ipcm n. 82 | July-August 2023

The smart journal for surface treatments

®

ISSN 2280-6083

ipcm digital on www.myipcm.com 2023

INTERNATIONAL PAINT&COATING MAGAZINE

14th Year - Bimonthly N° 82 - JULY/AUGUST

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CONTENTS JULY/AUGUST 2023 © ALIT Technologies

14

ADVANCEMENTS

© Idrotecnica Srl

36

ALIT Technologies Launches FASTRIP T2-120 MIX

© Gruppo ILTOM

50

FOCUS ON TECHNOLOGY

The ILTOM Group’s Powder Coating Plant Provides Production Flexibility while Reducing Energy Consumption and Improving Quality

05 EDITOR’S LETTER 06 BRAND NEW 16 ASK JOE POWDER

The “Ask an Expert” Column

18 HIGHLIGHT OF THE MONTH

A Change of Look for Zeus Electrostatic System and Its Product Range

20 BRAND NEW 22 FOCUS ON TECHNOLOGY

New Shot Blasting and Coating Plants Confirm Cos.Eco. as a Company of Excellence in Southern Italy

HIGHLIGHT OF THE MONTH

Market Trends in the Industrial Water Treatment Sector: An Analysis

by Idrotecnica

© Tecnologie Galvaniche Innocenti

62

31 WHERE WE HAVE BEEN 32 ADVANCEMENTS How to Reduce Edge Corrosion with a New-Generation Primer

ON TECHNOLOGY 40 FOCUS In Portugal’s Bike Valley, a Winning Partnership with a Powder Coating Manufacturer Raises the Bar on Finishing Quality

46 The Difference in the Pretreatment ADVANCEMENTS

of Aluminium for Different Climatic Environments Based on the Example of GSB-Certified Coating Companies

FOCUS ON TECHNOLOGY

Making the Best Use of Customers’ Time by Adding Value through State-of-the-Art Services: A Coating Contractor’s Bet on the Future

BREAKTHROUGH 58 RESEARCH The ‘Invisible’ Cellulose Coatings that Mitigate Surface Transmission of Pathogens

TO 2050 60 ROAD EcoBell4: Application Efficiency of up to 98% Saves Huge Amounts of Paint and Rinsing Agent

OF THE MONTH 68 HIGHLIGHT Lechler Tech: Industrial Coatings for Every Opportunity

THE FUTURE OF EVAPORATION

BE WASTEWATER FREE

ZLD SINCE 1984

www.eco-techno.it • sales@eco-techno.it

CONTENTS JULY/AUGUST 2023 © Nord Group

72

© Walther Trowal

FOCUS ON TECHNOLOGY

84

Halved Colour Change Times and Tenfold-Reduced Powder Disposal Volumes: Nord Laser’s Experience

ADVANCEMENTS

More Options for the Coating of Components for Electric Vehicles

© T&G

© Mauro Serra

96

ART WITHIN SURFACES

The Symbiosis of Industry and Design in the Exhibition “Red in Italy - I Colori del Rosso nel Design Italiano”

IT'S COATED 70 HOW The Colour of Wind: When Wind Power Becomes an Aesthetic Icon

80 ADVANCEMENTS The Circular Economy’s Challenges to the Coating Industry and Chemtec’s Answers

OF THE MONTH 88 HIGHLIGHT Brief Notes on the Development of Sustainability-oriented Technologies through Automation, Energy Efficiency, Digitalisation, and AI Used in Industrial Coating Processes

92 ADVANCEMENTS

Eliminate Masking from Coating Operations with Lasers

108

98 FOCUS ON TECHNOLOGY

CEB Invests in Flexibility and Repeatability Through Robots Capable of Self-Generating Powder Coating Programmes

104 HIGHLIGHT OF THE MONTH

Seven Quality Tests for Coating Processes According to Argos ST

WITHIN SURFACES 114 ART AkzoNobel Helps Southwest Celebrate Hawaiian Culture with Imua One

116 ADVANCEMENTS The Latest Generation of CONDOROIL Stainless’ Dialysis Cells

STUDY 118 COLOUR Deceiving Green

FOCUS ON TECHNOLOGY

T&G: The Loyalisation of the Coating Plant Engineering Partner to Support the Company’s Growth

122 BRAND NEW 126 ADVANCEMENTS

New Dip-And-Spin Technologies Reduce Material and Labour Costs in the Metal Coating Process

130 SPECIALIZED TRAINING

Research, Technology, and Innovation for a Sustainable Industrial Future

132 STANDARD&LEGISLATION ESG Criteria: From an Added Value to a Market Requirement

134 MEETING THE INDUSTRY

20 IPS ALREA SOLD D Y EURO IN P E!

THE NEXT GENERATION OF POWDER COATING. IPS

Powder coating center • Automatic color change • Excellent surface quality • Highly automated processes

wagner-group.com/it

Contact: Wagner S.p.A. a Member of WAGNER Group +39 0341 - 212200 commerciale@wagner-group.com

A NEW FOCUS ON INNOVATION www.adaptacolor.com

EDITOR’S LETTER

Richiedi la versione in italiano a info@ipcm.it

W

e are living in what sociologists and philosophers define as the information society, a concept familiar and dear to all those who – like me – have studied communication techniques and dynamics. In this society, whose pillars are information technology and telecommunications, an intangible good, namely information, prevails over the industry and the service sector.

As an operator in the communication sector, and a niche one at that, it is therefore natural to wonder what is the role of specialised information in the contemporary world, with information being placed in such a central position and considered a resource and a factor of social and economic development, growth, and cultural richness1.

Specialised technical information, such as that which ipcm® has been offering for almost fifteen years with its four magazines devoted to surface treatment-related topics in the general, heavy, and automotive industries, is a source of in-depth knowledge, industrial culture, and understanding of innovation. ipcm®, in particular, provides information that captures the essence of innovations and connects it with industrial reality. Through our reports about the end-users of surface treatment technologies, the conversation truly moves from abstract to concrete.

Our articles portray the market, its needs, and how it is developing, growing, and incorporating new technologies. They assess its efficiency, effectiveness, advantages, and disadvantages with a tone of voice that is as objective as possible.

They provide information that breaks away from the clinical cleanliness of scientific or technical articles written by companies’ laboratories.

High-quality information that is verified and verifiable, sometimes even uncomfortable because it opens up to disruptive technologies deviating from the past and from what is already known.

First-hand information that is very costly for the publisher, because it involves travel, transfers, hours of work. But also the type of information most appreciated by readers, who can recognise themselves, their companies, and their needs in it.

In a way, even an “insurance policy” against the kind of distinctly advertising-oriented information that many international magazines thrive on.

This vertical approach to information and such an extreme specialisation of content have helped us build a community of readers with whom we can engage in a conversation that from printed magazine crosses over into digital channels, our social media, and our website, which is not a simple platform to publish our issues online but is also aimed at offering daily first-hand news, expanding our magazines’ content, and fostering contact among businesses, between supply and demand.

With the hope that you, our readers, our most valuable resource, will continue to appreciate such content, but also to give us constructive criticism if necessary and even to start technical debates, I wish you a good summer and happy reading of this summer issue of ipcm®.

1

Source: https://www.treccani.it/enciclopedia/societa-dell-informazione_%28Enciclopedia-della-Scienza-e-della-Tecnica%29/

Alessia Venturi Editor-in-chief Direttore Responsabile

international PAINT&COATING magazine - JULY/AUGUST 2023 - N. 82

05

BRAND-NEW

© AdobeStock

AkzoNobel Powder Coatings Introduced the e-Commerce Platform My Interpon Portal My Interpon Portal enhances the digital services of AkzoNobel, providing quick and easy access to information on powder coatings.

A

kzoNobel has launched My Interpon Portal, an extended

site, we will continue to enrich and enhance the functionality of My

digital e-Commerce platform with enhanced features and

Interpon Portal with new features to help customers access the

functionalities that will ensure customers will have fast and easy

powder coatings they need for the most urgent of urgent jobs.”

access to information and products for powder coating.

My Interpon Portal makes it easy to manage new, ongoing and repeat

The online resources platform helps coaters to discover the range

orders. Users can instantly visualise the products in stock – with the

of Interpon powder coatings and also experience how the multitude

corresponding technical specification data which can be downloaded –

of colours and textures will perform, thanks to a 3D lightbox colour

and how quickly they can be shipped.

visualisation tool. As a matter of fact, its functionality enables customers

In addition, the Track and Trace feature enables to check how the

to easily navigate the site and search for, find and compare hundreds

order is progressing, while past and present invoices can also be

of powder coatings.

accessed, reviewed, printed and filed.

“The launch is further evidence of the commitment to customers of

The online portal is already live in United States, United Kingdom,

AkzoNobel. We strive to make things easier for our customers with

Germany and Australia, and is being rolled out in Canada, Czech

practical tools and support that makes us collectively more efficient,”

Republic, Poland, India, and New Zealand in the upcoming months.

has declared Jeff Jirak, the director of the Powder Coatings business unit of AkzoNobel. “A significant development of our existing e-commerce

06

N. 82 - JULY/AUGUST 2023 - international PAINT&COATING magazine

For further information: www.interpon.com

BRAND-NEW

ChemQuest Appointed Eric Casebolt as New Director Eric Casebolt will support ChemQuest to improve its business strategy services for the specialty materials industry.

T

he ChemQuest Group has recently announced that it has named Eric Casebolt as a new director of the company. Casebolt has a vast experience in managing international businesses and a deep

knowledge of the additives used in coatings, packaging and construction applications. So, he will support ChemQuest by focusing on market development, product innovation and business strategy services.

“Eric has had an accomplished career, excelling in business development and strategy. In addition, I anticipate that his work building innovation pipelines for diverse product lines will bring value to our teams working on product development at ChemQuest Technology Institute and ChemQuest Powder Coating Research. I’m delighted to have him on the team,” has stated Daniel Murad, the CEO of ChemQuest.

The newest director of ChemQuest holds three important qualifications: a bachelor’s degree in chemistry from the University of Wisconsin Parkside, a master’s degree in chemistry from the DePaul and an MBA from the Wake Forest University.

“I am excited and honored to become part of the ChemQuest team, a top-tier consulting organization that provides unmatched resources and expertise to the chemical industry. I look forward to working with the team and collaborating with our clients to help their businesses thrive in the markets they serve,” has commented Casebolt. © ChemQuest Group

For further information: https://chemquest.com

Fabtech, Chicago September 11-14, 2023 Booth # D 40108

FORGET ABOUT PRODUCTS. IT’S A PROCESS. Every challenge is different. And so are our solutions.

We offer individualized finishing technologies, tailor-made for your application.

Nutroinc.com

BRAND-NEW

RMIT Europe Will Take Part in the ALCOAT Research Project for Aluminium Alloy Coatings The ALCOAT project will develop two new families of recycled aluminium alloy coatings as a more sustainable alternative to zinc galvanisation.

T

he European hub of the global

atmosphere as well as steel sheet products

thinner and more sustainable given the

university of technology, design and

for automotive, building and home appliance

reduction in the quantity of primary raw

enterprise RMIT has recently announced

industries.

materials required, thereby also boosting

that it has been granted the sum of $294,000

“Scrap aluminium is widely available

efforts in the circular economy.

(around €272,500) to contribute to the

but being contaminated with iron and

“Using existing scrap materials will prevent

ALCOAT research project, which aims to

magnesium makes it brittle and unusable

the energy-intensive process of mining and

develop aluminium alloy coatings as a more

for many applications, meaning it is often

processing virgin zinc and the associated

sustainable alternative to zinc galvanisation.

either discarded or used for lower-level

negative costs to the environment. Compared

ALCOAT is a 42-month project sponsored

purposes such as pellets,” has stated Ivan

to traditional coating development processes,

by the EU Research Fund for Coal & Steel

Cole, the Research Director of RMIT Europe.

the procedure proposed by ALCOAT is highly

(RFCS) that will develop two new families

“However, this aluminium is exactly what we

innovative and advanced and will ensure

of recycled aluminium alloy coatings with

need to produce a good coating for steel as

a dramatic shortening of the development

chemically tailored electrochemical potential,

the contaminants it contains actually stop

process and reduce costs,” has concluded

in order to create an alternative to zinc for the

oxide from forming. ALCOAT will address a

Cole.

galvanisation of steel products.

sustainability issue rather than a performance

The ALCOAT project is coordinated by the

Steel is one of the most important

problem.”

University of Chemistry and Technology of

metallic construction materials, thanks

The aluminium alloy coatings developed by

Prague and will start on 1st September 2023.

to its mechanical properties, availability

the project are expected to have several

and affordability. However, when left

advantages, such as a lower corrosion

untreated, steel is susceptible to oxidation

rate and a reduced risk of hydrogen

For further information:

and subsequent deterioration, with tell-

embrittlement. They will also be lighter,

www.rmit.edu.au

tale signs of damage such as cracking and rusting especially prevalent in moisture-rich

© RMIT

environments.

The protection of steel structures against corrosion is therefore necessary to lengthen the service life of steel products and ensure the fulfilment of safety requirements by averting material failure.

Although zinc is widely used to protect steel from corrosion and is highly effective, it is also difficult to recycle. Recycling aluminium destined for landfill to create an alternative for the galvanisation of steel products will then ensure effective and sustainable coatings for the protection of wind towers, ships and other structures exposed to sea water and

08

N. 82 - JULY/AUGUST 2023 - international PAINT&COATING magazine

BRAND-NEW

The Adapta Color Headquarters Becomes a Cardiac-protected Area In order to improve the safety of staff and visitors, Adapta Color has updated its emergency and first aid plan.

A

dapta Color, a Spanish manufacturer of

burn kits, control bleed kits and eye wash kits

powder coatings, has always paid attention to

have been installed. The equipment will help to

the safety of its employees and collaborators.

significantly increase the survival rate in the event of

For this reason, the company has recently launched

an emergency.

a series of initiatives with the aim of improving

“On behalf of the management, I would like to thank

its emergency plan in its headquarters located

all the participating staff for their involvement and

in Peñiscola, Spain. 65 people from Adapta have

congratulate Ruth and Ximo from IRTA Asistencia

obtained the certification of the course in Basic Life

Médica Integral S.L. for their professionalism and the

Support (SVB - soporte vital básico) and for using

training provided”, said David Pellicer Roca, General

the semi-automatic external defibrillator (DESA -

Manager at Adapta Color S.L.

Hooks & CE Hooks

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

desfibrilador externo semiautomático) approved by EVES (Escola Valenciana d’Estudis per la Salut).

