however, do not focus on the

coatings can be used in the fields of architecture and design, as well

impact that silver itself has on the composite layer’s durability or

as in the medical, chemical, and pharmaceutical industries because of

changes to its aesthetic characteristics. Yet, a recent investigation

their special qualities, such as non-toxicity, hygiene, ease of cleaning,

examined the impact of colloidal silver on the resilience and cosmetic

resistance to corrosion and abrasion, surface smoothness, hardness,

qualities of an aqueous wood paint while examining its antibacterial

and durability.

capabilities [42]. The study showed that colloidal silver can be utilized

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RESEARCH BREAKTHROUGH

as a functional pigment in wood paint to change the coating’s look and enhance its antibacterial effectiveness without impairing its protective performance. However, because to the strong propensity of silver to

Get more from water

oxidize when exposed to UV-B light, these multifunctional paints are not appropriate for outdoor applications.

Conclusions Silver is an excellent resource as a multifunctional filler for protective coatings. Its main function is to provide the coating with intrinsic antibacterial properties, but silver can be applied to introduce different features into the composite layers, whether they are organic, inorganic or deriving from metal surface conversion processes.

However, literature works rarely investigate the effect that silver additives cause in terms of durability and protective properties of the coating. The few studies that have dealt with these issues have confirmed the excellent antibacterial activity of silver, but have also highlighted some problems associated with the development of defects in the coating matrix and with decay phenomena of the filler

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

itself. Therefore, it is advisable to use silver as a functional filler in

Batch type systems

coatings for outdoor applications, but it is always necessary to check

Flotation units

how the silver-based additive affects all the performance of the layer,

Chemicals and spare parts for water treatment

such as its integrity and durability.

Technical service, support and maintenance of wastewater treatment plants

© University of Trento

Figure 3: Colloidal silver acquired by SEM.

Beware of imitations, buy the original!

info@waterenergy.it

www.waterenergy.it

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[2] S. Ali, S. Perveen, M.R. Shah, M. Zareef, M. Arslan, S. Basheer, S. Ullah, M. Ali, Bactericidal potentials of silver and gold nanoparticles stabilized with cefixime: A strategy against antibiotic-resistant bacteria, Journal of Nanoparticle Research, 22 (2020) 1-12.

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[19] M. Calovi, B. Furlan, V. Coroneo, O. Massidda, S. Rossi, Facile Route to Effective Antimicrobial Aluminum Oxide Layer Realized by Co-Deposition with Silver Nitrate, Coatings, 12 (2022) 28.

[20] M. Calovi, S. Meschini, M. Condello, S. Rossi, Innovative Codeposition of a Ag–Al2O3 Layer: An Attractive Combination of High Durability and Lack of Cytotoxicity for Public Space Applications, ACS omega, 7 (2022) 25650-25662.

[21] S. Rossi, F. Russo, M. Calovi, Durability of vitreous enamel coatings and their resistance to abrasion, chemicals, and corrosion: a review, Journal of Coatings Technology and Research, 18 (2021) 39-52.

[22] O. Savvova, Effect of zinc and tin oxides on the bactericidal properties of glass enamel coatings, Glass and Ceramics, 71 (2014) 254-257.

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[24] H.U. Rehman, F. Russo, M. Calovi, O. Massidda, S. Rossi, Antimicrobial Performance of Innovative Functionalized Surfaces Based on Enamel Coatings: The Effect of Silver-Based Additives on the Antibacterial and Antifungal Activity, International Journal of Molecular Sciences, 24 (2023) 2364.

[25] A. Abbaszadegan, M. Nabavizadeh, A. Gholami, Z. Aleyasin, S. Dorostkar, M. Saliminasab, Y. Ghasemi, B. Hemmateenejad, H. Sharghi, Positively charged imidazolium-based ionic liquid-protected silver nanoparticles: a promising disinfectant in root canal treatment, International Endodontic Journal, 48 (2015) 790-800.

[26] A. El-Faham, A.M. Atta, S.M. Osman, A.O. Ezzat, A.M. El-saeed, Z.A. Al Othman, H.A. Al-Lohedan, Silver-embedded epoxy nanocomposites as organic coatings for steel, Progress in Organic Coatings, 123 (2018) 209-222.

[27] A. Rozilah, C.N. Aiza Jaafar, S.M. Sapuan, I. Zainol, R.A. Ilyas, The effects of silver nanoparticles compositions on the mechanical, physiochemical, antibacterial, and morphology properties of sugar palm starch biocomposites for antibacterial coating, Polymers, 12 (2020) 1-21.

[28] P. Ganguli, S. Chaudhuri, Nanomaterials in antimicrobial paints and coatings to prevent biodegradation of man-made surfaces: A review, in: Materials Today: Proceedings, 2020, pp. 3769-3777.

[29] A. Lateef, M.A. Azeez, T.B. Asafa, T.A. Yekeen, A. Akinboro, I.C. Oladipo, L. Azeez, S.E. Ajibade, S.A. Ojo, E.B. Gueguim-Kana, L.S. Beukes, Biogenic synthesis of silver nanoparticles using a pod extract of Cola nitida: Antibacterial and antioxidant activities and application as a paint additive, Journal of Taibah University for Science, 10 (2016) 551-562.

[30] C. Deyá, N. Bellotti, Biosynthesized silver nanoparticles to control fungal infections in indoor environments, Advances in Natural Sciences: Nanoscience and Nanotechnology, 8 (2017) 025005.

[31] S. Liu, J. He, J. Xue, W. Ding, Efficient fabrication of transparent antimicrobial poly(vinyl alcohol) thin films, Journal of Nanoparticle Research, 11 (2009) 553-560.

[32] M. Bechtold, A. Valério, A. Souza, D. Oliveira, C. Franco, R. Serafim, S. Guelli Souza, Synthesis and application of silver nanoparticles as biocidal agent in polyurethane coating, Journal of Coatings Technology and Research, 17 (2020).

[33] T. Asafa, R. Odediji, T. Salaudeen, A. Lateef, M. Durowoju, M. Azeez, T. Yekeen, I. Oladipo, H.M. Irshad, A. Hakeem, Physico-mechanical properties of emulsion paint embedded with silver nanoparticles, Bulletin of Materials Science, 44 (2021).

[34] M. Calovi, S. Rossi, Durability of Acrylic Cataphoretic Coatings Additivated with Colloidal Silver, Coatings, 12 (2022) 486.

[35] M. Nikolic, J.M. Lawther, A.R. Sanadi, Use of nanofillers in wood coatings: a scientific review, Journal of Coatings Technology and Research, 12 (2015) 445-461.

[36] B. Feng, S. Zhang, D. Wang, Y. Li, P. Zheng, L. Gao, D. Huo, L. Cheng, S. Wei, Study on antibacterial wood coatings with soybean protein isolate nano-silver hydrosol, Progress in Organic Coatings, (2022) 106766.

[37] S.M. Miri Tari, A. Tarmian, M. Azadfallah, Improving fungal decay resistance of solvent and waterborne polyurethane-coated wood by free and microencapsulated thyme essential oil, Journal of Coatings Technology and Research, (2022) 1-8.

[38] C.C. Tang, Y. Li, L.B. Kurnaz, J. Li, Development of eco-friendly antifungal coatings by curing natural seed oils on wood, Progress in Organic Coatings, 161 (2021) 106512.

[39] T. Künniger, M. Heeb, M. Arnold, Antimicrobial efficacy of silver nanoparticles in transparent wood coatings, European Journal of Wood and Wood Products, 72 (2014) 285-288.

[40] A. Can, S. Palanti, H. Sivrikaya, B. Hazer, F. Stefanı, Physical, biological and chemical characterisation of wood treated with silver nanoparticles, Cellulose, 26 (2019) 5075-5084.

[41] L. Gao, Y. Lu, J. Li, Q. Sun, Superhydrophobic conductive wood with oil repellency obtained by coating with silver nanoparticles modified by fluoroalkyl silane, Holzforschung, 70 (2016) 63-68.

[42] M. Calovi, V. Coroneo, S. Palanti, S. Rossi, Colloidal silver as innovative multifunctional pigment: The effect of Ag concentration on the durability and biocidal activity of wood paints, Progress in Organic Coatings, 175 (2023) 107354.

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MEETING THE INDUSTRY

European Coatings Show and Conference 2023 Closed Successfully ECS – European Coatings Show gathered paint and coatings community from 28 to 30 March in Nuremberg (Germany).

T

of the sector at the world-leading European Coatings Show and

European Coatings Show Conference with ECS Conference Award

Conference 2023 at Exhibition Centre Nuremberg. Despite a

As the European Coatings Show Conference got underway, a

he pandemic-induced hiatus was followed by a joyful reunion

nationwide strike by public transport workers on Monday 27 March that

nationwide strike by public transport workers almost crippled public

almost crippled public life in Germany, the halls in Nuremberg were

life in Germany. Despite this, 730 delegates travelled to take part in

packed with enthusiastic exhibitors and visitors.

the high-calibre programme of the two-day European Coatings Show

From 28 to 30 March, 24,605 coatings experts learned about the latest

Conference. The conference, which started on 27 March, provided

trends in paint and coatings from 1,017 exhibitors from 42 countries.

developers and engineers with plenty of scope for knowledge transfer

The high-calibre conference started the day before on 27 March and

in 143 presentations. Distinguished speakers from more than 40

was exceptionally well attended. The response from the 730 delegates

countries offered interesting insights into a wide variety of topics. The

was positive across the board.

opening keynote by Wijnand Bruinsma from Akzo Nobel was on “The

Eight exhibition halls offered trade visitors from the paint and coatings

role of paints and coatings in a sustainable future”. The highlight of the

industry information on all the global industry trends and innovations

conference was the presentation of the coveted European Coatings

in coatings, printing inks, laboratory, production, testing or measuring

Show Award. This year, the prestigious award was presented to Dr Hong

technology, adhesives and construction chemicals.

Xu and her co-authors Joseph Mauck (Cardolite USA) and James Zhao

With its focus on sustainability, nanotechnology or green coatings, the

(Cardolite China) for their work “Pursue greener – novel sustainable

show introduced developers, process engineers, quality managers and

CNSL-based diluent designed for high-performance low-VOC protective

purchasing officers to innovation solutions covering the entire coatings

coatings”. The next European Coatings Show Conference will take place

market.

on 24 and 25 March 2025.

For further information: www.european-coatings-show.com

© NuernbergMesse / Thomas Geiger

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© NuernbergMesse / Thomas Geiger

MEETING THE INDUSTRY © Blechexpo

Nine Halls of Blechexpo 2023 Are Already Fully Booked Blechexpo 2023 will be held jointly with Schweisstec from 7th to 10th November in Stuttgart.

T

he trade fair promoter P. E. Schall has announced that all nine

processing machines, precision tools and systems for punching,

halls of Blechexpo 2023 at the Stuttgart Exhibition Centre

bending, braking and forming, as well as innovative micro-waterjet

(Germany) are fully booked. The 16th edition of the trade fair

cutting technologies.

dedicated to sheet metal working will be held jointly with the 9th

The supplementary programme will include the ‘best-Award 2023’ and

Schweisstec – the international event for joining technology – from 7th

the ‘Blechexpo Steel Convention 2023’. Moreover, the “futureSteel”

to 10th November. The duo will allow exhibitors to present modern and

congress has also been scheduled for the second day, focusing on

forward-looking sheet metal technologies and showcase entire process

the future of the steel industry and the issue of sustainability. Visitors

sequences.

will also be provided with the opportunity of gathering more in-depth

“Interest in Blechexpo/Schweisstec is once again enormous. Most

information about the product and service portfolios of individual

exhibitors booked again immediately after the last event in 2021

companies, as well as their technological expertise and process know-

and even requested additional booth floor space for 2023 as well.

how. Beyond this, research institutes will present their projects in theory

Tremendous interest in the exhibition, strong dynamics within the

and in experimental practice.

industry sector and important future issues is how we sum up

In order to provide trade visitors with the best possible thematic

the current mood. On the whole it can be observed that process

overview, as well as an efficient visit, the organisers have structured

automation is being driven further and further in the field of sheet

the current layout of the event in a targeted manner. Sheet metal, pipe

metal working,” has declared Georg Knauer, the project manager of

and profile processing will be located in halls 1, 3, 5 and 9. Halls 4 and

Blechexpo/Schweisstec. “Expert visitors at Blechexpo/Schweisstec

6 are reserved for stamping technologies. Cutting, joining and fastening

experience the entire process chain for sheet metal. Suppliers and

technologies will be presented in hall 7. Hall 8 will focus on pressing and

investment decision-makers meet on an equal footing with direct

forming technologies. Finally, the issues of steel and metal services, as

practical relevance in a working atmosphere.”

well as surface finishing technology, will be addressed in hall 10.

The range of topics covered includes efficient process technologies for modern laser technology, fully automated robotic sheet metal

For further information: www.blechexpo-messe.de/en

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MEETING THE INDUSTRY

Meeting the industry 15-18 November 2023: FEL and ME Together for the Colour Sector The ME - MADE expo renewal process continues. As part of the current programme, the FEL (Festival Edilizia Leggera) will be held from 15th to 18th November 2023, the event dedicated to professionals involved in the paint, colour and lightweight construction sectors.

A

s the result of a vertical integration, ME will feature two closely

of building material retailers, specialized applicators and businesses

interconnected halls: Construction and Building Envelop. Holding

in general, through a proven formula that offers exposure with live

the FEL within the Construction confirms the importance of the

demonstrations. Retailers and in particular paint manufacturers will be

paints and varnishes sector and is designed to encourage and promote

the leading figures in the events organized among the stands in the FEL

continuous dialogue between the leading figures in the professional

area, all of them dedicated to offering a highly professional experience.

colour market and other elements of the construction sector.

Andrea Zanardi, Project Manager of the Festival talks about the route

“The decision to host FEL is an integral part of the ME - MADE expo

taken in order to arrive at this decision: “After the Turin edition, which

renewal process, and one which focuses on a clear specialization of

was surprisingly successful despite the turbulent period that the market

what is on offer” says MADE eventi CEO Nicola Bonacchi. “Thanks to FEL,

was facing at the end of 2021 (construction sites were overloaded due

the Construction Exhibition will concentrate on the business, retailers

to the situation caused by tax breaks and the fears of a return to the

and application sector with a clear and direct language, in line with

limitations due to the Covid pandemic), we felt that a careful analysis of

market expectations.”

the FEL project was necessary, not least through canvassing the opinion

This collaboration has been made possible by the flexibility of FEL -

of the exhibitors. 2022 was a landmark year for receiving requests for

Festival dell’Edilizia Leggera, which over the years has demonstrated that

information about the next edition of the festival, and because of this

it can sit alongside well-established trade fair events without losing its

we understood that the organizational machine behind FEL had to be

own identity as well as the strong points that have made it the reference

restarted and reinforced by choosing partners and locations able not

event for the professional colour market in the building sector.

only to respond to such needs, but which also offered the organization

Now in its eighth edition, the new location will emphasise FEL’s lively

design perspectives that were also valid for the future. The synergy with

and dynamic character: there will be top class demonstrations and

ME – MADE expo was immediately received by our staff and exhibitors

information activities all in a party atmosphere. The dynamic exhibition

in a highly positive manner, while this partnership has also been

format is also unchanged, featuring stands that have already been set

encouraged by the completely renewed trade fair format of the event.

up, allowing visitors to follow a straightforward and simple itinerary.

This has confirmed our faith in the event and convinced us to integrate it

There will also be designated areas in the hall exclusively dedicated to

with FEL, whose lean and dynamic approach allows companies to invest

practical demonstrations, training talks and workshops that will actively

energy in technical content rather than image.”

involve all the professional visitors.

© MADE Eventi

One of ME-MADE expo and FEL’s shared objectives is the involving

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For further information: www.madeexpo.it/en

MEETING THE INDUSTRY

Positive Signs and an Excellent Response for PaintExpo 2024 PaintExpo, the world’s leading trade fair for industrial coating technology, will take place from 9 to 12 April 2024 in Karlsruhe (Germany).

R

egistrations for the world’s leading trade fair for industrial coating technology are already at an excellent level one year before the next edition of the event opens its doors. From 9 to 12 April 2024, PaintExpo

will once again be providing a global showcase for the latest trends in industrial coating. The who’s who of the coating technology industry exhibits at PaintExpo 2024 in Karlsruhe.

With around 430 exhibitors from 27 countries and more than 9,000 trade visitors from 57 countries, PaintExpo was successfully restarted in 2022 following the pandemic break. More than one in three exhibitors travelled from abroad. Visitors included a large number of key decision-makers, specialists and managers, with around 90 per cent of visitors to the previous PaintExpo able to influence investment decisions in their companies.

Preparations for PaintExpo 2024 are in full swing. With one year still to go before the trade fair opens its doors, around 250 companies have registered and more than 70 per cent of the exhibition space of the previous event is already sold. “The response from the industry has been great. This clearly confirms that PaintExpo is a well-positioned, must-attend event for everyone in the industry. In April of next year, PaintExpo will once again serve as a worldwide showcase for innovations and future technologies as well as providing a platform for practical solutions in industrial coating technology,” says Markus Geisenberger, Chief Executive Officer of Leipziger Messe.

Registration information is available on the PaintExpo website.

Key Industry Players, Interesting New Exhibitors, High International Participation Global market and technology leaders will join innovative medium-sized companies in three exhibition halls at this world’s leading trade fair to present their latest products and applications in industrial coating technology.

Exhibitors will include important industry players from Germany and abroad such as Axalta, DeFelsko, Dürr, Eisenmann, FreiLacke, Gema Switzerland, J. Wagner, Krautzberger, Louis Schierholz, Nordson, PPG and Venjakob. In addition, interesting new exhibitors were also convinced by the trade fair concept: Among those in Karlsruhe presenting their range of products and services for the first time at PaintExpo will be Mitsuda, a Turkish supplier of

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MEETING THE INDUSTRY

cleaning and pretreatment technology and Neybo, a specialist in heating up industrial containers.

The coming edition of PaintExpo also has a lot to offer internationally: Most exhibitors will be from Western European countries. Alongside Germany, they will be primarily from Italy, Switzerland, Austria, the Netherlands and Spain. However, companies from countries such as Turkey and Greece have also already booked their stands. The proportion of international exhibitors is – as of today – around 40 per cent.

Full Spectrum of Industrial Coating The products and services on display at PaintExpo cover the full spectrum of industrial coating. Next year, the range of exhibits will again include surface treatment solutions, quality assurance, paints and paint finishing lines as well as powders and powder coating systems. The industry platform offers a comprehensive package of coating solutions for all industries, applications and materials, from wet coating and powder coating to coil coating.

About the PaintExpo At PaintExpo 2022, around 430 exhibitors from 27 countries presented their products and services and more than 9,000 trade visitors from 57 countries attended. The next edition of PaintExpo will take place from 9 to 12 April 2024 in Karlsruhe. The world’s leading trade fair for industrial coating technology serves as a showcase for innovations, applications, future technologies and trends in all areas of the coating industry. PaintExpo will cover the entire range of international products and services in the industrial coating technology supply chain. This global get-together of companies from the industry is unparalleled worldwide, making it highly attractive for coating service providers and in-house © Leipziger Messe GmbH - Tom Schulze

© Leipziger Messe GmbH - Tom Schulze

coating companies from around the world.