For further information:

In addition, two semi-automatic external defibrillators,

www.adaptacolor.com

HOOKS & CE HOOKS

COMPLETE SOLUTIONS FOR © Adapta Color

© Adapta Color

HANGING AND MASKING

www.rostirolla.it

BRAND-NEW

Evonik Presents TEGO® Rad 2550 Slip and Defoamer Additive for Radiation-Curing Coatings and Inks The new additive developed by Evonik provides slip and scratch resistance as well as defoaming and hydrophobicity for UV and UV-LED curing inks and coatings.

T

he Coating Additives business line of Evonik has expanded the

create products with the desired level of slip and flow and compatibility.

TEGO® Rad range of tailored silicone acrylates with TEGO Rad

“Due to its unique property profile, TEGO Rad 2550 is truly an excellent

2550, a new clear and low viscosity liquid cross-linkable additive

additive for the formulation of matte coatings, pigmented inks and

that effectively reduces static and dynamic surface tension in both

roller-applied wood top-coats. It offers a tailored cross-linkable

conventional UV- and LED-cured formulations.

performance. For inks and coatings formulators, this means great

Acrylated products allow to minimise migration and obtain very

long-term effectiveness in the final product, high resource-efficiency

pronounced and long-lasting effects. The new additive for radiation-

and a sustainable solution compared to alternative technologies,” says

curing paints, coatings and printing inks provides also a low coefficient

Courtney Thurau, the head of the global market segment for printing

of friction (COF), high scratch resistance, good defoaming and the ability

inks of Evonik Coating Additives.

to create hydrophobic surfaces.

Moreover, it ensures improved flow and levelling and optical appearance and prevents cratering. Finally, it allows formulators to

© Evonik

10

N. 82 - JULY/AUGUST 2023 - international PAINT&COATING magazine

For further information: www.coating-additives.com/en

BRAND-NEW

PPG Provides E-Coat System for Aerospace Parts to Satys Satys will use the PPG AEROCRON™ e-coat primer system for components destined to the aerospace industry.

T

he international coatings manufacturer PPG

(8 m3) bath – the largest in Europe – of chrome-

has recently announced that it has signed a

free electrocoat primer and charged with electrical

collaboration partnership with Satys, a French

current to apply the coating. This ensures corrosion

industrial group operating in the aerospace industry

and chemical resistance, meeting industry standards,

and dedicated to sealing, painting and surface

and provides an even surface finish and a consistent

treating aircraft components. The company will then

coating thickness, without drips, runs or sags in the

provide its waterborne PPG AEROCRON™ e-coat

dried film. In addition, PPG's sustainable solution

primer system to the facility in Dugny.

produces minimal waste, has low volatile organic

“PPG is proud to partner with Satys to provide our

compounds (VOCs) and helps to reduce fuel

innovative e-coat technology in close proximity to key

consumption due to weight savings provided by lower

aerospace OEMs. Our customers in France will benefit

paint usage.

from the PPG Aerocron system, which produces a

“We are always looking for innovative and efficient

more uniform finish on the aircraft parts, using less

ways to improve our aircraft painting capabilities

paint than traditional spray-applied methods,” stated

for our customers, as well as contributing to the

Sam Millikin, the global director of coatings and

decarbonization of the aerospace industry,” said

sealants for the Aerospace division of PPG.

Christophe Cador, the president and CEO of Satys.

With the AEROCRON™ system, metal aerospace components will be dipped into a 2,100-gallon

© PPG

For further information: www.ppg.com

BRAND-NEW

Graco Presented the New Electric-Operated Double Diaphragm QUANTM Pump The new pump for industrial and hygienic applications developed by Graco is a lightweight and easy to maintain solution for harsh environments.

T

he international manufacturer of fluid handling equipment

and environmental stewardship efforts,” has stated Bart Clerx, the

Graco has recently announced the release of its next-generation

product marketing manager for the EMEA region of Graco.

electric-operated double diaphragm QUANTM™ pump, which

The new pump is designed to be a highly reliable drop-in replacement

features a new electric motor design.

for current pneumatic pumps or greenfield construction, as it can

It is suitable for almost all fluid transfer applications and offers a wide

withstand harsh industrial or hygienic environments and its design with

range of materials of construction to support multiple industrial and

built-in controls and no gearbox is lightweight and easy to maintain.

hygienic operations, such as paint manufacturing, water treatment and

“Our new QUANTM pump is the perfect solution for upgrading your

chemical processing.

less-efficient air-operated pumps. The same great self-priming,

“The QUANTM pump is not a new twist on old technology. It’s an

stalling, seal-less design is a must-have for in-process applications,

entirely innovative design that changes how pumps perform in factories

filling systems and hygienic applications. The powerful new FluxCore™

and other installations around the world. We are excited to have

motors and drives deliver up to eight times more continuous torque

created an advanced, extremely efficient design that is lightweight

at low speeds than conventional motors. The plug-and-play installation

and provides significantly lower lifetime costs than other pump

allows you to replace existing pumps without additional investment or

technologies. The pump modernises operations by greatly reducing

infrastructure rework easily,” has concluded Clerx.

energy costs. This empowers industrial manufacturers to protect and

© Graco

grow margins and measurably contribute to energy savings, compliance

12

N. 82 - JULY/AUGUST 2023 - international PAINT&COATING magazine

For further information: www.graco.com

BRAND-NEW

SONGWON Will Cooperate with KRAHN Italia for the Coatings Business Through the distribution partnership, SONGWON will enhance its position in the Italian paints and coatings market.

T

he international supplier of specialty chemicals and polymer stabilisers SONGWON has recently announced a distribution

EQUIPMENT FOR

powder coating DESIGN Our powder coating systems and accessories are designed and manufactured with the utmost attention to details

partnership with KRAHN Italia for the coating business.

Effective from July 1st 2023, KRAHN Italia is the exclusive distributor

of SONGNOX® CS antioxidants, SONGSORB® CS UV absorbers and SONGSORB® CS HALS products in Italy. The company wants to enhance its position in the Italian market, which is considered to be one of the key regions in Europe for the paints and coatings industry.

“Italy is an important market for us and we are very pleased to have such an experienced partner join SONGWON’s extensive global

RESPONSIBILITY We are loyal to the customer and to the product: we build a real relationship of trust and responsibility day by day

distributor network. We are confident that KRAHN Italia’s expertise, strong market relationships and excellent customer service, combined with SONGWON’s products, will help us build and cement our position as the supplier of choice for additives for liquid coatings in Italy,” has stated Simona De Gradi, the sales manager for the EMEAI region of SONGWON. KRAHN Italia is specialised in the distribution of specialty chemicals.

It offers an extensive and high-quality product range and comprehensive technical services as well as an in-house laboratory

PROFESSIONALISM We follow each customer from design to implementation, from installation to after-sales training

to support its partners. Leveraging the deep knowledge of the Italian paints and coatings sector, SONGWON will then benefit from a targeted and sustainable product marketing approach.

“We are delighted to be chosen to represent SONGWON in the Italian market. This partnership presents a great opportunity for both companies to actively collaborate and grow, not only our businesses but also to add value for our customers in Italy as well. Expanding KRAHN Italia’s strong portfolio with SONGWON’s high-quality additives for coatings not only allows us to better meet customers’ needs but

MADE IN ITALY Booths, machines, guns and accessories for powder coating designed in Italy with rigorously selected suppliers in the Italian territory and in EU countries

also enables us to increase SONGWON’s visibility and expand its position in the coatings market in Italy,” has added Enrico Bozzi, the managing director of KRAHN Italia S.p.A. For further information: www.songwon.com

Find out more about ZEUS www.zeus-el.it

ADVANCEMENTS

ALIT Technologies Launches FASTRIP T2-120 MIX Edited by ALIT Technologies San Bonifacio (Verona), Italy

info@alit-tech.com

ALIT Technologies is pleased to announce FASTRIP T2-120 MIX, the T2’s range most compact paint stripping system.

A

LIT Technologies, a leading manufacturer of machines and

stripping machine in the T2 range, in order to offer an efficient and

products for the surface treatment of metals, is pleased to

space-saving solution.

announce the launch of FASTRIP T2-120 MIX, an even more

“ALIT TECHNOLOGIES has developed FASTRIP T2-120 MIX based on its many years of experience in the paint stripping industry” says Loris,

rapid paint removal.

CEO of ALIT Technologies. “This machine does not use ultrasound, as

Any company that coats metal parts in-house typically needs to

the mechanical action of the paint stripper on the parts’ is ensured by

paint strip two types of items: the frames or hooks used for hanging

the hydrostatic thrust generated by the mixer. The fact that ultrasound

operations and any defectively painted workpieces. ALIT Technologies

has been replaced by a mixer is precisely what distinguishes FASTRIP

has developed the FASTRIP T2-120 MIX, the most compact paint

T2-120 MIX from our top-of-the-line model FASTRIP T2-100. This makes

© ALIT Technologies

compact evolution of the T2 system, designed for an effective and a

14

N. 82 - JULY/AUGUST 2023 - international PAINT&COATING magazine

ADVANCEMENTS

the former a quieter machine that can also operate with a more polluted paint stripper; the absence of ultrasound also allows for the use of electronic components that are less sensitive to the heat developed during normal machine operation. Overall, these choices have resulted in the design of an extremely robust, reliable, safe, and well-functioning system”.

The process With FASTRIP T2-120 MIX, paint stripping is performed by immersing the workpieces in a tank containing a liquid paint stripping solution that is heated and kept under constant agitation through a special paddle mixer.

At the end of the paint stripping cycle, the basket containing the parts is removed from

© ALIT Technologies

the process tank; after a rinse, these can be

The mixer.

reprocessed normally.

The required process steps are the following: 1. Loading of the basket with the components to be stripped;

The coupling of the motor with the shaft is

mechanical slide that allows it to be removed

2. Manual immersion of the basket in the

not direct, but it occurs through a belt-pulley

for inspection or maintenance operations. It

FASTRIP T2-120 MIX tank;

transmission system that protects the motor

enables to adjust the temperature of the liquid

3. Paint stripping;

against both direct heating by the liquid and

and of the heating elements and to control the

4. Manual extraction of the basket;

vapours from the paint stripper.

electric lock and the mixer.

5. Dripping above the paint stripping tank;

• Electric heating elements fixed on the tank’s

• Thermal insulation on all sides of the tank,

6. External rinse of the treated workpieces.

exterior wall, which allow the maximum

made of rock wool with a high insulation

temperature of the paint-removing liquid to

coefficient.

be reached at 80°C. The choice of placing the

• Side panel made of AISI 304 stainless steel,

FASTRIP T2-120 MIX is made entirely of AISI

electric heating elements externally avoids

easily removable for maintenance.

304 stainless steel and it includes the following

direct contact between the paint stripping

elements:

liquid and the heating source, thus meeting

ALIT Technologies

Technical features

• Rectangular paint stripping tank with a clear

the highest safety standards.

ALIT Technologies is a privileged partner of

dimension of approximately 450 x 700 x h300

• Lid entirely made of steel, complete with

many high-technology industries operating

mm and 20/10 thick walls, with a filling volume

thermal insulation and 2 pistons to facilitate

in the coating sector which require highly

of about 120 liters. It has a 1” stainless steel

manual opening and closing operations. The

efficient products for the pre-treatment of

bottom valve for full emptying, a temperature

lid’s closure is shaped in such a way as to

metal components.

sensor for the paint stripping fluid, and a liquid

collect the condensation formed on it during

In addition to Drizzling, the new dosing and

level sensor. It is also equipped with a 2” upper

the paint stripping cycle.

application system for the passivation of metal

sleeve for possible connection to a suction

• Electric lock ensuring that the mixer stops if

parts, from its headquarters in the province

system.

the lid is opened.

of Verona ALIT Technologies is also able

• Steel mixer located on the short side of the

• Integrated control panel and external

to supply innovative in line chemical paint

tank. It keeps the liquid constantly circulating

electromechanical switches for process

stripping systems with the Fastrip series and

to ensure greater stripping efficiency and

parameter management. The panel is

high performance and low environmental-

better performance of the heating system.

located below the tank and mounted on a

impact chemical products.

international PAINT&COATING magazine - JULY/AUGUST 2023 - N. 82

15

ASK JOE POWDER

The “Ask an Expert” Column Kevin Biller

kbiller@chemquest.com

Hi Tu, Thank you for your message. I think I understand your problem. Here are some things I would investigate: 1. Particle size - this is the single most important property when it comes to transfer efficiency. Questions: what is your median (D50) particle size?

More important what is the percent below 10 microns and above 100 microns? How do you measure particle size distribution? How do you control it? You should target a median particle size of 35 to 40 microns and have less than 7.0% by volume particles less than 10 microns. In addition, you should target <1.0% by volume particles greater than 100 microns.

2. What is the specific gravity of your powder? Is it similar to the competitive product? Is it higher? Higher SG can reduce transfer efficiency by losing particles due to gravity (falling to the booth floor).

A word from our expert Joe Powder to solve more or less

3. How well does your customer maintain their application system? Do

conventional powder coating issues all over the world, from Vietnam

they have good grounding (earth) on the hangers and hooks? Are the

to South Africa.

spray guns well-maintained? How often do they provide maintenance for their equipment? You may be experiencing poor application performance due to poor maintenance on the spray guns, reclaim and booth.

Hi Joe,

BTW, I’m not a big fan of adding electrostatic additives to powders. I

Thank you for giving solutions in the past that have helped us

think that it’s a band aid approach and should be tried after all else fails.

improve our powder coating products. We will try to learn to

Please let me know if you have further questions?

develop our products more. However, if you don’t mind. Please

One last thing, where is your company located? It would be nice to visit

advise us on another issue.

you someday.

We are struggling to compete with competitors in the market.

Kind regards,

At the same application system conditions: the same type of

Joe

powder coatings gun, the same voltage level, the same flow, the same line speed. The resin ratio in the formula is 60-70% and we

Dear Joe,

use a special anti-stat additive but our powder coating only gives

Greetings from Johannesburg. I have a question. How can I

the product a thickness of 30-40 micrometers, while the powder

increase the fluidity of my powder coatings?

of the rival company can produce products with a thickness of

Thank you,

60-70 micrometers.

Johann Kunneke

What’s the problem with our product? We are trying to find the

South Africa

best solution, hopefully get comments from you.

Best regards,

Hi Johann,

Tu Nguyen

Increasing the fluidity of a powder coating and really any powder can

Alphabet Coatings

be tricky business. For our listeners unfamiliar with fluidity, we’re talking

Vietnam

about the behavior in which a powder can allow air to evenly space the

16

N. 82 - JULY/AUGUST 2023 - international PAINT&COATING magazine

powder particles from each other in air. This is a critical property in

Get more from water

the application of a powder coating.

In a powder application system, the bulk powder is introduced into a fluidized hopper. The fluidized hopper is either a cylindrical or box shaped container that has a porous Teflon© plate at its bottom.