About the Leipziger Messe The Leipziger Messe is one of the ten leading German trade fair companies and one of the top 50 worldwide. It organises events in Leipzig and at various locations all over Germany and abroad. With its five subsidiaries and the Congress Center Leipzig (CCL), Leipziger Messe is a comprehensive service provider covering the entire chain of the events business. It is due to this level of professionalism, that customers and visitors in 2022 voted the Leipziger Messe the service champion of the trade fair industry in Germany’s largest service ranking for the ninth time in a row. The Leipzig fairgrounds comprise an exhibition area of 111,900 m² and an open-air exhibition area of 70,000 m². Every year, over 270 events take place – from trade fairs, exhibitions and congresses to events. Leipzig was the first German trade fair company to be certified according to the Green Globe standards. Sustainability is a recurring theme in the Leipziger Messe’s corporate activities.

For further information: www.paintexpo.de/en

international PAINT&COATING magazine - MAY/JUNE 2023 - N. 81

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MEETING THE INDUSTRY

Paint & Coatings Italy, More of Everything you Need to Know After the success of its first edition, Paint & Coatings Italy returns on 17 & 18 October 2023 at the NH Milano Congress Centre in Milanofiori, Assago (Milan, Italy).

T

his edition promises to be greater than the first, the exhibition

technical advances available in this industry. Delivered by the people

brings together the leading companies active within the Italian

bringing them to market, these presentations are the opportunity to

Paint & Coatings Industry. Over the two days, visitors will be

learn more about these technical developments direct from the experts.

able to find every conceivable raw material, ingredient, equipment and formulation service needed to create market leading products.

Focus on Polymers

The exhibition has almost doubled since the last edition, meaning there

Polymers are the building blocks to help everyone formulate coatings.

is even more on offer for everyone onsite at Assago.

New for this year is a programme that is dedicated to polymer

The Scientific Programme

technology for the Paint & Coatings Industry.

Developed in collaboration with leading manufacturers of polymer

Returning for this year is the high-level scientific education programme

binders and resins and INSTM, the National Interuniversity Consortium

covering the different aspects impacting the Italian market. Created in

for Materials Science and Technology, this programme will cover the key

collaboration with AssICC & ASSOVERNICI, the Scientific Programme of

aspects of formulating with polymers.

Paint & Coatings Italy will have a special focus on relevant topics in the field of Coatings, Sustainability, circular economy, CLP regulation, REACH

Free to Attend

regulations, and bio-based solutions. There will also be contributions

For industry professionals, Paint & Coatings offers multiple networking

from various Italian universities.

and lead generation opportunities. In addition, the event represents a

A Focus on Innovation

truly national meeting forum not to be missed, where new suppliers, raw materials, services, solutions and creative ideas can be found.

The TechFocus programme at Paint & Coatings Italy brings a comprehensive programme detailing the latest innovations and

© Paint & Coatings Italy

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For further information: www.paint-coatings.it/en/

© Paint & Coatings Italy

More Content. 17-18 Ottobre More Exhibitors. 2023 Milano NH Milano Congress Centre More Innovations. Milanofiori, Assago, Italy

For everything you need to know visit www.paint-coatings.it ESPOSIZIONE • PROGRAMMA SCIENTIFICO • TECHFOCUS Associazioni di supporto:

pci@step-exhibitions.com

Media Partners:

+39 334 891 8603

Organizzatori:

MEETING THE INDUSTRY

The University of Trento Announces a Workshop on Coatings Several industry professionals are going to speak at the event “Organic coatings, the solution for protection and aesthetics: trends and innovations in the industry”.

T

he Department of Industrial Engineering of the University of

• Reinventing steel for a sustainable future – M. A. Fusco (Liberty

Trento has announced that it will dedicate an entire day to the

Magona).

paint and coatings sector with the event “Organic coatings, the

• Alternative applications for cataphoresis – G.L. Gazzola (Arsonsisi).

solution for protection and aesthetics: trends and innovations in the

• Wood coatings: a matter of aesthetics, protection, and application – G.

industry”, organised for 20 June 2023 in Room B107 (Via Sommarive 9,

Ciafrè (Renner Italia).

Trento, Italy) in the presence of many experts and professionals from

• What evolution can we expect for traditional building and corrosion

the field. After a welcome speech by the academic authorities, the day

protection coatings? – G. Di Tanna and L. Pau (AITIVA).

will be divided into two sessions, but it will also offer opportunities

• Paints, an applicator’s point of view – T. Pintarelli (Pintarelli

for networking and visiting the exhibitors’ stands, as well as a guided

Verniciature).

tour of the Coatings and Industrial Corrosion Control laboratory

• Pigments and colours in motion, a short journey between emotion and

(electrochemistry, accelerated ageing, surface abrasion, microscopy)

innovation – S. Corrado (Merck).

after the lunch break.

• Colour sustainability: timeless colours – F. Valan (Valan Studio).

Participation in the workshop is free of charge upon completion of the

Moderated by Michele Fedel and Stefano Rossi respectively, the two

online form by 10 June 2023. The maximum number of participants

sessions will include four presentations each:

allowed is 120.

• High-performance powder coatings for corrosion protection – L. Soldavini (PPG Italia).

For further information: www.dii.unitn.it

© Università di Trento

Scan or click the QR Code to register for the workshop

188 N. 81 - MAY/JUNE 2023 - international PAINT&COATING magazine

Speaker, Delegate Exhibitor, Sponsor: choose your participation

19 - 23 September 2023 Royal Hotel Carlton Bologna- Italy

…MAIN CONFERENCE TOPICS… MARKETS & STRATEGIES, ALLOYS BILLETS & RELATED EQUIPMENT, FOUNDRY, ROLLING TECHNOLOGY, ARCHITECTURE & SPECIAL USES, TRANSPORT & AUTOMOTIVE INDUSTRY, EXTRUSION, ANODIZING, COATING, NANO TECHNOLOGIES, AUTOMATION, MEASURING, TESTING & QUALITY TECHNIQUES, ADVANCED APPLICATIONS & RESEARCH, ENVIRONMENTAL PROTECTION & RECYCLING, CASTING & DIE CASTING

THE ALUSPECIALISTS' MEETING www.aluminium2000.com

EVENT HIGHLIGHTS

More than 90 highly specialized technical papers - Expected 300 delegates from 40 different countries - 3 parallel sessions running throughout the 3 days event - Social Program for all participants – Sponsorship and Exhibition opportunities – Anoding Workshop Official Language: English EVENT ORGANIZED BY: Interall Srl: Via Marzabotto, 20 – 41042 Fiorano Modenese (MO) - Italy - Tel. +39-059-282390 aluminium2000@interall.it - www.aluminium2000.com

Supplemento a IPCM n° 81 - Maggio/Giugno 2023

ICT digital on www.myipcm.com

ICT | TECHNOLOGY OVERVIEW

DORIS SCHULZ SCHULZ. PRESSE. TEXT., Korntal – Germany ds@pressetextschulz.de

Improved cleaning performances and lower media consumption: acp Systems launches an innovative nozzle technology for CO2 snow jet cleaning With an innovative, pulsed two-substance ring nozzle, acp systems AG is extending the range of applications for its quattroClean snow jet technology. In addition, the new development cuts carbon dioxide and compressed air consumption by up to 15%.

F

or some time now, the trend in industrial parts cleaning has been

To extend the range of application of the cost-effective and sustainable

towards dry processes that can remove particulate and filmic

cleaning process, the company has designed an innovative two-

contamination reliably and, if necessary, selectively. There is also

substance ring nozzle that generates a pulsed jet. The wear-free nozzle

a growing demand for integrating such processes into production lines

is equipped with a valve specially developed by acp for this purpose

in a simple and space-saving way. The quattroClean snow jet technology

which enables pulse times as fast as 20 milliseconds. In contrast with

from acp systems AG, which uses liquid, climate-neutral carbon dioxide

pilot-operated standard valves, the direct control of the valve prevents

as a cleaning medium, meets all these requirements.

icing and thus ensures reliable operation and consistently superior

© acp systems AG

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ICT | TECHNOLOGY OVERVIEW

results. The jet and pause times can be

© acp systems AG

set independently of each other, so that the pulses can be optimally adapted to the respective application and also to the partspecific cleaning sequence. At the same time, the pulsed jet reduces CO2 and compressed air consumption. Depending on the pulse

time, savings between 10 and 15 percent can be achieved. At the inaugural FiT2clean Awards 2022, where the Fachverband industrielle Teilereinigung e.V. (FiT) annually honours outstanding achievements and solutions for parts cleaning, acp systems’ innovation won third place.

New applications in cleaning, deburring and machining The pulsed jet of CO2 and compressed air has a higher kinetic energy than a

© acp systems AG

continuous jet, making it slightly abrasive.

This opens up potential applications where conventional CO2 snow jet cleaning previously

had to pass. These include, for example,

removing loosely adhering welding beads after welding processes and cleaning off particulate contamination adhering to metallic components due to dried-on process media.

The pulsed nozzle also has its advantages when it comes to cleaning off flux residues and particles from bonding surfaces.

It can also be deployed to remove partial film residues after hot stamping or laminating aluminium onto plastic parts. In addition, the pulsed jet of CO2 and compressed air

has sufficient cleaning power to remove fine burrs from aluminium and zinc die castings.

The innovative and wear-free two-substance ring nozzle, that generates a pulsed jet, contains a valve specially developed for this purpose and achieves pulse times as fast as 20 milliseconds.

The special nozzle cleaning bonding surfaces soiled with flux residues and particulate contamination quickly and efficiently.

international PAINT&COATING magazine - MAY/JUNE 2023 - N. 81

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ICT | TECHNOLOGY OVERVIEW

© acp systems AG

The new two-substance ring nozzle also offers further advantages, including a higher metal removal rate and thus improved productivity as well as reduced tool wear.

Furthermore, the technology can be used to simultaneously deburr

removes particulate and filmic contamination as well as fine burrs. The

and clean hard and brittle plastics such as PEEK and PPS. When

detached contaminants or burrs are carried away from the part by

machining these plastic and aluminium parts, the new two-substance

the aerodynamic force of the jet of compressed air and removed from

ring nozzle also offers optimisation potential. If used as an alternative to

the process chamber by an integrated extraction system. Since CO2

conventional cooling lubricants, the cold snow crystals made of carbon

sublimates at atmospheric pressure, the parts are immediately dry and

dioxide ensure a higher metal removal rate, thus improving productivity

can be further processed straightaway. When the quattroClean snow jet

and reducing tool wear. The workpieces and machine also stay cleaner.

technology is used in machining applications, the chips generated are both clean and dry, making them easy to recycle.

Four mechanisms of action guarantee excellent results

The scalable quattroClean process can be adapted to different

The wear-free two-substance ring nozzle is the “heart” of the process.

component geometries for partial or full-surface cleaning in a space-

Liquid carbon dioxide is fed through it and expands on exiting to form

saving and efficient manner. Process parameters are determined

fine snow crystals. These are then bundled by a separate jacket jet

via trials in the company’s own technical centre. Based on standard

of compressed air and accelerated to supersonic speed. When the

modules, the cleaning systems are designed to match the cleaning task

easy-to-focus jet impacts on the surface to be cleaned or deburred, a

and cycle time specified by the customer. The company builds stand-

combination of thermal, mechanical, solvent and sublimation effects

alone systems as well as solutions for integration into automated and/or

takes place. The interaction of these four mechanisms of action reliably

interlinked production lines.

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BEAUTIFUL OUTSIDE, SOPHISTICATED ON THE INSIDE. THE CLEANING OF THE FUTURE… NOW

KPKleen Power VACUUM WASHERS

MODIFIED ALCOHOLS . HYDROCARBONS

RESPECT FOR THE ENVIRONMENT IS ONE OF THE BASIC PRINCIPLES OF OUR PRODUCTION PHILOSOPHY. The entire KP Kleen Power line complies with the principles of the circular economy, guaranteeing the recovery of 99% of waste materials such as: oils, water and metal residues. The KP Kleen Power technology allows to obtain a low management cost, a limited consumption of strictly ecological washing liquids, maximum operator protection and limited machine stops due to the almost absent need for ordinary maintenance. In case of technical failures, in addition to the teleservice, remote service is active in the entire KP Kleen Power line washing machines, furthermore when it is necessary to solve the problem, an IFP Europe technician is ready to intervene in a short time replacing parts with original components or refurbished 100% guaranteed.

IFP Europe Srl Via Po, 1 35015 GALLIERA VENETA (PD) Italia - Tel. +39 049.5996883 - info@ifpsrl.com - www.ifpeurope.com

ICT | CASE STUDY

MONICA FUMAGALLI, ipcm®

A flexible, hybrid cleaning process to meet high cleanliness standards in the Swiss watch industry Immersion ultrasonic cleaning is the only solution that can be effective with the most diverse materials, particularly when it comes to precision micro-components with complex shapes.

Cleaning plants expert MEG has made this technology even more effective by integrating it in a hybrid solution combining the use of water and detergent with solvent, in order to achieve the extreme flexibility degree required by companies such as Monwitt SA, a manufacturer of precision microcomponents for the watchmaking industry.

A

mechanical watch is a miniature machine consisting of at least 50 micro-gears: their constant movement is ensured by the perfect concatenation of one into the other to transmit the energy

required for perpetual operation. One of the main production hubs for these masterpieces of mechanical engineering, which today are seen as elegant fashion accessories, lies in the heart of Europe, in the Swiss canton of Jura, which saw watchmaking become predominant as early as the 18th century. The history of Swiss watchmaking, however, has

even older origins: it can be traced back to the ban imposed by Calvin around the middle of the 16th century on wearing any luxury item. The goldsmiths and jewellers of the region were thus forced to convert their businesses to the manufacture of watches, for which Switzerland is now known throughout the world.

The export growth of this country’s watch industry, especially in the high-end segment, has not come to a halt even in the last few months, characterised by an uncertain political and economic situation in Europe: in the first quarter of 2023, it was around +12% compared with the same quarter in 2022. In fact, the sector exported almost 300,000 more watches in one month (source: FHS – Fédération de l’Horlogerie Suisse)1. As a consequence, the industry of precision components for the watchmaking sector is also facing a peak in production volumes combined with ever higher quality demands, including the perfect cleanliness of the tiniest gears.

We talked about this with Pascal Monbaron and Paola Fra, the Technical Sales Manager and Finishing Manager respectively of Monwitt SA, a company based in Courtelary and specialising in precision machining with wire and die-sinking electro-discharge machining (EDM) systems and component cleaning with a hybrid ultrasound system.

1

http://www.fhs.swiss/file/59/comm_230303_a.pdf

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© ipcm

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© ipcm

This was designed and installed by Italian company MEG Srl, which has been making plants for cleaning parts in a wide variety of sectors for over thirty years. “In watchmaking, the perfect manufacture and cleanliness of workpieces are crucial,” explains Monbaron. “If the tiniest residue remains on a component’s surface, the gear may malfunction or, in the worst case, get jammed.”

A Bernese company Located in the heart of the Bernese Jura region, Monwitt is currently managed by the third generation of its founder’s family. “My grandfather established this firm to mould products mainly intended for the military and textile industries,” confirms Monbaron. “Then, thanks to my father’s essential contribution, in the 1990s we started working for the watchmaking sector. This has now become our main target market, so much so that we have structured our entire company around its needs.” This industry, however, is becoming increasingly strict in terms of the cleanliness demands placed on the micro-gears of these timekeeping devices, particularly high-end watches.

“We design our punching dies according to the drawings we receive from customers,” indicates Monbaron, “and we produce all dies and tools in-house by wire and die-sinking EDM. We carry out numerous tests to ensure that they correspond exactly to our customer’s wishes.

Afterwards, we proceed with the blanking operation. The components are then subjected to heat treatment and to deburring and polishing with suitable pastes. If required, galvanic treatments are outsourced.

The micro-gears then undergo quality control and packaging before final dispatch.”

During this process, the components are cleaned both between one phase and the other and as a final step: in fact, they are subjected to cleaning after blanking, after heat treatments, and finally after deburring before packaging. “Today, we clean 100% of the components we manufacture in the most diverse materials – steel, copper, brass, and aluminium,” notes Monbaron. “Before installing our new cleaning system, we used to carry out a simple manual degreasing operation to remove the lubricating oils employed for blanking, which was useful to prevent oxidation of metal in the subsequent stages, and then to remove the polishing pastes. We soon realised, however, that the market was evolving and changing its needs very quickly: to keep up, we had to invest in a more advanced and complex machine and process. This is why we started our collaboration with MEG.”

Monwitt SA got specialised in the production of precision micro-components for the watchmaking industry in the 1990s.

Monwitt Sa’s finishing department (left photo). © ipcm

The basket loading station (right photo).

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© ipcm

© ipcm

One of the two basket-handling robots.

© ipcm

Some tanks in the plant.

The basket unloading station.

A hybrid system for two types of cleaning process

and at the same time improves and speeds up the drying phase of

The system installed a year and a half ago at Monwitt’s premises is

the treated parts, which, among other things, can be immediately

equipped with 2 Cartesian robots for basket handling and rotation, 4

handled upon unloading. Finally, the use of new-generation solvents

dual-frequency ultrasonic immersion cleaning tanks using water and

reduces electricity consumption and costs and the need for periodic

detergent, 2 rinsing tanks, 1 dewatering station, 1 ultrasonic cleaning

replacement of baths, thanks to the performance of low-temperature

section using a co-solvent, and 3 ultrasonic cleaning/rinsing sections

distillation.”

using solvent and/or solvent vapours.

“This hybrid plant,” states Alberto Gnoato, the Operations Director

A targeted change

of MEG, “can therefore perform multiple cleaning steps that allow

“Originally,” says Paola Fra, “we had planned to subject our parts to both

removing a wide range of contaminants while guaranteeing a high

cleaning processes, i.e. with water and detergent and with solvent, but

degree of cleanliness of the treated components. The first cleaning

we soon realised that having the possibility of managing the two cycles

phase takes place in a water and detergent solution. Here, the

separately as well would be more functional for achieving our expected

workpieces can be treated with different chemicals, as the 4 tanks

quality results. We therefore made a targeted change to the path of

can be filled with as many types of detergent. The mechanical action

the first robot, so that it did not stop at the dewatering station, but

generated by dual-frequency ultrasound and the rotation of the basket

proceeded to take the basket to the first solvent-based cleaning/rinsing/

in the tank ensure very high cleaning results already in this first step.

drying section (tank no. 9 – see the plant layout on page 200). Here, the

The second treatment phase, which takes place after dewatering to

second robot picks it up for any further solvent treatment. This makes

remove rinse water, is in turn composed of a stage using co-solvent

our machine more flexible and enables most of our components to

and 3 further possible stages in the 3 cleaning/rinsing/drying sections

reach directly the solvent-based cleaning phase, skipping the water and

using new-generation solvents. This enables to further refine the

detergent-based one.”

cleaning process, bringing the cleanliness results to excellent levels,

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Increased cleaning quality and flexibility “MEG’s Hybrid plant series,” emphasises Gnoato, “was designed and built to offer a hybrid cleaning option combining waterbased detergent solutions with co-solvent and/or solventbased solutions. The detergent is used to remove residues of a “polar nature”, such as, for example, flux activators, salts, and contaminants from various processes. Together with the latest generation of fluorinated solvents, the co-solvent enables to remove “non-polar” contaminants such as waxes, oils, and colophony-based fluxes. The advantages of this process include lower water consumption and significantly shorter cycle times compared with a normal water-based process with oven drying.