Compressed air is passed through this porous plate to fluidize or prepare the powder to be transported through a powder pump then hoses and finally through a spray gun. And fluidity is crucial in getting the powder to feed evenly through the system.

Now to your question, Johann. A few factors are important in optimizing fluidity. First, particle size distribution is critical. Note that I said “distribution” and not just particle size. This means that you have to manage the entire size distribution of particles. Most important is to minimize “fines”. Fines can be defined as particles below 10 microns in diameter.

Less is better and you should strive to have less than six or seven

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

percent fines. Too many fines will cause clumping, agglomeration

Batch type systems

and poor fluidity. Ditto for large particles. By large, I’m talking about

Flotation units

100 microns and above. These are more difficult to physically move with compressed air and therefore should be minimized. I would target less than one percent over 100 microns for the best fluidization behavior.

After you nail your particle size distribution, it’s time to incorporate a

Chemicals and spare parts for water treatment Technical service, support and maintenance of wastewater treatment plants

fluid flow or dry-blend additive. These are fumed silicas or a fumed alumina and act as ball bearings between the powder particles.

Keep in mind that a little goes a long way. The addition should be made during the powder coating manufacturing process after the extrusion process. Typically, people add the fumed material with the extrudate chips (flakes) just prior to the pulverization process.

This ensures that the agglomerated fumed silica or alumina is evenly dispersed. Otherwise, it can cause seeds and bits in the finished powder film.

One problem is that the fumed material can get pulled out of the grinding system and into the waste stream that deposits into the baghouse. Some manufacturers have devised ways to introduce the silica after the grinding process with a deagglomeration technique.

I mentioned a little goes a long way – I would shoot for a concentration well under 1%, say closer to 0.2%.

Hope this helps and that you and your loved ones are all doing well in SA. Warm regards, Joe Powder

Beware of imitations, buy the original!

info@waterenergy.it

www.waterenergy.it

© Zeus Electrostatic System

HIGHLIGHT OF THE MONTH

A Change of Look for Zeus Electrostatic System and Its Product Range From an interview with Massimo Ricci owner of Zeus Electrostatic System

The new corporate image, the restyling of the range already on the market, and the launch of new products are the results of a strategic vision aimed at expanding internationally and providing the market with state-of-the-art powder coating solutions.

“A

ppearance matters too, but there is much more behind” .

not known and nowadays, in order to be successful worldwide and

This is what Massimo Ricci, the owner of Zeus Electrostatic

be perceived as a reliable and highly professional partner, companies

System, an Italian company specialising in the design and

need to pay close attention not only to the quality and efficiency of their

production of systems and accessories for powder coating operations, said

products but also to their corporate identity, i.e. the set of graphic-

during an interview with ipcm _International Paint&Coating Magazine.

visual elements that communicate the company’s values and mission to

For a small company aimed at the national market, moving to an

customers.

international market requires acting on all corporate aspects; Zeus is

Starting from this concept, Zeus, a company based in Argenta, in

®

18

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HIGHLIGHT OF THE MONTH

the province of Ferrara (Italy), undertook a series of marketing and

range, the JE-asy project aimed at a simpler and lower-cost market

corporate communication activities with the aim of improving its market

will follow. The three devices are characterised by different designs,

positioning at the international level. Zeus’ new image reflects the

technical features, and special accessories. The combination of these

evolution of the company and in particular the mission increasingly

three factors gives rise to a series capable of meeting any requirement

aimed at placing the customer at the centre. Similarly, its product

in terms of production and costs,” indicated Zeus’ owner.

portfolio was also restyled in terms of both technology and graphics.

J2, the flagship product of this new series, which will be launched on

A new corporate image, the same values as always

the market in the coming months, is the result of a collaboration with an international designer who carried out thorough research to create

This corporate image renovation project came about after a careful

a user interface that is different from the standard, with sophisticated

study in collaboration with a local communications agency and aims at

icons and a modern layout. The J2 electrostatic control unit features as

making the Zeus brand more modern and internationally appealing.

follows:

“The internationalisation process of a small company like ours can be

• a user-friendly interface thanks to a 7-inch touch screen that displays

long and not always easy, as numerous organisational changes have to

all system information and warnings on one page;

be implemented in every department of the company, from production

• modules that can be expanded and easily integrated into Industry 4.0

to marketing,” stated Massimo Ricci. “As for graphics, we decided to keep

systems;

the company logo intact and to refresh the colours and design of our

• easy access to process parameter settings to control and manage

website, social profiles, and promotional materials such as brochures,

quality and productivity;

catalogues, and advertisements, with a more appealing and modern

• possibility of carrying out software updates remotely and

style in line with current graphic design trends, which favour minimal

independently, without the need for the intervention of a Zeus

and simple aesthetics, as well as the use of a few contrasting colours

technician.

(in this case, red for the logo and highlights anthracite gray for the

In addition to the new control units, there is a long series of innovations

background)".

that will follow in the coming months: a sign of a dynamic and constantly

In addition to digital and offline communication, the project also involved

evolving company.

all products in the Zeus range, whose design was technologically and aesthetically restyled to make the brand recognisable at all times. “The new corporate image project is the result of Zeus’ desire to expand its presence in new markets, especially at the European level. However, despite these changes, the management and all the company’s employees have never lost sight of the identity and fundamental values that have distinguished us since the company’s foundation in the

© Zeus Electrostatic System

1970s’,” added Ricci.

“We follow each customer from design to implementation, from installation to after-sales training; we provide support in the purchasing process, guaranteeing the ethics and quality of our suppliers (all rigorously selected in Italy and Europe) and we deliver a product completely made in Italy. In recent years this has allowed us to consolidate real relationships of trust and mutual responsibility with those who choose us. From all this comes our new payoff, which we have adopted for the first time: Coating your world”.

The new series of powder coating operation control units In order to meet all the needs of the professionals involved in powder coating operations, Zeus also plans to launch a line of next-generation powder coating control systems. “This new series, called J2, will complement the J1 model that is currently in production, and represents a leap forward in terms of connectivity and control. To complete the

international PAINT&COATING magazine - JULY/AUGUST 2023 - N. 82

19

BRAND-NEW

Total Finishing Systems Introduces New PVC Cyclone Powder Booth At Fabtech Chicago, which will be held from 11 to 14 September 2023, Total Finishing Systems will exhibit a new PVC Cyclone Powder Booth Systems developed in collaboration with Erzinger.

T

otal Finishing Systems is pleased to announce an expansion

designer and system integrator of high-quality and complex industrial

of its partnership with the Erzinger Equipment, Brazilian

liquid paint and powder coat finishing systems.

manufacturer of coating equipment, by introducing their PVC

The company, located in Riverside, California, US, specializes in

Cyclone Powder Booth Systems into the North American market.

surface finishing, materials process automation, and sophisticated

Along with the Cyclone booth, we will also be introducing their state-

installations of fluid and dry coating systems, including thermal

of-the-art Smart In-Line Control System, Application Automation and

treating equipment.

Powder Distribution Centers.

In addition to the Systems group, the Total Finishing family includes:

This expanded product line will provide new and affordable options for

Total Finishing Solutions, which is specialized in the supply of spray

our customers and is a complete solution for all your powder coating

booths, UV and IR ovens, abrasive blasting equipment, and industrial

needs. The company will display these solutions at the booth D40351

automation; and Total Finishing Supplies, the division devoted to

in hall D at Fabtech Chicago, taking place 11-14 September 2023 at

the supply of all consumable materials and equipment necessary to

McCormick Place, Chicago, US.

maintain the operation and efficiency of plants.

About Total Finishing Systems

For further information:

Operating across North America, Total Finishing Systems is a leading

https://totalfinishingsystems.com

© Total Finishing Systems

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N. 82 - JULY/AUGUST 2023 - international PAINT&COATING magazine

© Total Finishing Systems

eosmarketing.it

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Single-stage, room temperature multi-metal pre-treatment process, with no VOC emissions, no rinsing, no pre-degreasing, no creation of wastewater or sludge. The unique and innovative anhydrous process is based on organic high-boiling fluids and guarantees degreasing as well as immediate protection against oxidation, leading to excellent performances in the finishing cycle.

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Waste water are purified and re-circulated instead of discharged to meet the demand of circular economy.

BRAND-NEW

Impact Coatings to Open New Headquarters in Sweden in 2024 The new site will double the production capacity of Impact Coatings and include an updated laboratory to test coating systems and technologies.

I

mpact Coatings has recently announced the beginning of the

we can continue to grow our company and streamline and automate

construction of a new plant and headquarters in Linköping (Sweden).

our production flows. Key aspects to be able to fully support the fast-

The new premises are located adjacent to Linköping University and

growing industries that together with us work on the next generation of

Linköping Science Park, in close proximity to its innovation hotspots. The

energy and transportation solutions”, has stated Torbjörn Sandberg, the

company expects to move in during the second half of 2024.

CEO of Impact Coatings.

The new facility will consist of around 3,000 m², doubling the current

The headquarters is being built in close collaboration with Wilzéns

production area and thus resulting in a significantly increased capacity

Fastighetsförvaltning, that will own and manage the property. The

for the assembly of coating systems as well as an expanded space for

construction works for the new plant are taking place at the same time

the Swedish Coating Service Center.

as production in the new Coating Service Center in Shanghai (China),

Besides providing a better capacity to support the clients and continue

while the company is also planning to build another site in the United

to grow the operations of the company, the new Swedish site will also

States of America in 2024.

host new departmental offices and conference rooms, an updated

“It is gratifying to carry out this project for Impact Coatings, not least

laboratory, a pre-production zone for washing and blasting and a

considering their commitment in the green technology sector and use

logistics hub. In addition, the Coating Service Center will enable Impact

of sustainable production methods, which goes hand in hand with our

Coatings to carry out tests of coating technology and customers to learn

values. I would also like to commend Linköping municipality, for the

more about complete coating solutions first-hand.

fast pace and positive attitude throughout the planning process,” has

“The new headquarters are an important puzzle piece in our growth

commented Andreas Wilzén, the CEO of Wilzéns Fastighetsförvaltning.

journey. With a new attractive and advantageous logistical location and production-optimized workspaces in modern premises, we will be able to continue to attract the region’s top talents. At the same time,

© Impact Coatings

For further information: www.impactcoatings.com

© Impact Coatings

Areal view of the new headquarters’ premises in Kåparp, Linköping.

Andreas Wilzén, CEO at Wilzéns Fastighetsförvaltning AB, and Torbjörn Sandberg Kanon, CEO at Impact Coatings at the new headquarters’ premises.

international PAINT&COATING magazine - JULY/AUGUST 2023 - N. 82

21

FOCUS ON TECHNOLOGY

New Shot Blasting and Coating Plants Confirm Cos.Eco. as a Company of Excellence in Southern Italy Monica Fumagalli ipcm®

Being a Southern Italian firm of excellence means combining innovation and sustainability in increasingly high-performance products. This article presents the success story of Cos.Eco., based in the Apulia region, the fourth company in Europe for the production of environmentally friendly vehicles. It chose an OMSG shot blasting machine to optimise substrate preparation and ensure greater adhesion and durability of its coatings, which it applies in a new Savim system, also improving work comfort for its employees and the sustainability of its production processes.

A

ccording to the figures recently updated by the European

According to the report, “From 2018 to 2021 the average amount of

Parliament, 2.2 billion tonnes of waste are produced within

municipal waste as measured per capita increased in the EU.

the EU every year1. Municipal solid waste, i.e. waste generated

However, trends can vary by country. […] Even though the waste

every day mainly by private citizens, then collected and treated by

generated per capita has increased, the way we manage waste has

municipalities, accounts for more than a quarter, about 27%.

improved - with more recycling and composting and a decrease in landfill.”

In fact, one of the EU’s circular economy objectives is to promote not only waste prevention but also the reuse of products whenever possible, with

https://www.europarl.europa.eu/news/en/headlines/society/20180328STO00751/ waste-management-in-the-eu-infographic-with-facts-and-figures

1

© Cos.Eco.

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a focus on recycling, composting, and incineration.

FOCUS ON TECHNOLOGY

The same increasingly sustainable approach characterises the sector of vehicles for the collection and transport of urban solid waste.

Cos.Eco. Industrie Group Srl specialises in the production of equipment for the collection, transport, and disposal of municipal solid waste. Below, the new paint shop, with the OMSG shot blasting machine on the right and the Savim coating plant on the left.

Giuseppe Debernardis, the sole director of one of Italy’s national and international leading manufacturers of municipal waste transport vehicles, explains: “Cos.Eco. Industrie Group Srl specialises in the design, construction, marketing, and after-sales technical assistance of equipment for the collection, transport, and disposal of municipal solid waste, such as compactor trucks, dumpers, and bin washers. Since 2015, we have been carrying out every necessary design, raw material processing, assembly, and coating phase in-house, including testing of each individual product, within a complete, fully integrated, and environmentally friendly production cycle. “Our vehicles must convey an idea of cleanliness and sustainability even in their aesthetics, which is why our substrate preparation and actual coating operations are particularly strategic. This is also the reason why in a manufacturing flow © ipcm

international PAINT&COATING magazine - JULY/AUGUST 2023 - N. 82

23

© ipcm

like this, when the surface treatment phase turns into a bottleneck, the

transport sector to devote ourselves entirely to the production of

problem must be solved with extreme urgency.” Indeed, about a year

ecology equipment.”

ago, Cos.Eco. completely renovated its paint shop by equipping itself

“Through continuous technological innovation and the utmost care

with a new automatic shot blasting machine, designed and installed by

taken in every process step,” adds Farella, “we have succeeded in

OMSG - Officine Meccaniche San Giorgio (Villa Cortese, in the province

establishing ourselves also at the European level, despite being based

of Milan, Italy), and a new coating system supplied by Savim Europe Srl

in a complex area such as Southern Italy, characterised by numerous

(Arbizzano, Verona, Italy).

resources but also still with some gaps to fill in terms of industrial

Cos.Eco.: a success story from Southern Italy

development. And Cos.Eco. has certainly contributed to the growth of this area, fostering the creation of numerous companies revolving

The story of this flagship company in Apulia’s Murge area started

around our business and providing numerous jobs. Currently, we have

with the entrepreneurial idea of two men: Nicola Farella and Donato

110 employees working in our 44,000-m2 plant. We are present in 40

Debernardis, who founded DI.CAR. in Altamura in the 1970s as a

countries, from the closest markets such as Northern Europe, Spain,

manufacturer of transport equipment. At the beginning of the 1980s,

and the United Arab Emirates to more distant ones such as South Africa,

after a serious setback due to the 1981 earthquake that brought

Singapore, and New Zealand. We have built our leadership over time

companies in Lucania to their knees as they were no longer able to

thanks to technologically advanced machinery, specialised personnel,

meet any payments due, Nicola Farella decided to focus exclusively

and the attention that our company has always paid to its customers all

on the production of municipal vehicles, including compactor trucks,

over the world.”

street sweepers, and school buses. “In that same period,” says Nicola

“To guarantee a high quality level of products and services,”

Farella himself, recently appointed Cavaliere della Repubblica for his

indicates Debernardis, “we have obtained both the ISO 9001 and

professional and social commitment, “we decided to sell the entire fleet

ISO 14001 certifications, which, in addition to product quality, verify

of trucks we previously used for transporting goods and to establish

the organisational structure of the company itself also in terms of

Cos.Eco. Costruzioni Ecologiche Srl, later moving our headquarters

effective management, especially with regard to the most significant

from Altamura to Grumo Appula. Here, we eventually abandoned the

environmental aspects. Further certifications attest to the quality,

24

N. 82 - JULY/AUGUST 2023 - international PAINT&COATING magazine

FOCUS ON TECHNOLOGY

GLOBAL SOLUTIONS FOR WATER TREATMENT

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

© ipcm

mechanical, and technological characteristics of the materials we employ, such as for example Hardox, one of the most abrasionresistant steels, and S355 and S275 carbon steels.”