In the case of Monwitt, the complete cycle, which includes 2 cleaning phases and 2 rinses, lasts on average about 35

© ipcm

minutes.” Finally, the cleaning plant is equipped with a steam extraction system to prevent the formation of moisture in the detergent-based cleaning area and a suction system with an active carbon filter in the solvent and co-solvent-based one.

“Our old cleaning plant,” confirms Paola Fra, “allowed selecting only two types of operation depending on the treated material – one for steel and one for all others. As long as we were producing components with a simpler geometry, it met all our requirements. When we started to manufacture components requiring more complex decoration work, e.g. cerclage, satinfinishing, and polishing, our cleaning requirements also changed: we can no longer afford to carry out bulk operations, but we rather treat a maximum of 50 workpieces per basket. This also means that our main needs have become process flexibility and increased cleaning performance – and the system designed and

© ipcm

installed by MEG meets these needs perfectly. In fact, we can separate the 2 baths devoted to steel from the other 2 baths devoted to other materials and we can choose whether to use water and detergents alone, solvents alone, or both.”

From top to bottom: Two specially designed basket types, cylindrical and rectangular.

Some micro-gears manufactured and cleaned by Monwitt.

From left to right: Alessia Venturi from ipcm®, Pascal Monbaron and Paola Fra from Monwitt Sa, Gian Luca Desliens and Alberto Gnoato from MEG.

© ipcm

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Basket loading station; 1. First dual-frequency ultrasonic cleaning stage in water-detergent, with basket rotation in the tank and/or on the robot; 2. Second dual-frequency ultrasonic cleaning stage in water-detergent, with basket rotation in the tank and/or on the robot; 3. Third dual-frequency ultrasonic cleaning stage in water-detergent, with basket rotation in the tank and/or on the robot; 4. Fourth dual-frequency ultrasonic cleaning stage in water-detergent, with basket rotation in the tank and/or on the robot; 5. First dual-frequency ultrasonic rinse in hot mains water, with basket rotation in the tank and/or on the robot; 6. Second dual-frequency ultrasonic rinse in hot mains water, with basket rotation in the tank and/or on the robot; 7. Removal of rinse water in a dewatering solution, with basket rotation; 8. Ultrasonic cleaning in a co-solvent, with basket rotation in the tank and/or on the robot; 9. Cleaning in a solvent and/or solvent vapours; 10. Cleaning/rinsing in a solvent and/or solvent vapours; 11. Cleaning/rinsing in a solvent and/or solvent vapours and drying in a cold area; Basket unloading station. © MEG

160,000 workpieces cleaned in one cycle

system supplied by MEG itself at its Competence Centre built in 2019,

The baskets were also specially conceived and manufactured to adapt

where Monwitt’s technical team was later hosted to carry out tests on

to the extreme diversity of the micro-gears produced by Monwitt.

its components. “The most complex aspect of this project,” emphasises

“They can be rectangular or cylindrical”, says Gian Luca Desliens

Paola Fra, “was not so much to understand the operating principles of

from MEG’s Sales Division, “depending on the type of workpiece to be

a machine combining two processes with such different characteristics,

processed, with holders and meshes specifically designed for each

but rather to identify the cycles best suited to our micro-gears. Once

characteristic. The components can be arranged in a fixed position or

finished, these are mounted directly on watches without undergoing any

in bulk. The machine is capable of processing around 160,000 parts at

further intermediate machining: therefore, effective cleaning is much

a time. Another special feature of this system is that the baskets can

more important than one might think. Now this is possible thanks to

rotate both when hooked to the handling robots and when released

MEG’s technical staff, who worked with us to determine which solutions

into the tanks, based on pre-set programmes and according to any

and processes were best suited to our production. Thanks to them,

specific handling requirements.” The water-based detergents used

today Monwitt can compete in an increasingly competitive market with

are supplied by company Borer Chemie AG. This is one of MEG’s most

more and more exclusive demands, including the high-end watches

well-established partners, so much so that it installed a hybrid cleaning

segment, for which our country is known throughout the world.”

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ILARIA PAOLOMELO, ipcm®

Freudenberg sealing technologies chooses bicarbonate-based detergent cleaning technology for the future of its electrical batteries The Freudenberg Sealing Technologies site in Luserna San Giovanni (Turin, Italy) is developing one of the most important technological innovation projects in the electric mobility sector for the industrialisation of batteries in Europe. The high degree of cleanliness required for the proper functioning and long-term efficiency of these components led it to choose STS as its technology partner for the cleaning phase.

E

lectric vehicles are the future of mobility. Both car manufacturers

production requires a complex process consisting of several steps, all

and governments are increasingly promoting green and

calling for high precision, high specialisation, and advanced technology.

sustainable alternatives with the aim of reducing the carbon

At present, electric battery production is mainly concentrated in

footprint and environmental impact of vehicles. Electric cars are

Asian countries, with China, Taiwan, and South Korea leading the

thus gradually increasing their market share; according to statistics,

way. Recently, however, Europe too has been gradually carving out its

exponential increase is expected in the coming years and especially

own space in the field of electric battery production, with the short to

from 2025, when, as reported by some studies, one in three vehicles on

medium-term aims of competing with the current industry leaders and

the road is going to be electric.

fostering the development of new-generation, safer, more durable,

The core of an electric car is its battery pack, a set of components whose

100% European products.

The Freudenberg Sealing Technologies plant in Luserna San Giovanni (Turin) is developing a cutting-edge project to industrialise the production cycle of cell caps, one of the components of electric batteries.

©

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This is the case of the Freudenberg Sealing

© ipcm

Technologies site in Pinerolo (Turin, Italy), which is developing one of the most important technological innovation projects in the EV sector for the industrialisation of electric batteries in Europe.

The project’s development The project is developed in the Freudenberg plant in Luserna San Giovanni (Turin, Italy), where, since 2001, it has specialized in the production of robotic islands used exclusively in other plants of this German Group. After more than twenty years of experience in this field, as of 2016, it began industrialising entire manufacturing cycles for the Freudenberg Group’s products. In 2020, after several successful projects and experiments and building on its expertise, it began to support US car manufacturers looking to enter the

The STS EE30 AIO rotational cleaning plant supplied by STS.

field of battery production for electric vehicles.

Freudenberg thus accepted a new challenge: industrialising the entire production process

© ipcm

of cell caps, the terminal component of battery packs. The aim is to produce them at low costs and in quantities of tens of millions of units per year, in order to provide OEMs with an alternative to parts produced in the East. To date, indeed, only Asian manufacturers can supply battery packs and their components within very short times and in significant numbers, which in fact forces European car makers to import such products. The project is currently at an advanced stage of research and development: Freudenberg is now carrying out several prototype tests to analyse all critical issues related to cell cap production and develop an ad hoc industrialisation process. Mass production of cell caps is expected to be in full swing by 2025.

An overview of the production cycle and the cleaning process To design the most suitable production cycle for its cell caps, Freudenberg has installed

Detail of the cleaning baskets.

several state-of-the-art machining centres,

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plants, and technological systems at its

© ipcm

Luserna San Giovanni site. Once the industrial process will be defined, all the manufacturing production steps currently required for the cell cap prototypes will be transferred and implemented in a plant dedicated exclusively to the mass production of this component.

“One of the main critical issues that arose during the prototyping phase of cell caps concerns the degree of cleanliness of all its components. In fact, they must necessarily meet very high, clean room-level cleanliness requirements, as the presence of any contaminating particles could cause problems and safety risks for the entire battery pack,” says Maurizio Barale, Technology Innovation Director, Automation & Robotic application, and Plant Manager at Freudenberg.

Although, at this late development stage, we cannot reveal in detail the production steps that constitute the project, we can outline its In order to ensure a high cleanliness degree and minimise contamination, STS’s part cleaner is protected and enclosed by a polyethylene sheet barrier and a kind of antechamber. Moreover, to access the machine, operators must wear a disposable non-woven fabric protective suit, shoe covers, a hood, and a mask.

key elements. “The production cycle can only begin with cleaning and drying each individual component precisely because, as pointed out, there must be no traces of contaminants dragged from the previous processing steps,

© ipcm

let alone particles from the air of the plant.”

“Freudenberg relied on STS for its cleaning process. We are a manufacturer of cleaning equipment based in Ravenna (Italy) and we supplied this customer with an STS EE30 AIO rotational system performing ultrasound cleaning, two rinses, and vacuum drying. The system uses a Rollclean STS bicarbonatebased detergent with a 0.0.0 safety sheet,” explains Pier Damiano D’Ignazio, the Marketing & Sales Director of STS. In order to eliminate any contamination and achieve the desired degree of cleanliness, production is going to take place in a clean room. However, at this early stage and in the absence of a clean room, STS’s part cleaner is protected and enclosed by a polyethylene sheet barrier and a kind of antechamber; to access it, operators A cell cap component placed into the basket before the cleaning cycle.

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must wear a disposable non-woven fabric

ICT | CASE STUDY

protective suit, shoe covers, a hood, and a

© ipcm

mask.

“Once clean, the components undergo an assembly phase, the complexity of which depends on the number of parts necessary to produce the different cell cap models.