A fully insourced production cycle “Given the difficulty of finding contractors in our area but also for greater control of our production flow, we have insourced all our production phases, from the machining stages such as cutting, bending, and welding to the surface treatment ones, that is, shot blasting and coating,” explains Farella. Before mechanical pretreatment, the parts are cleaned manually with a high-pressure cleaner to remove machining oils and the different materials deposited during welding. “Thanks to this cleaning operation,” notes

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Debernardis, “we also preserve the quality of the grit, which remains cleaner and can thus be recovered. To achieve our specified surface roughness profile, we use angular steel grit.”

From the left: - The treated workpieces can have a length of up to 11 m.

srl

- Overview of the shot blasting system.

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

© ipcm

© ipcm

A component entering the shot blasting tunnel and a side view of the shot blasting plant, with 4 of the 16 single-disc turbines.

The new OMSG automatic tunnel shot blasting machine was installed

shutters allows us to heat individual zones to the required temperature

about a year ago to solve a production bottleneck. “We used to carry out

depending on the operations we have to perform. Then, the workpieces

a manual mechanical pre-treatment operation, which was burdensome

reach the drying oven where they are left to dry, sometimes even at

for our employees in terms of both handling, due to the weight of the

room temperature without the need for heating, thanks to the high

large components, and application, because it required their physical

temperatures typical of our area.”

presence inside the blast chamber. Now, we carry out manual shot blasting operations only on smaller parts and we use our automatic

Features of the new shot blasting plant

machine to pre-treat products such as semi-trailers, with dimensions up

The company selected an automatic shot blasting plant type Tunnelblast

to 11 x 2.5 x 2.5 m.”

2535/16 H26 C. “It treats parts with a maximum cross-section of 2.5

The workpieces’ surfaces are then blown and the grit is recovered.

x 3.5 m,” indicates Enzo Dell’Orto, the CEO of OMSG. “The system is

Afterwards, the parts reach the coating plant, equipped with a manual

equipped with 16 single-disc turbines featuring direct drive motors

static booth. “In this case, we ruled out automation because our

with a power of 7.5 kW each. The electrical panel is equipped with 16

components’ conformations are too varied to be able to take full

inverters to control the rotation speed of the turbines and therefore

advantage of the benefits of an automated system. We apply high-solid

the kinetic energy of the steel abrasive projected onto the workpieces.

liquid polyurethane paints in three coats using WAGNER spray guns.

In addition to inverters, the shot blasting machine has special turbine

Our system consists of several stations for primer application, drying,

feed valves, featuring a double pneumatic cylinder to regulate the

sealing, and topcoat application, which is done in two coats. After

flow of abrasive to the turbines. The overhead conveyor, which has an

application of the primer, sealing is carried out in a chamber that can be

extension outside the plant of 12 m at the inlet and 12 m at the outlet,

heated as needed to evaporate the solvent-based paint product or cure

is equipped with a pair of hoists with a capacity of 6,000 kg each. We

the sealant. This is in fact one of the most interesting features of the

also installed a manual shot blasting cabin downstream of the tunnel to

coating system designed and installed by Savim: its partitioning through

touch up any masked areas or undercuts that cannot be reached by the

26

N. 82 - JULY/AUGUST 2023 - international PAINT&COATING magazine

FOCUS ON TECHNOLOGY

direct impact of the abrasive projected by the turbines. Its size is 15 x 5 x 4.7 m. The simple blowing operations are also carried out inside the booth to remove the abrasive deposited on the pieces.”

“The entire plant,” adds Dell’Orto, “is Industry 4.0-oriented. The work cycle is managed by a PLC and the machine is equipped with sensors to control the level of metal abrasive in the separator and the rotation of the elevator’s lower pulley, remote assistance devices, a bar code reader, and digital amperometric controls. Both the turbine shot blasting machine and the manual cabin are equipped with cartridge filters made with antistatic polyester cartridges and ATEX components, the former with a capacity of 20,000 m3/h, the latter of 7,500 m3/h.”

The advantages of the new system combination “One of the main benefits brought by our

© ipcm

new mechanical pre-treatment plant,” says Debernardis, “has been the reduction of our production times. Today we can produce two compactor trucks per day, as well as various components such as tanks made of welded steel or aluminium sheet and other smaller vehicles. The shot blasting operation takes 20 minutes, compared with the about 5 hours required by the previous manual operation.

This is our first experience with an OMSG machine, but we can only be satisfied with it.

At the same time as we upgraded the shot blasting department, we decided to build a new paint shop because the previous one only consisted of one booth where we applied both primers and topcoats. To do this, we turned to another well-established company with profound expertise, Savim. Relying on companies with a sound corporate structure is our precise choice to make sure that in the event of a plant issue of any kind, the solution will be quick and effective. For us, stopping the shot blasting or coating system means stopping the entire production cycle.”

© ipcm

The inside of the manual blasting chamber (above photo) and the inside of the manual coating booth.

international PAINT&COATING magazine - JULY/AUGUST 2023 - N. 82

27

© ipcm © ipcm

© ipcm

© ipcm

From top left, clockwise: The WAGNER liquid paint management unit; A finished component; One of the garbage compactor trucks manufactured by Cos.Eco.; From left to right: Nicola Farella, founder of Cos.Eco, technical office manager Giorgio Casiello, and Giuseppe Debernardis.

Conclusions

compactor truck equipped with an internal weighing system, which cuts

“More careful environmental waste management,” summarises

its costs and environmental impact while reducing noise and emissions

Debernardis, “is one of the targets the European Union has set for

to zero. This continuous search for innovative and environmentally

itself by 2050. The road is certainly one of the most difficult ones to

friendly solutions has always characterised the history of our company

travel, because modifying the collection methods used so far involves

and the entrepreneurial strategy of our founder, Nicola Farella. The

changing the mentality not only of private citizens but also of public

search for innovative solutions also calls for collaboration with highly

bodies. But whatever the method chosen, Cos.Eco. is ready for it: in

skilled, well-established companies, such as OMSG and Savim, with

addition to the attention we have been always paying to the impact

which we have updated and optimised our paint shop: today, coating

of our production cycles, for some time now we have been making

has turned from a critical phase into one of our main production

electric vehicles available to municipalities, which are becoming very

resources, enabling us to confirm ourselves as a company of excellence

popular. We have also launched a new, patented solar-powered waste

in Southern Italy.”

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N. 82 - JULY/AUGUST 2023 - international PAINT&COATING magazine

www.infragas.com

INFRARED RADIANT GAS SYSTEMS FOR THERMAL TREATMENTS

Products, networking, business and training.

under the patronage of:

WHERE WE HAVE BEEN

international PAINT&COATING magazine - JULY/AUGUST 2023 - N. 82

31

ADVANCEMENTS

How to Reduce Edge Corrosion with a New-Generation Primer Andrea Perelli Pulverit Spa – Milan, Italy

a.perelli@pulverit.it

Pulverit has developed Endurance, a series of new protective primers with increased corrosion resistance, especially on parts’ edges.

H

ow much does metal corrosion cost? In industrialised countries,

also sharp edges. Impacts and scratches can be prevented through

it is approximately equal to 6-8% of GDP, with estimated costs

proper handling and/or packaging. The criticality of edges, however,

for the whole of Europe of more than €750 billion per year.

is more difficult to curb. In this framework, the Pulverit laboratories

Given the costs associated with corrosion, therefore, the durability of

have developed a series of primers called Endurance, which increase

products becomes of vital importance.

corrosion resistance even on the edges of workpieces.

The corrosion of a metal part generally starts at critical surface points

The Endurance 16J0 series, in particular, combines a slightly wrinkled

and then, once triggered, it spreads to the rest of the component.

epoxy base coat with barrier-effect and passivating additives to provide

Such critical points include areas where the part has suffered

optimal edge coverage, excellent corrosion protection, and primer

mechanical impacts or scratches that have affected the paint film, but

overcoatability.

32

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ADVANCEMENTS

The causes of edge corrosion © Pulverit

The main causes of corrosion on parts’ edges can be different, including faulty design, inadequate pre-treatment, and the inherent difficulty of covering sharp edges with paint. Why is it so difficult to achieve adequate edge coverage? On the one hand, this is due to the difficulty of painting a narrow, thin surface and, on the other hand, to the viscosity of the coating systems used. Conventional primers are normally smooth epoxy products, which as such tend to slip on edges. Figures 1 and 2 show microscopic images of some parts’ sections coated with a traditional primer and a top coat: as can be seen in Figure 1, the paint thickness at the edge is

Fig. 1 and 2 – The paint thickness achieved on the edge with a conventional primer is much lower than on the flat part (left) and applying a second coat of paint does not solve the problem (right).

much lower than on the flat side, and this difference © Pulverit

cannot be compensated for even by applying a second layer, as shown in Figure 2.

The Endurance primers Pulverit has developed its Endurance primers to solve this problem: their different rheology and the action of special additives make it possible to considerably increase the thickness of powder deposited on edges. As can be seen in the microsection of Figure 3, edge protection is complete: from a traditional primer thickness of less than 10 µm in Figure 1, a value of over 100 µm was obtained with the Endurance primer in Figure 3.

The same top coat as before, however, began to

Fig. 3 and 4 – The application of Endurance 16J primer allows achieving a thickness of more than 100 µm (left). On the right, the applied top coat layer has evidently slipped on the edge, whereas the Endurance 16J primer protects the edge effectively.

slip again after application, as can be observed in © Pulverit

Figure 4: this means that the protective effect is guaranteed almost exclusively by the Endurance primer.

Test results proving these products’ effectiveness We performed a comparative cyclic corrosion test (KSP) by applying two different primers on sheets that were pre-treated with zinc phosphating technology and painted with the primers alone.

The edges were not mechanically rounded. In both cases, the primer’s thickness ranged between 70 and 90 µm. At the end of the test, the sheet coated with the standard primer showed the complete detachment of the paint film in the area around the holes as well as the first traces of corrosion

Fig. 5 and 6 – Results of the comparative cyclic corrosion test (KSP) using sheets pre-treated with zinc phosphating technology and painted with primers alone.

On the left, a conventional primer and, on the right, the Endurance 16J primer.

on the edges (Figure 5). Conversely, with the new embossed primer 16J, no film delamination or edge international PAINT&COATING magazine - JULY/AUGUST 2023 - N. 82

33

© Pulverit

corrosion could be detected (Figure 6).

The duration of the KSP test was 720 hours.

Since the sharper the edge, the higher the level of criticality, we also carried out an “extreme” test with commercially available razor blades. These were painted both with one coat of primer and with a primer + top coat two-coat system: also in this case, the photos taken under the microscope are highly explanatory. When looking at Figures 7 and 8 (razor blades painted with primers alone), one can see that in Figure 7 (standard Fig. 7 and 8 – Microscopic images of razor blades painted with one coat of primer: on the left, a conventional primer and, on the right, Endurance 16J.

primer) the cutting edge is not covered by the primer, to the extent that the blade shimmers through, whereas in Figure 8 the Endurance primer also covers the cutting edge and the surface looks well rounded. The result

© Pulverit

becomes even clearer when analysing the cross-section images. Figures 9 and 10 show the double-coated razor blades. In Figure 9, despite the two layers deposited on the cutting edge of the blade, the thickness of the film cannot even be measured. Conversely, with the Endurance 16J primer, a thickness of 61 µm is also achieved at the tip of the blade (Figure 10). This means that optimal protection against edge corrosion can be guaranteed even under the most critical conditions.

Finally, we tested our primers through an NSS accelerated corrosion test of over 2000 hours with a twoFig. 9 and 10 – Microscopic images of razor blades painted with a primer + top coat two-coat system: on the left, a conventional primer and, on the right, Endurance 16J.

coat system composed of Endurance primer 16J0/0083 + RAL 7031 polyurethane top coat (pre-treatment with high-thickness iron phosphating technology and passivation without rinsing, Haug). After 2000 hours,

© Pulverit

delamination at the cut was between 0 and 1.5 mm and corrosion at the cut was between 0 and 1.5 mm (Figure 11). Very good results were also obtained on the edges of the sheet, where no corrosion points could be detected (Figure 12).

Conclusions The Endurance 16J0 primer can be partially or fully cured before top coat application according to customer requirements. If a wrinkled top coat is used, it can also be applied wet-on-wet.

For the Endurance 16J0 primer, we chose two colours: 16J0/0083 RAL 1013 as a light hue and 16J0/0463 RAL Fig. 11 and 12 – Results of the NSS accelerated corrosion test of over 2000 hours with a two-coat system. On the left, we can observe delamination at the cut between 0 and 1.5 mm and corrosion between 0 and 1.5 mm; on the right, there are no corrosion points on the edges.

7021 as a dark hue. Since its wrinkled effect is very fine, the product can be recoated with any smooth top coat without altering its appearance. It can be safely said that this innovative primer sets a new benchmark in the field of corrosion protection primers.

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CHEMICAL MAKING SOLUTIONS

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TRATTAMENTO ACQUE WATER TREATMENTS

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PREVERNICIATURA E NANOTECNOLOGIE COATING PRETREATMENT AND NANOTECHNOLOGIES

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© Idrotecnica Srl

HIGHLIGHT OF THE MONTH

Market Trends in the Industrial Water Treatment Sector: An Analysis by Idrotecnica From an interview with Federico Marcenaro, CEO of Idrotecnica Srl

In its first thirty years of history, Idrotecnica, an Italian manufacturer of industrial water purification and demineralisation plants, has collected a long series of successes and achievements. In addition to being one of the first Italian companies to build a reverse osmosis treatment system, it now distributes its products almost all over the world while serving an increasingly significant number of industrial sectors. We interviewed its CEO, Federico Marcenaro, to outline the milestones in the history of Idrotecnica and analyse the current market trends in the field of water treatment.

W

ater is a key resource in many industrial sectors and its

In the case of the surface treatment sector, this plays an indispensable

treatment guarantees improved process performance as well

role in the pre-treatment phases prior to coating, as using demineralised

as greater environmental protection.

water in the last rinsing stage enhances corrosion resistance and

Purifying and/or demineralising water for industrial processes through

improves paint adhesion. The most common treatment technologies are

purpose-built systems and plants is therefore a factor of primary

reverse osmosis and ion exchange. ipcm®_International Paint&Coating

importance, without which the entire production cycle would grind to

Magazine delved into the main features and advantages of both

a halt leading to significant production stoppages and cost and time

processes in this interview with Federico Marcenaro, the CEO of

increases.

Idrotecnica Srl (Genoa, Italy).

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HIGHLIGHT OF THE MONTH

specialising in one core business, namely water demineralisation, and having in-depth technical knowledge of the application fields in which its plants can be installed. “Stemming from the desire to devote all our skills, time, and resources to a single industry, this choice enables us to offer our customers a fast and effective pre and after-sales service. Our team is always able to provide technical support in less than an hour, even in English and in different time zones for companies working in other continents, as well as shipping any spare parts in about 24 hours.”

From left to right: Alessia Venturi of ipcm , Federico Marcenaro, owner of Idrotecnica Srl, and Ilaria Paolomelo of ipcm®. ®

About Idrotecnica

“We are acutely aware of the responsibility our machines bear as they feed lines that are of far greater technical and economic importance and, for this reason, we invest daily in our customer service and work hard to develop systems that are extremely

The history of Idrotecnica Srl, an Italian company

user-friendly and easy to install and use, yet robust

specialising in the production of water purification and

and reliable.” This philosophy has certainly rewarded

demineralisation systems, began in 1991. Already with

Idrotecnica, allowing it to position itself on the market

a considerable wealth of experience and expertise,

as a trustworthy partner and to grow steadily in its

its owners decided to use their skills and know-how

first thirty years in business, operating in more and

to design and implement industrial water treatment

more industrial sectors and markets and supplying

solutions and specialised particularly in the production

more and more companies with its systems.

of ion exchange and reverse osmosis plants. In 1993, able to supply the Italian market with this innovative

A wide range of standard and customised plants

technology, which was still little known at the time.

To meet customer needs, Idrotecnica’s production

From that moment on, the company began to collect

department is equipped to produce both standard

a series of important successes and achievements:

and customised systems and devices. The standard

the continuously increasing demand allowed it

range of water filtration and demineralisation plants

to structure itself in a more complex manner,

using ion exchange and reverse osmosis technology

progressively hire more technicians, and move to

includes around 130 different models, which are

a larger factory located in the Bolzaneto district

delivered in most cases in less than a month (often

of Genoa. In the early 2000s, Idrotecnica began

in one or two weeks). “The extreme modularity

exhibiting its technologies at numerous international

and flexibility of our plants enable us to offer

trade fairs and industry events and it succeeded in

ideal solutions that are in line with our customers’

reaching new markets and industrial sectors. Today,

production requirements. However, if our standard

its plants are in use in almost every corner of the

products do not meet their specifications, we can

globe, from Europe to Latin America and from North

always tailor the most suitable plant solution in terms

Africa to Oceania, and serve a variety of industries,

of technology, reliability, and running costs.”

Idrotecnica was therefore one of the first companies

including coating, industrial cleaning, cosmetics, pharmaceuticals, and research and analysis

Market trends

laboratories.

“In the early 1990s, Idrotecnica was one of the few

The choice to specialise exclusively in water demineralisation processes Idrotecnica was founded based on a clear philosophy:

Italian companies to believe in the potential of the reverse osmosis technology, based on a physical principle that at the time was still little known and widespread at the industrial level. For decades,

various industries have in fact continued to prefer ion exchange

“Despite the market’s preference for reverse osmosis treatments,

demineralisers. However, in recent years, our company has been

Idrotecnica strives to identify the ideal solution together with each

experiencing an exponential increase in demand for reverse osmosis

customer by taking into consideration several factors, including the

plants at the expense of the ion exchange technology in several

company’s production cycle, the plants used in the factory, the technical

industrial sectors, including the coating industry.”

skills of operators, and the way products are disposed of.”

One of the main reasons why companies now prefer the reverse

Future projects

hydrochloric acid and caustic soda, which results in greater safety for

“Idrotecnica is an extremely well-established company with significant

the environment and the operators and facilitates discharge operations.

experience, but it also maintains a fresh and dynamic approach typical

The reverse osmosis process ensures much more streamlined water

of a start-up. At the same time, it has set itself the goal of putting its

management: the semi-permeable membrane that acts as a filter

customers and their satisfaction at the centre of every activity and

removes almost all the present substances from the liquid, which, with

project since the year of its foundation. This is why, given the increase

the right precautions and following the advice of a competent technician,

in demand that we have been experiencing over the past few years

can then flow into the sewer without further treatment. Furthermore, the

and that is continuing steadily, in the coming months we are going

performance degree of the reverse osmosis process depends neither

to hire further technical staff capable of supporting our customers

on the presence or absence of salts in the feed water nor on the type of

and providing them with excellent service. In addition, to facilitate

water (soft or hard): this further differentiates it from the ion exchange

the management of our products, we plan to install some Industry

technology, whose performance is tightly related to water quality. The

4.0-oriented systems even on cheaper and smaller plants. Currently,

main disadvantage of reverse osmosis compared to ion exchange, on

only our most complex systems are equipped with 4.0 solutions, but

the other hand, relates to water saving, as ion exchange demineralisers

we believe it is crucial to provide both companies and plant engineering

can recirculate the liquid inside the cleaning tunnel and control its

firms interfacing with end customers with the possibility to remotely

conductivity, thus significantly reducing water consumption.

manage all the components that make up their plants.”

© Idrotecnica Srl

© Idrotecnica Srl

osmosis process is the absence of hazardous chemical agents such as

Reverse osmosis demineralisation plants of the IDRO RO series.

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N. 82 - JULY/AUGUST 2023 - international PAINT&COATING magazine

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

© InCycles

FOCUS ON TECHNOLOGY

In Portugal’s Bike Valley, a Winning Partnership with a Powder Coating Manufacturer Raises the Bar on Finishing Quality Monica Fumagalli ipcm®

Development of polyester powder coatings and colour matching: these are the growth tools that Portuguese company InCycles, specialising in the assembly and sale of electric and traditional bicycles, has been implementing together with one of its paint suppliers, ST Powder Coatings. Its aim is to change the concept of urban mobility as we know it and raise the market’s appreciation of products coated with powders instead of liquid paints.

I

n February, the European Parliament decisively implemented its

development of a more conscious approach to this rapidly developing

Cycling Strategy, instructing the Commission to double the number

sector at the European level. As stated in the press release of the

of kilometres of bike paths in Europe by 2030 . According to the

European Cyclists’ Federation (ECF)2, “The call marks a recognition of

main industry associations, this marks an important turning point in the

cycling as a fully-fledged mode of transport and key industrial asset

1

1

https://www.europarl.europa.eu/doceo/document/B-9-2023-0102_EN.html

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2

https://ecf.com/civicrm/mailing/view?id=5606&reset=1

FOCUS ON TECHNOLOGY

to meet long-term climate and clean manufacturing objectives.” The

the vision of clean manufacturing as advocated by the European

statement ends with a wish: “Cycling stakeholders also hope that

Parliament’s motion. “About three years ago,” explains Pedro Conceição,

the proposed designation of 2024 as the European Year of Cycling

the General Manager of InCycles, “we started a winning partnership with

[…] encourages national governments to take additional actions

the Italian powder coatings manufacturer ST Powder Coatings, which in

such as reducing VAT rates, multiplying initiatives to promote cycling

2018 opened a branch in Maia, in the industrial district of Porto, not far

and replicating the “Portugal Bike Valley” reindustrialisation success

from our headquarters. From the outset, powders have been our main

story in other regions, with targeted support from European funding

choice of finish for two reasons. Firstly, because they are characterised

programmes.”

by greater resistance in harsh environmental conditions, which is a

The success case cited refers to the Águeda area, south of Porto, where

key element especially for our Northern European partners. Secondly,

the bicycle (particularly e-bike) manufacturing industry has become so

because they are environmentally friendly paints producing no VOC

flourishing that Portugal has become the largest producer of bicycles in

emissions and fully recyclable: an increasing number of customers

the EU. This nation of 10 million people, just over 2% of the European

consider this aspect a discriminating factor when choosing their

Union’s population, produces a quarter of the continent’s bicycles. Such

supplier.”

a development was the result of a growing passion for cycling in Europe particularly after the pandemic period and it has been completely

The future is electric even for bicycles

changing the concept of urban mobility.

“We are riding the wave of the exponential growth of two-wheel mobility

To provide an idea of how much this sector has developed, right in the

occurring all over Europe,” confirms Conceição. “We have been focussing

heart of Portugal’s Bike Valley, we visited a company that has seen its

on electric products and, to date, we can say that it has been the

turnover multiply 22-fold in the space of a few years – from 3 million

winning choice. This is evidenced, for example, by an important project

Euros in 2018 to 65 million last year – and the number of its employees

aimed at making e-bikes available for hire in all major European cities.”

grow from 15 to 300. InCycles Bike Group (Águeda) specialises in the

To cope with the production peak, this Portuguese company recently

assembly, powder coating, and distribution of e-bikes and traditional

invested in a new plant merging 1 coating system, 4 assembly lines (of

bicycles both for major international brands and under its own brand,

which 3 are devoted to e-bikes and 1 to traditional bicycles,) and 6 lines

Eleven.

for the production of wheels.

Today, coating operations play an increasingly important role in its

Paint shop manager Alberto Cardoso explains the main steps in InCycles

production process, whose focus on paint sustainability is in line with

Bike Group’s production process: “We receive our components already

© ipcm

© ipcm

One of the three bicycle assembly lines and the powder coating plant.

international PAINT&COATING magazine - JULY/AUGUST 2023 - N. 82

41

© ipcm

© ipcm

From left to right: Some shot blasted parts; The primer application booth; Top coat application.

shot blasted; we only perform manual sanding if necessary. The parts

sourced from China.” This trend, however, is changing, as evidenced by

reach directly our coating department, where they are loaded onto the

the already mentioned motion of the European Parliament, and more

conveyor to be taken to the first station for manual powder application.

and more manufactured goods are now being produced in Europe in

They then move to the curing oven before the required water-based

the cycling sector as well. “At present, therefore, the strategy that we

decals are applied. This is followed by a drying phase, the removal of

consider successful for establishing ourselves in this complex market

decal masks, and the application of the final top coat, which can be

is to guarantee the best possible coating performance with two main

glossy or matte. The coating cycle ends with the final curing phase in the

objectives: finishing quality and production flexibility.”

oven. Afterwards, the parts are ready to be transported to the assembly department, where they are placed on one of the 4 designated lines and

A perfect partnership for growth

subsequently packed and stored for final shipment.”

“Our first contact with ST Powder Coatings was decisive in the choice of

Investment in coating

our supplier,” states Cardoso. “Although we also apply liquid paints for special projects, we already knew that powders would be the perfect

“The internationalisation of our production,” notes Conceição, “called for

solution, especially to meet the need of Northern European customers,

the increase in the number of our assembly lines, but also for a growing

who are more demanding in terms of finishing quality and resistance

investment in the powder coating line we had installed three years ago.

in harsher climatic conditions than those in Southern Europe. Until our

The continuing demand for high-quality surface coatings is so strong

encounter with this Italian manufacturer, we had been using epoxy

that we would have already installed a further plant, if the war in Ukraine

paint. Thanks to the tests suggested by its team, however, we realised

and the resulting negative global financial outlook had not stopped our

that polyesters were better suited to give our finishes greater outdoor

project, hopefully only temporarily. The reason why it is important for

resistance and durability, especially in conditions of proximity to the sea,

us to focus on coating at this time is that the quality of the paint applied

low temperatures, and exposure to snow or ice.

on the components imported from Asia does not meet the minimum

“Polyester powder coatings,” says José Carlos Manta, the general

requirements. The European Union is also taking action on this aspect

manager of ST Powder Coatings Portugal, “are available in both

with anti-dumping measures, stemming largely from the realisation that

industrial and architectural quality. Polyester products are especially

we are excessively dependent on the Asian market in the bicycle sector,

ideal for coating metals intended for outdoor use precisely because

too. Currently, 90% of the components we assemble in our factory are

they ensure excellent resistance to chemical and weathering agents

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EPISTOLIO EPISTOLIO

FOCUS ON TECHNOLOGY

towards the future

© ipcm

SOLUZIONI ROBOTIZZATE DI ROBOTIC PAINTING SOLUTIONS VERNICIATURA

and excellent colour retention. Specifically, InCycles uses industrial polyester powders as standard and Qualicoat polyester powders for special requirements. Our laboratory formulates and develops powders according to every customer’s needs: for InCycles, we tried to develop the entire colour range they required to find the perfect colour match with the liquid-coated components from the Asian market. Actually, it is not always easy to find the perfect powder hue to match the distinctive, shiny, and sometimes “loud” metallic effect obtained with Chinese liquid paints. Colour matching with the coatings already applied on the components imported by InCycles is one of the most demanding challenges for our team.”

“Yet, ST Powder Coatings has managed to find the right balance,” notes Conceição. “Despite these issues, it has been able to provide us with colour matching solutions that meet all our customers’ requirements. The primers and powder top coats it supplies us with, even those with metallic and special effects, guarantee lowkey finishes that are definitely less showy than the liquid paints with the same effects or colours. This is why we are trying to convince our

Epistolio Srl.

customers to choose powder coating whenever the hue developed

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

by ST Powder Coatings is very close to that obtainable with a liquid product. The feedback from the market is currently very positive.

In addition to such extreme care in searching for the most suitable solutions for our needs, we greatly appreciate other aspects, such as the speed and efficiency of ST Powder Coatings’ service and the

Publierre_Milano

reliability of its solutions. I guess this is partly due to its experience in

the field of bicycle manufacturing and coating, in which Italy and Veneto

of improving the quality of life and human relations. The goal is to

in particular, the home region of ST Powder Coatings, are more than

consolidate the change of mentality already initiated, which has become

well-established benchmarks.”

necessary in light of the current world economic situation, in which the restrictions imposed on low-cost products from the Asian market can be

The bicycle becomes the protagonist of a sustainable mindset change

a boost to the growth of the European manufacturing sector. InCycles is ready to face this breakthrough with the support of skilled and flexible

“We firmly believe that the daily use and acceptance of the bike as

partners such as ST Powder Coatings, which has contributed decisively

a means of transport,” concludes Conceição, “is an opportunity to

to the growth of our company, since powder coating is becoming an

implement non-polluting and sustainable mobility solutions that are

increasingly decisive strategic asset in the choices of our customers in

an excellent alternative to traditional ones, with the ultimate aim

terms of both finishing quality and sustainability.”