Some relatively simpler products require the combination of only a few components, whereas some complex ones have more than twelve components. Assembly is an extremely important and challenging phase, as we are trying to dramatically reduce our takt time to meet very tight production schedules: in fact, our goal is to be able to manufacture one component in less than a second. The following steps include mechanical joining by plastic deformation, laser welding, and several internationally recognised fluid tightness tests to check if the entire process has been successful, as well as electrical tests to measure conductivity and insulation and thus ensure that the product meets customer

Freudenberg’s technical team in charge of the project.

requirements. The process ends with a further fine cleaning cycle, which we are currently developing with STS, and the packaging phase,

need to select a technological partner for its

its ability to provide not only advanced

which is not to be underestimated as the cell

cleaning process, it looked at the solutions

technology but also a highly professional

caps will need to be stored under vacuum and

and processes offered by several companies

technical service. At this point in the project,

inside special blisters,” notes Barale.

active in this field. The choice fell on STS

it was essential for Freudenberg to establish

for several reasons. “In the past, STS had

a fruitful collaboration and work closely with

STS as a technology partner: the reasons for this choice

already collaborated with Freudenberg

STS’ engineers as if we were one project team

on the installation of different systems in

focused on achieving a common goal,” states

When Freudenberg was faced with the

the Group’s various plants, demonstrating

Barale.

ICT | CASE STUDY

STS was able to fit in with Freudenberg’s project team, providing industrialisation solutions that did not only concern individual cleaning systems, but also their integration with the production lines that Freudenberg is designing with a view to starting the industrialisation of cell caps. “Through a continuous exchange of technical information and data, we were able to identify the most suitable solutions for our production needs, which were mainly related to reducing the cleaning cycle time and increasing productivity: two extremely important factors as they both contribute to lowering unit costs,” explains Barale.

Another decisive factor in choosing the right cleaning system supplier was the guarantee of a high degree of cleanliness. At the same time, the ability to offer a cleaning agent that was free of solvents, modified alcohols, or surfactants, which could damage the battery and cause major risks, was also crucial for

© ipcm

From left to right: Maurizio Barale, Technology Innovation Director, Automation & Robotic application, and Plant Manager at Freudenberg, Pier Damiano D’Ignazio, Marketing & Sales Director at STS, and Paolo Peirone, technician at Freudenberg.

maximum safety. The Ravenna-based plant engineering company was able to meet

months ago, they did not expect to see

component in less than a second, as well

both requirements by presenting a machine

an actual production area, albeit at the

as high cleanliness, precision, and process

technology capable of achieving a level of

prototyping level, and this was also thanks to

repeatability levels. We cannot proceed with

cleanliness appropriate to Freudenberg’s

STS, which had provided us with its plant in

the next industrialisation phase if we do not

needs and a battery-safe cleaner like the

less than thirty days.”

fine-tune all these factors, as producing such a

bicarbonate-based Rollclean.

large number of parts without a fully perfected

Finally, STS proved to be able to support

Conclusions

process would lead to very high scrap rates.”

the company by delivering its plant within a

“At the moment, Freudenberg is a European

Meanwhile, Freudenberg is still investigating

short time frame. “When the need arose for

flagship, the only company with sound

the optimal cleaning solution to remove any

us to install a system for the pre-industrial

expertise and knowledge in the production of

contamination coming from both the previous

prototyping phase, STS provided us with its

cell caps for electric batteries.

processing steps and the surrounding

technological solution in less than a month,

Our objective is to industrialise our cell cap

environment. Together with STS engineers, it is

enabling us to proceed successfully and

manufacturing process by 2025, by developing

therefore defining a fully customised cleaning

quickly,” states Freudenberg’s Plant Manager.

advanced processes that will allow us to

system, with cycle times and processes

“When the engineers of a well-known

achieve a very high automation intensity

consistent with the Freudenberg production

automotive group visited our factory a few

and density degree for manufacturing one

line’s characteristics.

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LA SFIDA DELL’ELETTRICO alti gradi di pulizia sicurezza per batterie e powertrain

LA RISPOSTA

tecnologie di lavaggio e impregnazione STS

ev Lavaggio detergente potente e sicuro scheda sicurezza 0.0.0.

NO alcoli, solventi, tensioattivi

ev Impregnazione sigillatura sicura chiusura microporosità 100% resine a recupero

Non basta dipingere alberelli per essere green.

Senza scheda di sicurezza 0.0.0. su un ev non sali.

dà sicurezza al tuo veicolo elettrico

CHRISTINE BRUEHOEFNER

ICT | TECHNOLOGY OVERVIEW

BvL Oberflächentechnik GmbH – Emsbüren, Germany christine.bruehoefner@bvl-group.de

Cleaning tumble dryer drums with short cycle times Tumble dryer drums must be thoroughly clean and spotlessly dry before they can be installed in the household appliances.

Short cycle times for the cleaning system are important for achieving a high throughput.

T

he Polish factory of a world-renowned Group of companies in

The plant operator can control the conveying speed to thus react

the field of household and industrial kitchen appliances chose

flexibly.

a cleaning solution from BvL Oberflächentechnik GmbH to

thoroughly clean and spotlessly dry tumble dryer drums. After the

Individually adapted cleaning system

manufacturing process, the drums are soiled with traces of oil and

When planning the system, BvL considered more than just the

grease.

manufacturer’s specifications for quantity and time. The restricted

For installation into a clothes dryer, it is imperative that the drums

space at the installation site also had to be taken into account in

have been thoroughly cleaned and are mostly stain-free. The BvL

order to achieve optimum integration of the cleaning system into the

Yukon continuous cleaning system cleans and dries the tumble dryer

production flow. As a result, the continuous system was equipped with a

drums thoroughly in a cycle time of only 12 seconds per part.

180-degree corner transport system in this case and the cleaning zones

The drums continuously move through the following sequential

were arranged parallel to the drying zone.

treatment zones of the cleaning system to ensure consistent material

A manual maintenance opening on the loading station makes the

flow and high throughput.

machine easily accessible for the operator from all sides.

© BvL Group

BvL Oberflächentechnik GmbH is one of the largest suppliers of water-based industrial cleaning systems in Germany.

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ICT | TECHNOLOGY OVERVIEW

© BvL Group

The Yukon continuous cleaning system for thoroughly cleaning tumble dryer drums in a short cycle time of just 12 seconds.

Efficient cleaning technology

Saving energy with intelligent sensor technology

After automatic loading of the tumble dryer drums into the cleaning

The Nevada drying system not only delivers consistent drying results,

system, they are positioned automatically in the feed zone: a special

but also saves energy with intelligent sensor technology. Water

system lowers the drums onto the workpiece holders. This ensures

and energy consumption are significantly reduced compared to a

that the parts are in the optimum position for the subsequent cleaning

conventional drying system.

process and prevents poor cleaning results due to incorrect positioning

The exhaust air management, for example, controls the fan based on

of the workpieces.

the measured humidity, while the energy discharged in the form of hot

The drums then continuously move through the following sequential

exhaust air is kept to the necessary minimum. The optimised flow of the

treatment zones of the system: They are cleaned thoroughly from all

drying process also reduces the required heating input and therefore

sides in the cleaning zone. The nozzle system is individually aligned

any unnecessary energy consumption. Of course, all tubes, filters and

for the specific parts. Before the drums move on to the rinsing zone,

tank covers are insulated to reduce the loss of thermal energy in these

they are blasted with unheated air in an intermediate zone to prevent

areas.

the cleaning media from mixing or spraying out between cleaning and process. In this case, this is done from above and underneath with a

Flexible adaptation to changed operational requirements in future

rotating air blast system that is also specifically tailored to the drums.

The cleaning system can be adapted to changed operational

The final drying of the drums takes place in the BvL Nevada drying zone

requirements at any time. The household manufacturer is well prepared

by means of electrically heated air. After this step, the cleaned and dried

for the future as upgrade options are available if the requirements for

drums can be removed from the roller conveyor in the discharge zone.

capacity and throughput should change over time.

rinsing. The parts are then blasted with air again before the drying

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EDITED BY LAYTON TECHNOLOGIES LTD

ICT | CASE STUDY

Staffordshire, United Kingdom websales@laytontechnologies.com

© Adobe Stock

Ceramic components for orthopaedic implants.

Development of new quicker cleaning process for ceramic components A world-renowned manufacturer of advanced technical ceramics components approached Layton Technologies Limited with a requirement to rationalise the cleaning and drying process used on ceramic components destined for the medical device industry.

T

he client operated a time and chemistry heavy cleaning process

high degree of safety for both the environment and operatives.

carried out in two separate systems which were in excess of 20

The list also included increasing yields, removing the requirement

years old and they had already identified the substantial risks

for the multiple operators of the current systems, reducing energy

to their operation due to increasing issues with the reliability of the

usage, increasing throughput and removing any need for the use of

ageing systems.

hazardous chemistries.

They had a long list of requirements for the project the main focus

Layton were tasked with developing a streamlined automated process

being that they needed to be able to manage their forecasted

which would meet all of the above requirements, and were required

increased throughput, which was in excess of 10 times the current

to ensure that due to the extremely fragile nature of the product no

throughput, whilst at the same time ensuring that they maintained a

damage occurred to them during the cleaning and drying process.

scrupulously clean process to medical device standards and provide a

In addition to the client’s already lengthy wish list was the ability of any

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new system to provide a high level of functionality to improve process

the client to ensure that all contamination was removed, and the parts

control and data collection.

sustained zero damage.

To achieve all the requirements placed upon Layton, the following key

An extensive Technical Proposal was produced which included for

uncertainties needed to be resolved:

automated processing, complete system enclosure, automated chemical

• Would it be possible to introduce a more reliable automated system

dosing and monitoring and data logging this satisfied the concerns that

with the ability to increase yields with a more effective cleaning and

the client had expressed as to the overall ability of the new system to

drying process whist reducing energy consumed?

meet the requirements of the project.

• Could the manual intervention required for the current process be

Following the issue of the purchase order to Layton their in-house

removed by automation?

design team produced a comprehensive Design Documentation

• Could the process be rationalised resulting in a consistent end-

Package which included a general arrangement diagram, a piping

product and shorter overall process time?

and instrumentation diagram and a functional design specification, a

• How could the level of functionality be improved to provide greater

software design specification together with a comprehensive Project

process control and data collection?

Plan. At the same time as the main system design and manufacture

• Could the risk be removed to operators and the environment due to

Layton undertook the design, development and manufacture of a

exposure to the chemicals employed.

specialist fixturing to hold the components and to optimise the cleaning

Extensive, customer witnessed, trials were conducted to rationalise the

and drying process.

current process and to ensure a clean and dry end product.

The final design resulted in a new, fully automated, multistage cleaning

Due to the fragile nature of the components, tests were developed with

and drying system complete with Layton’s unique 5-year warranty.

© Layton Technologies

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FRANCESCA PIRERA

ICT | HIGHLIGHT OF THE MONTH

Rösler Italiana Srl – Concorezzo (MB), Italy f.pirera@rosler.com

A fast, efficient, and gentle shot peening solution The Multi-Tumbler RMT solution produces absolutely homogeneous and consistent shot peening results.

W

hen talking about state-of-the-art shot peening systems, one cannot but mention Rösler’s Multi-Tumbler RMT machine.

Conceived, designed, and developed based on Rösler’s customer requirements and recommendations, the RMT plant differs from other shot blasting systems in the special geometry of its highperformance rotary drum. Its walls have specially shaped mixing cams and its bottom is characterised by a triangular pyramid.

This innovative conformation produces the so-called “multitumbler effect”: during rotation, the cams mix the parts, whereas the pyramid at the bottom facilitates the movement of the upper and lower masses of the product. In this way, all the treated surfaces are evenly exposed to the media flow.

Rösler RMT 8, in particular, has proved to be the ideal plant for a manufacturer of small metal parts operating in various fields, from automotive to agricultural machinery. Its main requirement was to be able to carry out shot blasting prior to coating, i.e. to hit its components’ surfaces with media to make them porous enough to improve the adhesion of paint – in other words, to make these surfaces’ pores functional for paint adhesion.

Rösler’s collaboration with this manufacturer began in 2018 with the purchase of a RMT system, fully customised to enable optimal integration within its production line. First, the output of the standard GAMMA 300 turbines had to be increased from 7.5

© Rösler

to 11 kW. This resulted in the need to raise the bucket elevator’s power, thus also increasing the media flow rate. In addition, some structural changes were made, including reinforcing the inner side and housing of the drum to meet the customer’s demand for increased performance with low wear levels.

Today, this customer’s production line integrates two fully tailormade RMT shot blasting plants.

© Rösler

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www.gattomatto.biz

METAL CLEANING EVOLUTION

WATER BASED PARTS WASHER, THE AGREEMENT BETWEEN NATURE AND TECHNOLOGY

107

MACHINES MODELS, INFINITE COMBINATIONS

WWW.TEKNOX.NET BOLOGNA - ITALY ADVANCED TECHNICAL SOLUTIONS FOR SURFACE TREATMENT

NEWS

ICT | INDUSTRY NEWS

Alliance Manufacturing acquired Technical Devices Company Technical Devices Company, a company specialising in cleaning equipment for the electronics and printed circuit board industries, is now part of Alliance Manufacturing, Inc.

L

ast December, Alliance Manufacturing, Inc., a parts cleaning

upon the legacy that has been built by Doug and the TDC team.

system manufacturer in Fond du Lac (WI, United States) acquired

Through this acquisition, Alliance Manufacturing, Inc. will be bringing

TDC (Technical Devices Company) based in Torrance, California,

over the TDC staff to its local facilities, which will add approximately

a manufacturer of cleaning equipment for the electronics and printed

200 years of combined cleaning expertise to its already extensive

circuit board industries. TDC has continued to maintain the values

knowledge base.

established by their founders back in 1952. Their high-quality standards,

Alliance Manufacturing, Inc. is a leading provider of industrial parts

excellent employee relationships, and close partnerships with their

cleaning systems across a wide range of industries. “Our core

customers have made TDC an ideal fit for the culture and direction of

cleaning products include both aqueous and solvent based cleaning

Alliance Manufacturing, Inc.

systems. With the addition of TDC, we will now have expertise related

The company has thrived under the direction of Mr. Douglas Winther

to electronic component cleaning, printed circuit board cleaning and

for the past 40 years. He started with the company in 1963 and worked

deionized water recycling systems. Alliance’s engineering team will

his way up from Machine Shop Trainee/Assembler, all the way up

continue to expand upon Alliance’s and TDC’s patented technologies,”

to President/Owner. Doug has built a team that provides excellent

the company states.

equipment and services to a very diverse customer base in the electronics manufacturing industry. Alliance will continue to expand

For further information: www.alliancemfginc.com

© Alliance Manufacturing, Inc.

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N. 81 - MAY/JUNE 2023 - international PAINT&COATING magazine

Protection upgraded

Specialità chimiche per il trattamento delle superfici Lavaggio Industriale

Pretrattamento metalli alla verniciatura

Lavaggio di precisione

Processi di conversione esenti

Sgrassanti interoperazionali

Cromo e Fosfati

Miscele di tensioattivi

Fosfatanti a bassa temperatura

Protezione temporanea

Passivanti per acciaio zincato a caldo Passivazione conduttiva su Alluminio TCP

Galvanica Funzionale

Galvanica Decorativa

Zinco e leghe di zinco

Rame, Nichel e Cromo

Passivanti e Sigillanti

Deposizione su plastica (POP)

Rivestimenti resistenti all'usura

Stagno e leghe di Stagno

Pretrattamento

Pretrattamento

SurTec Italia Sas di Externa Holding Srl Via Boito, 251 Tel.: +39 059 8579901 41019 Soliera (MO) E-Mail: info-it@surtec.com Italia Web: www.SurTec.com

NEWS

ICT | INDUSTRY NEWS

EnviroTech ProSolv®5408e: Fluorocarbon vapour degreasing engineering fluid for precision cleaning applications ProSolv®5408e is a fluorocarbon vapour degreasing engineering fluid for precision cleaning applications that has been developed

by EnviroTech Europe Ltd for parts cleaning or cleaning automated machinery at strip down.

E

nviroTech has presented ProSolv®5408e, a high-performance

© EnviroTech

solvent cleaner used for sustainable and future proof vapour

degreasing specifically developed to provide superior critical cleaning performance for manufacturers of electronic and electrical components. Soft on the environment and safe for users, it offers improved cleaning at lower costs.

ProSolv®5408e is the perfect replacement for trichloroethylene,

nPB (n-propyl bromide), perchloroethylene or other flammable solvents used in general engineering cleaning processes. It ensures future-proof cleaning and can offer savings without compromising quality. Substitution is simple with little or no changes to equipment or control settings needed. It is also friendly to the environment, as it has zero Ozone Depletion Potential (ODP) and a very low impact on Global Warming (GWP). In addition, it is a nonflammable stable azeotrope needing no testing for acid acceptance or stabilising additives, easy to use and maintain and safer for employees and the workplace.

It is then extremely effective for precision cleaning in hightech industries such as aerospace, aviation, electronics and medical device cleaning due to the use of an additive trans 1,2-dichloroethylene that produces a powerful cleaning solvent with a very low surfaces tension that cleans blind holes and the smallest gaps more effectively at a lower cost. With these wide range of properties, ProSolv®5408e is particularly effective when used with ultrasonics.

However, it can usually be used in existing degreasers or dip tanks.

The fluorinated solvents are ideal for the cost-conscious user for precision cleaning and degreasing of electronics, metals and glass.

It can be employed to remove adhesives, fluxes, pastes, buffing compounds, greases, silicone oils, particulates, resins, waxes and other oils and soils.

For further information: www.envirotech-europe.com

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N. 81 - MAY/JUNE 2023 - international PAINT&COATING magazine

© EnviroTech

ICT | TECHNOLOGY OVERVIEW

PETER SCHRAMM MetaLine Surface Protection GmbH – Hildrizhausen, Germany info@metaline.de

Sensible repair measures on worn vibratory finishing systems in the focus of the expected service life and feasibility MetaLine provides the right materials, the right application methods and the right adhesion promoters in order to allow users to successfully carry repairs themselves.

T

ribo finishing is abrasive – and that is exactly how it should be. But

Today, they are mainly filled with polyurethane. What if this protective

unfortunately, the abrasiveness does not only turn against the

lining has now become a target itself and time has gnawed away at

parts to be ground, but rather also against the vibratory finishing

it? Mostly in the form of localised wear and tear, even to the point of

equipment itself. And to an extreme degree.

impact on the bare metal substrate.

In the past, the hemispherical vibratory grinding tanks were therefore

Just like in real life, it is better to react too early than too late. In

lined with rubber.

other words, if there is visible damage or wear, plan and organise a

ICT | TECHNOLOGY OVERVIEW

‘professional’ repair in good time rather than waiting too long. Because

The damaged area is measured, cut to size, roughened, cleaned, dried,

after the wear and tear, comes the puncture to the metallic substrate.

primed and then poured on or filled or sprayed – just as the individual

Followed by moisture infiltration, corrosion, detachment and in the end

skill and geometry require. MetaLine has the right materials, the right

even quality loss in the vibratory finishing itself.

application methods and the right adhesion promoters so that you can

Timely repair is an economically and ecologically good way. Planned in

successfully carry out these repairs yourself.

time – before the entire coating is mechanically or chemically attacked –

The situation is quite different, however, if the protective coating is

repairs are possible in the installed condition. But it goes without saying

grossly worn, infiltrated or full of holes.

that the bowl must be drained for this purpose. Otherwise, a complete

Then the question arises whether the coating residues can remain

damage assessment and professional substrate preparation is not

or must be completely removed. Unfortunately, there is no

possible.

environmentally compatible method for removal.