© ipcm

© ipcm

From top left clockwise: The curing oven; A finished component; A detail of a powder coated component; The InCycles showroom where e-bikes and traditional bicycles are on display.

44

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© ipcm

© ipcm

FASTRIP T2-120 MIX our brand new and most compact paint stripping system FASTRIP T2-120 MIX uses the mechanical action of the paint stripper on the parts that is ensured by the hydrostatic thrust generated by a specially designed mixer.

• Rectangular tank in AISI 304 stainless steel, 450 x 700 x h300 mm, with 20/10 thick walls and a 1” bottom valve for easy emptying • Steel mixer for continuous fluid circulation, enhancing paint stripping efficiency and heating system performance • Motor is protected from heat and an electric lock that stops the mixer when the lid is opened • Integrated control panel, removable lid with thermal insulation and pistons for easy access.

• Safety, efficiency, and superior quality.

www.alit-tech.com

ALIT Technologies Srl - San Bonifacio, Italy +39 045.245.6638 - info@alit-tech.com

ADVANCEMENTS

The Difference in the Pretreatment of Aluminium for Different Climatic Environments Based on the Example of GSB-Certified Coating Companies Philipp Mader, GSB International e.V. – Düsseldorf, Germany

info@gsb-international.de

In the market of aluminium coatings, there is sometimes great confusion when it comes to planning and choosing the correct pretreatment.

© Lukas Roth Cologne / © KARL BUBENHOFER AG.

I

n GSB’s field of activity, which is dedicated to the quality assurance of coatings on aluminium, steel and galvanised steel in the field of architecture, the question of the correct pretreatment for a particular

environment is part of the daily business.

The quality assurance system has been developed over decades, and there are various GSB Quality Seals for different areas of application. So how is a quality assurance system dedicated to coatings for outdoor use by means of powder and liquid paint structured?

The GSB quality assurance system in a nutshell The best way to understand how to select a pretreatment for an exterior coating is to go through GSB’s quality assurance system briefly. Today we will limit ourselves to the substrate aluminium.

A coating is only GSB-compliant if it has been pretreated with GSB-certified chrome or chrome VI-free pretreatment chemicals in an appropriate overall process. Alternatively, a pretreatment can also be carried out by means of pre-anodising - more on this later.

Furthermore, it is mandatory that the coating is carried out by GSB-certified coating companies and that GSB-certified coating powders or liquid paints (coating materials) are used.

Coater inspections are the centrepiece of securing the coating process chain.

GSB-certified coating companies are audited twice a year unannounced by independent and accredited testing institutes.

Today we do not want to dwell too much on what are considered to be among the most stringent tests on the architecture market for pretreatment chemicals and coating materials, but rather on the inspections carried out at the coating companies.

Corrosivity categories and differences in GSB quality seals There are different quality seals, which essentially differ in the corrosion tests carried out as part of the audits and the way how they are evaluated. In the case of coating companies that are certified with the Standard or Master

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ADVANCEMENTS

Quality Seal without an additional seal, the inspector takes sample

additional seal pre-anodisation Sea Proof Plus. Here, too, the maximum

sheets from production as part of the audits. An acetic acid salt spray

filament length shall not exceed 2 mm.

test is then carried out on the sheets (according to ISO 9227). The test

However, the rule for F is stricter (F ≤ 0.1). Compared to coaters that

lasts 1000 hours, the delamination at the T-cut must be at a maximum

do not carry an additional seal or the additional seal Sea Proof, coaters

of dmax ≤ 1 mm. For the bubble degree, 0 S(0) is mandatory.

with the additional seal Pre-anodisation Sea Proof Plus carry out a

The coatings by GSB Standard and Master Coaters are the choice

pre-anodising. The difference between decorative anodising and

for use in environments that can be characterised by the corrosivity

pre-anodising is that in the case of pre-anodising, the pores remain

category C3 (following ISO 9223).

open and thus help to ensure good adhesion of the coating applied

In addition, there are GSB Master and GSB Premium Coaters that

afterwards. If a coating is to be used in an environment that can be

carry the additional seal Sea Proof. In addition to the AASS test, the

characterised by the corrosivity class C5, coaters with the additional seal

filiform corrosion test is carried out in those cases (according to ISO

Pre-anodisation Sea Proof Plus are the companies of choice to carry out

4623-2). Here, the maximum filament length shall not exceed 2 mm.

the job. Typically, such a corrosive environment is found on a coastline

Furthermore, there is a special value for the filiform corrosion. This

where the air has a high salt content for example.

value (F) is calculated from the average filament length multiplied by the filament frequency and must not exceed 0.3.

Which corrosivity category applies to my application?

Coatings of GSB Master and Premium Coaters having the additional seal

But how do you know which corrosivity category to use to characterise

Sea Proof can be used in environments that can be characterised by the

an environment? There are overview maps that divide countries into

corrosivity category C4 (following ISO 9223).

categories, for example. However, these maps can only be used as

Then there are GSB Master and GSB Premium coaters, which have the

rough indicators. The corrosiveness of the environment can vary

EVERYTHING

FROM A SINGLE

SOURCE est.

1987

.com www.emptmeyer

HOOKS & S HANGING SYSTEM

MASKING

RACKS

MENT

UIP ACCESSORIES & EQ

© e. Luterbach AG

Pretreatment line.

international PAINT&COATING magazine - JULY/AUGUST 2023 - N. 82

47

© Lukas Roth Cologne / © KARL BUBENHOFER AG.

© Lukas Roth Cologne / © KARL BUBENHOFER AG.

The Superblock building in Winterthur (Switzerland).

enormously locally, even in small areas - for example, copper abrasion

purpose in the case of aluminium (for the alloys mentioned above).

from overhead lines can increase corrosiveness. Industrial facilities or

“Matching the coating to the corrosivity category” goes far beyond ISO

heavily frequented roads can also increase the corrosiveness.

9223, which does not take coatings into account. This is why the GSB

The only way to reliably determine the corrosivity category is to take

has based the recommendations for coatings on aluminium for different

a close look at the target location with an expert. ISO 9223 gives a

environments on the corrosivity categories of the ISO 9223.

guideline to determine the corrosivity class based on the mass loss for aluminium, steel, copper and zinc for the first year exposure. That

The coating is applied - a few words about cleaning

would be the first way to determine the corrosivity class and is done by

Now assume that the project has been completed and the coating has

evaluation the uniform corrosion.

been properly planned and carried out by a GSB Coater. What happens

In this case, ISO 9223 states that it is not possible to determine uniform

next? Adequate cleaning is extremely important and the GSB makes

and localised corrosion of aluminium for the first year by outdoor testing

recommendations here regarding cleaning intervals. For coatings for

of specimen. The reason for this is the passivation behaviour and the

projects in environments that can be characterised by the corrosivity

decreasing corrosion rates of aluminium over time. If the evaluation

categories C3 and C4, the GSB recommends one cleaning per year. For

based on the corrosion rate is not possible, the ISO 9223 allows to

projects in areas that can be characterised by the category C5, GSB

determine the corrosivity category based on environmental information

recommends two cleanings per year. These cleaning intervals are part of

– of course this leaves room for interpretation.

the general terms and conditions of many GSB Coaters.

If you are unsure and fluctuate between two corrosivity categories, especially if you are uncertain about the corrosivity of the environment

A final word on ISO 9223 and a practical recommendation

in the future. It is also important to consider possible future changes in

At the end of the day, the following is recommended for the coating of

the corrosiveness of the environment. These can result, for example,

aluminium:

from new roads being built in the area - emissions and also input from

1. Determine the corrosiveness of the environment in the area of

road salt can additionally increase the corrosiveness.

intended use.

At the end of the day, aluminium alloys used in construction (Profiles EN

2. Select GSB coater based on the corrosivity category:

AW-6060 and EN AW-6063; for Sheets EN AW-5005/5005a and EN AW-

• GSB Standard or Master without additional seal: C3

5754) can be left in normal weathering conditions without coating and

• GSB Master or Premium Coater with additional seal Sea Proof: C4

without having to worry about structural damage. Matching the coating

• GSB Master or Premium Coater with additional seal Pre-anodisation

to the corrosiveness of the environment thus has a purely decorative

Sea Proof Plus: C5.

for example, you should opt for the next higher corrosivity category -

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FOCUS ON TECHNOLOGY

The ILTOM Group’s Powder Coating Plant Provides Production Flexibility while Reducing Energy Consumption and Improving Quality Gabriele Lazzari ipcm®

Over the years, the ILTOM Group has transformed itself from a small craft business into a renowned industrial holding company through a strategy of dimensional growth, production synergy, and innovative investment.

Its latest acquisition was the new automatic powder coating plant designed and built by M.I. DUE, which allows it to handle components in different sizes and shapes while guaranteeing high quality, repeatability, and fast delivery.

© Gruppo ILTOM

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FOCUS ON TECHNOLOGY

© ipcm

The pre-treatment tunnel and the entrance to the drying oven.

A

© ipcm

Parts exiting the spray pre-treatment tunnel.

common strategy to stand out from competitors in an

S.R.L (Besana in Brianza, Monza e Brianza, Italy), which has enabled it

increasingly dynamic and global manufacturing environment

to increase its production capacity while reducing energy consumption

is implementing highly efficient supply and logistics chains

by 15% compared with conventional plants and always meeting the

through smart devices, advanced technologies, and seamlessly interconnected processes that enable a timely and efficient response

stringent technical specifications imposed by customers.

to customer needs.

ILTOM: a family-run industrial holding company

The ILTOM Group is an international company headquartered in

The ILTOM Group is an industrial but family-owned holding company

Romanengo (Cremona), whose implementation of this approach

specialising in contract sheet metal processing. Founded in 1970 by

represents an Italian success case. Over the years, the company has

Francesco Venturelli as a small workshop, it evolved over the years

pursued a growth strategy focusing on the acquisition of multiple

thanks to the entry of his sons Luca and Pierangelo Venturelli into the

production sites and their upgrade through technologically advanced

company in 1996, who fostered its growth exponentially. To support the

and interconnected solutions, to ensure that all factories meet the

increasing production rates, ILTOM acquired a new plant in Romanengo

same quality standards and can quickly satisfy any customer request.

in 2000, where it still maintains its offices and some manufacturing

In doing so, it achieved a remarkable milestone last year, exceeding

departments today. Following the financial crisis in 2007, the Group

100 million Euros in turnover for the first time. The ILTOM Group is a

also decided to expand into foreign markets, selling its products in

metalwork company with customers from several different industries

France (which now accounts for 65% of its turnover), Switzerland,

and it is also strongly committed to environmental sustainability. That

Hungary, Poland, Romania, and other non-European countries.

is why it has significantly invested in energy efficiency as well, with a

“The ILTOM Group’s corporate structure is the result of a strategy

focus on reducing its gas consumption.

in which production synergies, dimensional growth, innovation,

In line with its corporate strategy, the ILTOM Group recently invested in

and quality have always been considered the prerequisites to be

a new powder coating plant designed, built, and installed by M.I. DUE

competitive on the market. We have tried to grow gradually, combining

international PAINT&COATING magazine - JULY/AUGUST 2023 - N. 82

51

the increase in production volumes with the acquisition of other firms that would allow us not only to quickly meet our manufacturing needs, but also to expand into new sectors or geographical areas that we were previously unable to cover,” says Roberto Cagna, the purchasing and supply chain manager of ILTOM Spa. “These are all perfectly integrated into our Group’s logics: the SAP management system, production technologies, programming software, and quality procedures are in fact common elements for all our companies. This made it possible to obtain a Group’s quality certification and to become particularly flexible in handling peaks in demand; in the presence of any manufacturing issues, we can shift production among our various locations. The investment in a new coating plant provided by M.I. DUE, which replaced a previous line that was no longer able to meet our quality and © ipcm

repeatability requirements, was therefore part of this framework aimed at providing our international

The drying and curing ovens.

customers with a complete service, delivering readyfor-use parts in a short time and in compliance with the highest quality standards.”

From the selection of raw materials to the delivery of finished, packaged products Today, the ILTOM Group produces structures and components for switchboards, electrical cabins, machine tools, food and beverage vending machines, air conditioning and heating systems, industrial and agricultural vehicles, medical and pharmaceutical instrumentation, and systems for the nuclear and electronics industries. Mould design and construction, precision sheet metal machining, and powder coating are integral parts of its core business. Its production flow starts with the acquisition of raw materials, i.e. coils or sheets of pickled, polished, galvanised, electrogalvanised, and aluminised steel sheet in different sizes, which are subjected to numerous machining processes such as blanking, punching, CO2

or fibre laser cutting, and bending with CNC machining centres. “As market demands are increasingly focusing on ever-smaller production volumes with just-in-time orders, the ILTOM Group has a variety of state-of-theart machinery and highly qualified personnel at its © ipcm

Plant overview.

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disposal to meet all requirements,” explains Roberto

FOCUS ON TECHNOLOGY

Coatings according to GSB: Long-lasting attractiveness of facades, buildings and industrial products made of aluminium, steel and galvanized steel

Cagna. After machining, the products are welded and assembled, powder coated, and finally mounted and packaged.

Different coating plants, same technical specifications The ILTOM Group has many years of experience in the industrial coating sector thanks to the numerous powder application plants installed at its sites, which can treat all metal surfaces and guarantee the production of high-quality components with excellent corrosion resistance. “Powder coatings ensure high-quality finishes for a wide range of surfaces, providing excellent look and feel, long service life, high process efficiency, and the sustainable use of resources, as well as offering a wide range of colours and surface effects. This is why we have coating lines in our CMA, Paillet, Bruder Keller, and

constantly monitor compliance with customer specifications to ensure the same levels of coating quality, film thickness uniformity, and result repeatability are achieved regardless of where the process is performed. For example, our main customer carries out regular audits of our plants and specific salt spray tests before allowing us to powder coat its low and medium-voltage circuit breakers

A

and components for substations, servers, and switchboards.”

The Romanengo factory’s old powder coating system, however,

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The pre-finishing station.

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“With all this equipment available, however, it is essential to

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warehouses,” adds Cagna.

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

ed

allow us to guarantee very short delivery times despite the reduced

ov

addition to the two lines installed at the Romanengo site, which

© KARL BUBENHOFER AG / Photo by Lukas Roth Cologne

Bresto factories in France and in the Fraven one in Romania, in

pr

© Gruppo ILTOM

© ipcm

Parts coated in the Wagner automatic booth.