First of all, however, a hydrolysis test must be carried out to determine

As a rule, the old coating is burned off thermally by pyrolysis, or blasted

whether the existing coating is still capable of bonding at all and is thus

off by cryogenic processes (cold shock). After that, the equipment

repairable – because here, too, there are age limits just like in real life.

manufacturer can cast in the new lining by means of casting mould.

© Metaline

© Metaline

The protective lining may be subject to localized wear and tear, even to the point of impact on the bare metal substrate.

international PAINT&COATING magazine - MAY/JUNE 2023 - N. 81

219

ICT | TECHNOLOGY OVERVIEW

Of course, this is no longer a do-it-yourself process. For simple geometries of the vibratory finishing drum (without flap ejection), a sprayed coating can alternatively be applied. MetaLine also has the material and the suitable spraying process for this.

The various epoxy-ceramic based fillers or wild elastic fillers that are applied to a rather less prepared substrate in sheer technical desperation disappear just as quickly as they were applied. It depends on a very special bond to the substrate and therefore also on an extremely careful preparation, that MetaLine has stood for with its elastomeric coating technology for more than 63 years.

And the costs are very interesting in © Metaline

comparison with the container replacement and repair effort and durability. Properly applied, the repairs have OEM coating quality and can massively improve overall service life.

From top: A timely repair – before the entire coating is mechanically or chemically attacked – is a cost-effective and ecological solution.

© Metaline

220 N. 81 - MAY/JUNE 2023 - international PAINT&COATING magazine

Properly applied, the repairs have OEM coating quality and can massively improve overall service life.

le due facce di

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SOLVENTI CLORURATI

CEMASTIR SRL Via O. Guerrini 4, 40069 Zola Predosa (BO) Italia Tel. 0516256111 - email info@cemastir.it

cemastir.it

ICT | MEETING THE INDUSTRY

DeburringEXPO – Eliminating the culprit: Burrs The 5th leading trade fair for deburring technology and precision surface finishing will take place from 10th to 12th October 2023 at the Karlsruhe Exhibition Centre (Germany).

T

he requirements for burr-free, clean components with high-

companies also include businesses and startups who will be

quality surface finishes continue to increase in growth-oriented

presenting processes to the public which have been developed in

industry sectors such as components manufacturing for

collaboration with research institutes and universities.

battery and fuel cell-based electromobility, hydraulics, sensor and pharmaceuticals technology, as well as electronics and systems and

Supplementary programme with issues of relevance for competition

machinery manufacturing.

The supplementary programme at this year’s DeburringEXPO will

At the same time, disruptive developments are challenging parts

also be ideally adapted to increasing demands placed on quality,

manufacturers to gain a foothold in new market segments. However,

reproducibility and efficiency in production, as well as to changing

success can only be ensured by means of further development and

production technologies. For example, the “Automated Deburring”

the adaptation of existing expertise and processes. Deburring, edge

theme park will demonstrate options for automated polishing, grinding

rounding, cleaning and the production of precision surface finishes

and deburring of components with robots.

definitely play a decisive role in this regard. In order to position

Automation is also a possible solution for dealing with the shortage

themselves competitively for the future, numerous companies are

of qualified personnel. Whether before or after deburring, technical

seeking appropriate partners and solutions.

cleanliness in accordance with the specified requirements is an

analysis technology, the semiconductor supplier sector, medical and

essential prerequisite for the quality of downstream processes, and

A trade fair for all industry sectors, materials and tasks

thus for high-quality components as well.

DeburringEXPO, organised by private trade fair promoters fairXperts

Corresponding methods and processes will be presented in the

GmbH & Co. KG, provides an internationally unique communication

“Cleaning After Deburring” theme park. To an ever-greater extent,

and procurement platform to this end. It covers the entire spectrum of

specifications for deburring, edge rounding and surface finishing are

technologies, processes, tools and services for deburring, cleaning and

being defined more and more precisely, for example rounding in the

surface finishing – across all industries and materials.

μm range and clear-cut specifications for roughness values. In-process

“Its comprehensive range of offerings makes DeburringEXPO the ideal

or subsequent quality control is required in order to exclude possible

marketplace where users can search in a targeted fashion for solution-

defects. The

oriented partners for changing and new tasks in deburring and the

“Quality Assurance in the Deburring Process” theme park provides an

production of precision surface finishes,” explains Gitta Steinmann,

overview of the various measuring methods, as well as their strengths and limitations.

project manager at fairXperts. “44% of the visitors in 2021 came to the trade fair in order to prepare or finalise investment decisions.”

Knowledge transfer as added value

Due to the great significance of DeburringEXPO

The integrated 3-day expert forum is an

for the operational procurement process, it’s

established supplement to the exhibition

also no surprise that all of the sector’s market

programme at DeburringEXPO. Solutions

and technology leaders have already made firm

for actual applications, as well as current

bookings for booth floor space at the upcoming

developments, trends and future strategies

event, which will take place at the Karlsruhe

will be at the centre of attention at the

Exhibition Centre from the 10th through the

simultaneously interpreted presentations

12th of October, 2023.

(German <> English).

“Demand for booth floor space from companies in Germany and from abroad For further information:

has increased considerably since the end of February,” adds Gitta Steinmann. These

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N. 81 - MAY/JUNE 2023 - international PAINT&COATING magazine

© fairXperts GmbH & Co. KG

www.deburring-expo.de/en

ICT | MEETING THE INDUSTRY

parts2clean 2023: High purity cleaning – Mere hype or new reality?

20th parts2clean will take place from 26 to 28 September 2023 in Stuttgart (Germany).

T

he cleanliness requirements for

and ultra-high-vacuum environments are used

high-tech components are becoming

to ensure specific properties of processes

increasingly stringent. As a result, in

and end products. In addition to particulate

addition to the terms “ultra-fine” and “precision

and filmic-organic as well as inorganic

cleaning”, the term “high-purity cleaning” has

contaminants, so-called hydrogen-induced

become established in recent years. But what

outgassing (HIO) substances or elements must

is behind it and what are the differences

be taken into account here – not only for the

between the three terms? These questions will

component materials but also for the operating

be addressed at this year’s parts2clean fair,

materials and cleaning media.

featuring the highlight topic of “High Purity”.

Not just a cleaning job

This complements the classic core areas covered at this, the leading international trade

© VACOM Vakuum Komponenten & Messtechnik GmbH

fair for industrial parts and surface cleaning,

In high-purity, precision and ultra-fine cleaning, the aim is to remove even the tiniest amounts

which will be held from 26 – 28 September 2023 at the Stuttgart

of dirt, which can vary depending on the industry and the component.

Exhibition Center in Germany.

This often involves ultra-fine particles and filmic contaminants, organics

The enormously amplified and continually rising demands on the

and/or inorganics, ionic residues or residues of microorganisms. The

reliability and performance of parts and components also have an

focus here is much more on the entire production chain than in the

impact on component cleaning. This affects industries such as the

case of classic cleaning – for example, upstream machining processes

semiconductor supply industry, electronics manufacturing, electric

must support the cleanliness objective, as well as cleanliness-compliant

mobility, precision optics, the optoelectronic industry, sensor

parts handling and the ambient conditions, for example, in a cleanroom.

technology, photonics, thin-film technology, vacuum, laser and analysis

In order to remove even the tiniest impurities, it is necessary for the

technology, aerospace, and medical and pharmaceutical technology.

equipment and cleaning technologies used – wet-chemical processes

In these industrial sectors, the term “high purity” is increasingly being

with solvents and aqueous media, dry cleaning with, for example,

used. “Despite the comparatively recent discussion about this area of

CO2 snow jets, plasma cleaning and vacuum bakeout systems – to be

application for industrial component cleaning, parts2clean has already

appropriately designed and constructed, and adapted to the specific

taken it up through its exhibitors, who have a wide variety of solutions

cleanliness requirements of the components. In the case of wet-

on offer,” explains Christoph Nowak, Project Director at Deutsche

chemical processes, this also applies to the cleaning media and water

Messe. “Due to the growing importance of this field of expertise, we

qualities involved.

have decided for the first time to supplement the classic core areas of

Another aspect involves the clean handling of the already cleaned

parts2clean with the highlight topic of High Purity.”

parts. For this reason, the components are cleaned or discharged into a cleanroom in accordance with the applicable cleanliness specifications.

High purity, precision and ultra-fine cleaning There is no generally applicable definition of the prerequisites and

“High Purity” also a hot topic at international Expert Forum

requirements that need to be met to achieve high-purity, precision

“As the leading trade show for industrial component cleaning, we

and ultra-fine cleaning. These terms are therefore often used

aim not only to be a reflection of the market, but also to drive the

synonymously and also have a few things in common – basically,

professional communication of tomorrow’s topics,” emphasizes

extremely high levels of particulate cleanliness, in some cases down

Christoph Nowak. “The topic of high purity will therefore be explored

to the nanometer range, and extremely stringent specifications with

in greater depth in the bilingual Expert Forum.” These presentations

regard to residual film contamination. Those are the requirements.

by renowned speakers from science, research and industry will also be

However, there are also differences. For example, high purity is often

simultaneously translated (English <> German).

used in the context of the semiconductor industry and its suppliers, precision optics, aerospace, and other industries, where high-vacuum

For further information: www.parts2clean.de/en

international PAINT&COATING magazine - MAY/JUNE 2023 - N. 81

223

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There is a strength enclosed in the composition of Europolveri’s products, a formulation that determines their quality and which is reflected in the appearance and resistance of the treated surfaces.

A quality that is never casual but it is the result of a commitment to product development and industrial processes that, since their beginning, determine the powders’ strong technologic imprint.

Europolveri offers either a wide range of powder coatings in different finishes and gloss levels, with a stock of about 1000 always available different colors, and the possibility of formulating and delivering customized products in the short term.

advanced solutions for metal surfaces treatment since 1982

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

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