The thermal oil boiler that feeds the M.I. DUE plant’s ovens.

only performed three pre-treatment stages, which did not ensure the

with a Lesta self-learning articulated robot, and a manual post-finishing

achievement of the quality standards imposed by the most demanding

station. After curing in an oven with a double exchanger and a thermal

customers. This is why in 2022, ILTOM decided to invest in the new M.I.

oil battery, the workpieces are finally led to a special cooling zone, where

DUE plant.

unloading operations can also be carried out, and finally back to the

The M.I. DUE automatic powder coating plant

loading/unloading area. This enables the staff to perform the unloading operations in two separate locations in order to optimise the logistics

In August 2022, M.I. DUE designed, built, and installed a new powder

flows and the subsequent packaging activities. To this end, smart screens

coating plant, with a loading and unloading area where the operators can

have been installed on the line that provide the personnel with the

arrange the many components manufactured by the ILTOM Group, from

necessary information on how to package the products, any required

small parts to large metalwork fabrications with a maximum size of 900 x

checks, and the further processing steps.

2,000 x 4,000 mm, on the load bars, each with a maximum capacity of 250 kg. The line’s one-rail conveyor takes them through the six-stage insulated

Thermal oil-heated ovens for energy savings

spray pre-treatment tunnel, where they undergo alkaline degreasing, two

“The powder coating plant went into full operation at the end of

rinses with mains water, one rinse with demineralised water, a conversion

September 2022. We expressly asked M.I. DUE for a solution that could

stage with the nanotechnology product Oxsilan®, and one final rinse with

meet the quality requirements imposed by our customers but was

demineralised water. After exiting the pre-treatment tunnel, the parts

also ecologically sustainable. Therefore, all motors are equipped with

move along a dripping area equipped with a platform that allows the water

inverters and we use thermal oil to heat the ovens and the pre-treatment

drained from the parts to be collected and reused. Subsequently, the load

tunnel. This has reduced our energy consumption by 15%,” says Gianluca

bars are taken to the drying oven and then to the powder coating booth,

Cremonesi, the ILTOM Group’s paint shop manager. The line’s ovens

where an advanced, smart powder feed and preparation system enables

are heated through thermal oil batteries to reduce gas consumption

colour changes to be carried out in just a few minutes.

and avoid the use of burners, and therefore eliminate the presence of

The booth is equipped with automatic guns, a pre-finishing station

flames inside the building. The boiler, located outside the factory, heats

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FOCUS ON TECHNOLOGY

the recirculating oil and sends it to the batteries of the drying and curing ovens, where its temperature can be adjusted through temperature controllers and modulating valves. In addition, an oil-water exchanger heats the coils of the pre-treatment tunnel.

“The use of thermal oil enables to keep the temperature more stable and adjust it by as little as one degree, thus improving film distension and colour consistency during curing. This system was also designed with a view to heat recovery, so the boiler is equipped with a very efficient burner and a heat recovery unit that utilises the heat of fumes (300° C) to obtain hot water for raising the temperature in the alkaline degreasing tank. As a consequence, the company has increased both its energy savings and the safety of its working environment. Boiler maintenance is also facilitated and does not hinder production operations,” notes Andrea Mattavelli, the technical designer from M.I. DUE who was responsible for the development and construction of the new plant.

Flexibility and repeatability with self-learning robots ILTOM uses a variety of powder coatings and performs an average of eight colour change operations per shift. The operational flexibility of the plant is therefore crucial. “The previous machine integrated a Lesta fiveaxis articulated robot with a self-learning function and an RFID management system, which we decided to

© ipcm

The self-learning articulated robot supplied by Lesta.

maintain in this line as well for pre-finishing operations on components with complex shapes such as box profiles or parts with particular angles and curvatures,” says Cremonesi. “An operator performs the movements

plants. The Group also decided to rely on this

required to effectively coat a part using an ergonomic

partner for the construction of a coating line in

joystick and the robot saves the data so that it can

one of its five production facilities in Romania. “M.I.

replicate them independently. In addition, the entire

DUE has always been professional, reliable, and

plant is Industry 4.0-oriented. Through a tablet in

helpful in finding the best solution to our needs.

the department and even with an app on the mobile

For example, when we moved to a new Romanian

phones available to staff, it is possible to set various

plant, they dismantled the existing coating system

operating parameters.”

and immediately reassembled it at the second

The ongoing collaboration with M.I. DUE

site: our production restarted without a hitch in less than one month. When our management

The strategic collaboration between the ILTOM Group

decided to invest in a new plant for the Italian

and M.I. DUE was not, however, limited exclusively to

site, after a thorough benchmarking, MI.DUE’s

the coating system installed at the Romanengo site. This

offer proved to be the best in terms of technical

plant engineering company, in fact, has repeatedly been

characteristics, installation times, and assistance.

responsible for updating and maintaining ILTOM’s other

The customisation level it is able to achieve and

© ipcm

The tablet with the app to control the system remotely.

© ipcm

The pre-treatment tunnel.

the expertise of its technicians have enabled us to continue to meet

plant supplied by M.I. DUE has a higher capacity than the old one, despite

all the stringent specifications of our customers, whether for coating

requiring lower energy consumption. “Equipping our site with a plant

large components such as air conditioning, boiler, and refrigerator

with much higher quality standards that could meet all our customers’

metalwork fabrications or for finishing small parts typical of the

requirements was an absolute necessity, not least because of the risk

beverage distributor and electrical industries – all while reducing energy

of overloading due to work peaks or breakdowns. We are completely

consumption and costs,” states Roberto Cagna.

satisfied with this new chapter in our collaboration with M.I. DUE, as we

Cost-effective and green investment

have been able to increase our production capacity and quality standards while at the same time gaining economic benefits (thanks to reduced

In addition to achieving the quality degree required to meet the needs

consumption) and improving our operations’ sustainability (thanks to flue

of the ILTOM Group’s diverse customer base, the new powder coating

gas heat recovery),” concludes Roberto Cagna.

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© iStock

RESEARCH BREAKTHROUGH

The ‘Invisible’ Cellulose Coatings that Mitigate Surface Transmission of Pathogens Edited by University of Birmingham Birmingham – United Kingdom

A thin film of cellulose fibre that is invisible to the naked eye, is suitable for use on high traffic objects such as door handles and handrails.

R

esearch confirmed the stability of the coating, which showed no

The coating was developed by scientific teams from the University

noticeable damage when dry, but easy removal from the surface

of Birmingham, Cambridge University, and FiberLean Technologies,

when wetted, making it convenient and suitable for daily cleaning

who worked on a project funded by the Engineering and Physical

1

and disinfection practice. Research has shown that a thin cellulose film

Science Research Council to formulate treatments2 for glass, metal or

can inactivate the SARS-CoV-2 virus within minutes, inhibit the growth of

laminate surfaces that would deliver long-lasting protection against the

bacteria including E.Coli, and mitigate contact transfer of pathogens.

COVID-19 virus.

The coating consists of a thin film of cellulose fibre that is invisible to

While conventional chemical disinfectants and antiviral surface designs

the naked eye, and is abrasion-resistant under dry conditions, making

target either the structural proteins or nucleic acids, the researchers,

it suitable for use on high traffic objects such as door handles and

led by Professor Zhenyu Jason Zhang, from Birmingham’s School of

handrails.

Chemical Engineering, focussed on drying out the respiratory droplets

1

https://pubs.acs.org/doi/10.1021/acsami.2c23251

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https://www.birmingham.ac.uk/news-archive/2020/researchers-tackle-the-surfacetransmission-of-covid-19-in-new-partnership

2

RESEARCH BREAKTHROUGH

that contain the viruses by the capillary force introduced by the porous

The experiments were repeated with aerosolized artificial saliva, and

structure. The COVID-19 virus is known to remain active for several days

here the analysis suggested that the cellulose thin film is also effective in

on surfaces such as plastic and stainless steel, but for only a few hours

suppressing the contact transfer of respiratory aerosols.

on newspaper. The team, which has expertise in surface chemistry and

Professor Zhang commented: “The risk of surface transmission, as

formulation engineering, investigated the structure and performance

opposed to aerosol transmission, comes from large droplets which

of a coating made from micro-fibrillated cellulose (MFC) provided by

remain infective if they land on hard surfaces, where they can be

FiberLean Technologies, the leading global producer of MFC for the

transferred by touch. This surface coating technology uses sustainable

paper and packaging industry.

materials and could potentially be used in conjunction with other

The researchers found that the porous nature of the film plays a

antimicrobial actives to deliver a long-lasting and slow-release

significant role: it accelerates the evaporation rate of liquid droplets, and

antimicrobial effect.”

introduces an imbalanced osmotic pressure across bacteria membrane.

The researchers confirmed the stability of the coating by mechanical

They then tested whether the coating could inhibit surface transmission

scraping tests, where the coating showed no noticeable damage

of SARS-CoV-2. Here they found a three-fold reduction of infectivity

when dry, but easy removal from the surface when wetted, making it

when droplets containing the virus were left on the coating for 5

convenient and suitable for daily cleaning and disinfection practice.

minutes, and, after 10 minutes, the infectivity fell to zero.

University of Birmingham Enterprise has filed a joint patent application

By contrast when droplets containing SARS-CoV-2 were left on a glass

with FiberLean Technologies and Cambridge University covering a

surface, their initial infectivity was still maintained after 10 minutes. The

microfibrillated cellulose which can inactivate viruses by disrupting the

antimicrobial tests were repeated with droplets containing bacteria

lipid envelop of the virion.

(E.Coli and S.epidermidis), and here again, the researchers saw substantial reductions in infectivity at 1 hour and 24 hours.

This work is funded by the European Union under SUPREME Project (GA101058422).

© eosmarketing

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With over 50 ZLD plants installed all over the world, CIE is a leader company in Zero Liquid Discharge for metal finishing industry www.cieeng.com - info@cieeng.com

ROAD TO 2050

EcoBell4: Application Efficiency of up to 98% Saves Huge Amounts of Paint and Rinsing Agent With the new EcoBell4 atomizer family, Dürr is setting new benchmarks in sustainable production. The innovative application technology achieves efficiencies of up to 98 percent for clear coat. Paint losses and rinsing agent consumption can be reduced by 50 percent during colour changes, or even by up to 91 percent in combination with the EcoProBooth modular paint booth concept. The improvements are made possible by the unique 4-main needle technology as well as changes to the process parameters for paint application.

T

he higher the efficiency during paint application, the less material,

With the EcoBell4 Pro E atomizers with external charging for exterior

resources, and energy are required. In other words, higher

painting, the efficiency for base coat also increases from 75 to 78

efficiency makes for more sustainable production. With the

percent compared with the predecessor model EcoBell3. The EcoBell4

latest atomizer generation EcoBell4 Pro Hu with direct charging and

Pro Ci atomizer for interior painting also continues to achieve unrivalled

EcoBell4 Pro Ux with external charging, Dürr is scaling new heights. For

high efficiencies of up to 70 percent. Efficient collaboration with OEMs

clear coat application, application efficiencies of 95 to 98 percent are

and paint suppliers in the Dürr technical centre offers further potential

achieved according to DIN EN 13966-1.

for improving the efficiency and the quality of paint application.

For the atomizer to apply the paint with maximum efficiency, the are significantly reduced. This maximizes the effect of the high voltage.

Fast colour changes reduce paint and rinsing agent consumption

The flow rate of the paint remains high. In addition, the shaping air is

In addition to the painting process, technical innovations in the design

reduced to a minimum and the high-voltage control is adjusted.

elevate the EcoBell4 atomizer generation to a new quality level. The

Dürr is testing the implementation of this painting process in a concrete

new generation makes the painting process more flexible and more

automotive paint shop in a collaboration with interested OEMs.

efficient, and therefore more sustainable. Colour changes can be

Existing systems can be retrofitted too.

carried out more quickly with the EcoBell4 than with any other high-

process parameters are set as follows: the speed and spray distance

How the measures impact the process

speed rotary atomizer on the market. This is because the patented 4-main needle technology not only saves time, but also reduces paint

Reducing the shaping air volume to a rate of between 90 and 200

and rinsing agent consumption as well as VOC emissions.

standard litres per minute produces a softer spray jet. Together with

Here’s how the principle works: three of the four main needles are

a lower bell disk speed, energy consumption is reduced. If the spray

reserved exclusively for the most frequently used colours. All other

distance is decreased to around 100 millimetres at the same time,

colours go through the fourth main needle. Real-world evidence shows

more paint reaches the car body. There are two reasons for this:

that in the automotive sector, 50 percent and more of the total number

firstly because the spray pattern is much less scattered, and secondly

of bodies are painted in the three most frequently used colours.

because a stronger electrical field between the bell disk and car body

The technology leverages this fact and provides the three colours

surface enables optimum use of the electrostatic force via a constant

permanently via the main needles. These are located directly behind

voltage.

the bell disk. When a colour change is due, the system can switch to

The atomized paint therefore reaches the body to a far greater extent

another main needle within four seconds without it being necessary

instead of being lost in the booth air. In order to achieve the required

to rinse and clean the channel. This reduces both the paint losses

layer thicknesses in the given cycle time, a paint outflow rate of up to

and the rinsing agent consumption associated with colour changes. If

400 millilitres per minute is possible. In total, the EcoBell4 Pro Hu with

a less frequently used colour is requested, the colour can already be

direct charging achieves efficiencies of up to 98 percent for clear coat in

primed via the fourth channel while one of the three main colours are

this way.

still being applied. This means that each colour is available for the next body within an extremely short time.

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ROAD TO 2050

© Dürr

Further savings through the new paint booth concept Compared with the predecessor model EcoBell3 (1C), the consumption of paint and rinsing agent is reduced by 51 percent in the conventional line setup. This is good for the environment and minimizes the process costs.

The new atomizer generation is especially efficient and sustainable in combination with the EcoProBooth. Since the interior and exterior painting can be performed in a single booth, not only the colour change times but also the handling times are reduced compared with the line concept.

The universal atomizer EcoBell4 Pro Ux is a perfect match for the EcoProBooth. It is suitable for interior, exterior, and metallic

Thanks to the four main needles, EcoBell4 Pro manages colour changes in just four seconds without paint loss.

painting, and uses one and the same bell disk/ shaping air ring system and external charging

© Dürr

system for this.

The combination of the EcoBell4 Pro Ux and EcoProBooth even permits savings of up to 91 percent during colour changes by reducing paint losses and rinsing agent consumption.

“This is a huge step. Our model calculations are based on a paint shop that uses 24 colours and coats 30 bodies an hour, working 230 days a year on a three-shift basis. The amount of paint saved would be enough to paint an additional 15,600 bodies,” says Frank Herre, Head of Application Technology Development at Dürr.

Just four robots reduce colour change and handling times The system with up to four main needles covers all painting requirements, from the 4x1C solution for base coats to the 3x2C solution for clear coats. Dürr offers a total of ten different versions of the EcoBell4, for all exterior and interior painting applications with direct or external charging.

For the first time, the product family includes a basic version for standard applications as well as a pro version for special processes such as 4x1C or 3x2C.

The flexible EcoBell4 Pro Ux universal atomizer.

international PAINT&COATING magazine - JULY/AUGUST 2023 - N. 82

61

FOCUS ON TECHNOLOGY

Making the Best Use of Customers’ Time by Adding Value through State-of-the-Art Services: A Coating Contractor’s Bet on the Future Monica Fumagalli ipcm®

An innovative concept of contract coating, based on offering a service that does not end with the delivery of high-quality finishes but also includes the management of the time allocated by customers through state-ofthe-art systems. This is what stood out during our visit to the premises of Tecnologie Galvaniche Innocenti, a coating contractor that has recently integrated the latest generation of Gema Europe devices to project its production flow into the 4.0 future.

T

he term “contracting” generally refers to the services of a firm that performs certain processing steps or entire manufacturing processes on behalf of one or more other businesses. Typically, a company

turns to a “third-party” firm and entrusts it with the processing of some of its products to optimise costs, to cope with production peaks that are difficult to handle in-house, or to rely on a partner with better or different technologies and skills than its own: this is the most frequent case in the contract coating sector. Customers turn to contractors intending to establish solid and reliable partnerships. This means that, in addition to taking advantage of their expertise, they also expect their orders to be managed within the required time frames.

“Recently, especially after the pandemic, the delivery time for coating components has dramatically reduced from five to two working days,” emphasises Leonardo Innocenti, the owner of Tecnologie Galvaniche Innocenti Srl (Anagni, Frosinone, Italy), which specialises in the contract shot

© Tecnologie Galvaniche Innocenti

Some components that were powder-coated by Tecnologie Galvaniche Innocenti (Anagni, Frosinone).

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blasting and liquid and powder coating of small, medium, and large metal parts for the most diverse sectors, from automotive to aerospace, from architecture to HVAC and the general industry.

FOCUS ON TECHNOLOGY

© ipcm

The loading area of the automatic powder line.

© ipcm

The primer application booth, equipped with Gema reciprocators.

“To adapt our factory to these new market requirements, we decided

of the 1960s and the beginning of the 1970s, he decided to move its

to equip it with the latest 4.0 technologies, taking advantage of the

headquarters to the southeast of Rome, continuing to offer contracting

Italian government incentives for SMEs and turning to our long-standing

services but specialising in galvanic treatments. The plant in which we

suppliers of equipment and plant solutions, such as Gema Europe Srl

are headquartered now in nearby Anagni was opened in 1995 to offer

(Trezzano sul Naviglio, Milan, Italy) and Euroimpianti (Valeggio sul Mincio,

powder coating in addition to galvanic treatments, which we still carry

Verona, Italy).”

out in our Rome plant. Here, in 2012, we also installed a plant for liquid

“I firmly believe in looking at contracting services from a different

coating and one for stainless steel pickling and passivation, which we

perspective,” adds Innocenti. “Contractors do not produce anything,

perform at the request of an individual customer from the oil & gas

but we rather manage the time that customers give us to carry out

sector.

their required surface treatments. Reflecting on our work with a view to

“Currently, powder coating on any type of ferrous material accounts

not only improving finishing quality but also optimising our customers’

for 98% of our production. We apply liquid paints rarely, generally on

production times is certainly more difficult. However, if we manage to do

components for special industries, such as boiler parts, which must

this and therefore enhance our service with the right plant solutions, we

withstand the highest temperatures. For all other sectors, our staff

are on the right track to succeed.”

always suggests the use of powders, both because of the progress

Tecnologie Galvaniche Innocenti: from the post-war period to the family’s fourth, all-female generation

that this type of coatings has made over time, moving from a purely industrial product to a wide range of applications even in unexpected sectors – such as architecture and design, which are now increasingly

The growth of Tecnologie Galvaniche Innocenti has gone hand in hand

demanding – and because of the smaller environmental impact of their

with the development of the contract coating sector from the post-war

application process.”

period to the present day, with one distinctive trait: Leonardo Innocenti, from the third generation of the family at the helm of the company, is

Revamping the automatic powder coating plant

now supported by his three daughters Cristiana, Giorgia, and Fabiana,

“We are equipped with three coating systems,” explains Cristiana,

who work in the administrative, production and planning, and sales

“including one liquid coating and two powder coating plants. Out of the

departments, respectively. “The history of our company began with

latter, the manual one is devoted to large, heavy metalwork fabrications

a small blacksmithing and painting workshop created by my great-

with a dimension up to 14 x 2.2 x 3 m and a weight up to 5000 kg

grandfather on the Tiber River right after World War II,” says Cristiana.

handled through trolleys, whereas the automatic one treats small and

“The business was then taken over by my grandfather. Towards the end

medium-sized parts operating with a continuous flow on three shifts.

international PAINT&COATING magazine - JULY/AUGUST 2023 - N. 82

63

Euroimpianti designed and installed both lines. More recently, thanks to

ups, to treat small batches, and to apply the most challenging colours in

the Industry 4.0-related incentives, it also supported us in the revamping

terms of colour change. In the past, our cycle time for two-coat systems

of the automated system, which started before the pandemic and was

was of up to 6 hours; today, the new layout and the addition of one

completed in 2022.”

booth enable us to perform the complete cycle in 4.5 hours.”

The project entailed modifying the line’s design, switching from a ring layout that required two-coat systems to be applied in two passes to an

Gema’s last-generation booth

“L-shaped” layout that ensures a faster, more linear cycle. This includes a

“Tecnologie Galvaniche Innocenti chose to install a MagicCylinder booth

booth exclusively applying primers equipped with already-existing Gema

equipped with 10 automatic guns (5 on each side) and 4 manual guns,

reciprocators, a hot-air oven for primer gelling and top coat curing,

and OptiSpray AP 01 dense phase pumps, a 3D laser scanner system for

and a new Gema top coat application booth. “Our automatic plant is

shape recognition, and a powder management unit,” indicates Claudio

equipped with three booths in total: one for primer application, one for

Sergenti, area manager at Gema Europe. “The booth’s cylindrical design

top coat application, and one that was previously used for applying top

reduces powder accumulation, thanks to the absence of edges and

coats in any colours but is now devoted to performing manual touch-

corners where the paint product could accumulate. This guarantees

© ipcm

© ipcm

© ipcm

© ipcm

From top left clockwise: The hot-air oven; The last-generation MagicCylinder booth during a top coat application phase; OptiSpray AP 01 dense phase pumps; The OptiCenter powder management and recovery unit.

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FOCUS ON TECHNOLOGY

short cleaning times without the need for the operator to enter the machine. One of the special features of this line is the presence of two cyclones, which ensures optimum handling of light and dark colours through faster colour change operations and higher powder quality through the elimination of any contamination risk. In addition, the EquiFlow suction system creates the ideal work environment in every section of the coating booth: a consistent, homogeneous air flow in its central area guarantees the ideal conditions for paint application and prevents the powder from escaping from the plant.”

“This company’s management decided to install the best devices available to optimise its line as much as possible,” concludes Sergenti. “The whole plant is interconnected with the central management system in line with the Industry 4.0 parameters. This allows managing paint programmes optimally and receiving reports about the daily consumption of paint and energy.”

“We have invested in the most advanced equipment on the market,” confirms Leonardo, “to guarantee that high finishing quality degree that was previously considered a minimum requirement only by certain types of customers, generally medium-large companies in particular sectors such as automotive and aerospace, but that today is included in every specification, often in association with increasing requests for special finishes ranging from textured to weathering steel and gold-effect ones, just to name the most recent trends.

Alongside increasingly higher coating resistance, high aesthetics requirements can no longer be disregarded.”

www.cmautomazione.com

Advantages of the new booth “Among the advantages we have obtained with the integration of the new booth and the new layout of our automated system,” says Cristiana, “we have improved the repeatability of our operations.

Thanks to the pre-set programmes, we now have a reference standard and therefore a more efficient production flow. Automation has made the management of our coating phases easier because the booth does not have to be manned by an operator, who can thus be assigned to other tasks, such as the more complex ones required by the manual system. The operator is only active in the touch-up booth. This has halved the workforce employed on our automatic line from 4 to 2 operators. In addition, it has minimised the environmental impact of our processes, reduced product consumption thanks to the possibility of recovering 25% of the paint product, and zeroed waste disposal. Finally, the dense phase technology provides us with excellent coating consistency during application, which further enhances the aesthetic quality of the products we treat and fully meets our customers’ needs.”

CM AUTOMAZIONE s.r.l.

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

An innovative vision to overcome future challenges “After the pandemic period, our company experienced a production peak related to the boom in the construction sector, which prompted us to take some significant decisions,” notes Leonardo.

“In a very short space of time, we have tripled our staff and invested in the best technologies on the market, such as the equipment supplied

by Gema, one of our long-standing suppliers and a company with longestablished expertise. Our MagicCylinder booth is one of its best and most innovative solutions, combined with 3D scanning, suction, and dense phase technologies. To create a facility that is fully managed in compliance with the Industry 4.0 parameters, another project we are going to implement within the next year is the integration of pre- and post-finishing robots. © ipcm

“Finally, apart from investment in technology, the other project into which I am putting most of my energy is the continued growth and training of the new generation of people that are currently joining our company. These include my daughters, who will inherit the business founded by my grandfather, but also many newly-hired professionals, including a salesperson, who has a strategic role in communicating what we do and how we work to potential customers. The message I want to convey is that we need to know how to best manage the time that our clients give us to lay the foundations of future success.

The required delivery times are getting shorter and shorter, and we must be able to cope with the continuous changes in the market not only through the most innovative technologies but also with the right attitude. This makes us reliable partners for our customers, rather than mere contractors.”

© Tecnologie Galvaniche Innocenti.

From top to bottom: One of the special features of the plant is the presence of two cyclones, which allows the separate handling of light and dark colours.

A large-sized component coated in the manual system.

The fourth generation at the helm of Tecnologie Galvaniche Innocenti: Cristiana Innocenti (centre) with Giorgia (right) and Fabiana (left).

© ipcm

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HIGHLIGHT OF THE MONTH

Lechler Tech: Industrial Coatings for Every Opportunity Edited by Lechler Spa Como - Italy

info@lechler.eu

The treated substrate makes no difference, the paint applied on it does.

I

t is already well known that paint makes all the difference by

phase, this should always be thoroughly addressed and assessed. To do

enhancing the characteristics of a coated substrate, as well as

this, Lechler offers endless technical and colour solutions with dedicated

improving its aesthetics and making it “eye-catching” through a

water and solvent-based systems for all sectors, including the general

variety of finishes. However, the design necessity to faithfully reproduce

industry, appliances and consumer electronics (ACE), habitat, and original

an exact colour point or effect regardless of the type of surface to be

equipment manufacturer (OEM) fields. The wealth of solutions provided

treated is often not easy to fulfil. In this article, we will tackle this issue

by Lechler Tech embraces any surface and application in the design

with Lechler, which has made the replicability of colours and finishes on

world, enabling to work with any substrate and offering refined finishes

any substrate, be it plastic or metal, a goal and a significant strength.

capable of protecting and enhancing the parts over time. Out of the

The refraction of light modifies the visual perception of tints on products

many colour solutions that Lechler makes available to its customers,

made in different materials and with different shapes: in the design

Architectural X is the most innovative tool for the design industry.

Out of the many colour solutions that Lechler makes available to its customers, Architectural X is the most innovative tool for the design industry.

© Lechler Spa

© Lechler Spa

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THE EASIEST WAY TO AUTOMATE YOUR PAINTING LINE

SELF-LEARNING ROBOT

1 OPERATOR REQUIRED

EUROPEAN ASSISTANCE

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

Lesta srl

Lesta

Lesta Srl Milan

THE SCANNER RECOGNISES THE PARTS, THE ROBOT THEN PAINTS AUTOMATICALLY

info@Lesta.it Lesta srl

www.Lesta.it Lesta srl

Lesta

Lesta Srl Milan

HIGHLIGHT OF THE MONTH

It consists of 3 special-effect palettes that complete its

© Lechler Spa

range of highly aesthetic effects and finishes, complying with low VOC emission requirements and including a univocal colour proposal with both water and solventbased products. The METAL, METAL TEXTURE, and HABITAT BUILDING palettes that make up this collection contain a complete range of finishes for the habitat sector, with a wide choice of metallic colours in glossy, matte, and textured versions. Their tactile effect allows experiencing these finishes with the sense of touch as well and makes it possible to meet any project requirement in architecture and design.

In particular, METAL TEXTURE includes products capable of creating fine surface structures through textured, fullbodied finishes, reducing the “cold” sensation of metal substrates and embellishing plastics with an elegant metallised effect. This also creates more rub-resistant, matte surfaces that mask any defects in the substrates.

Ideal for both the contract and furniture worlds, the tints presented are in line with the demands of architecture, but also of the interior and product design sectors. The 29943 and YD943 binders were chosen to guarantee finish consistency with both solvent and water-based coatings. The latter version also complies with the international VOC emission requirements for the LEED,

Some of the colours included in the Architectural X collection.

WELL, and BREEAM certifications.

The HABITAT BUILDING palette, on the other hand,

© Lechler Spa

includes colours and finishes evocative of the classic materials used in architecture to improve the aesthetics of plastic components (such as PVC window and door frames) of façades, making them interact harmonically with their surrounding elements. Lechler’s solutions for coating PVC profiles are QB Profilés PVC revêtus1 certified and they include water-based systems for direct adhesion on PVC (Hydroframe Coat PVC Flex LH282) and solvent-based systems for direct adhesion on both plastic and metal (Framecoat PVC LS 282 and LS472, Plasticgrip 2K WS LS943).

The QB - Quality in Building label certifies the quality, performance, and reliability degree of products and of production and construction processes in the habitat sector.

1

The HABITAT BUILDING palette includes colours and finishes evocative of the classic materials used in architecture.

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?

HOW IT’S COATED

The Colour of Wind: When Wind Power Becomes an Aesthetic Icon Interview with Alberto Tessaro, Business manager and founder of Enessere Srl

From green technologies criticised as being unaesthetic to street furniture elements to be installed in plain sight: a new culture of sustainability was born thanks to Enessere’s wind turbines for domestic use, characterised by sinuous, elegant lines and striking material colours.

W

ind energy is among the most widespread renewable

any direction. We interviewed its founder, Alberto Tessaro, to find out

technologies. According to data reported by the International

how wind turbines have moved from being criticised as disfiguring for

Energy Agency (IEA), wind-generated electricity increased by

the environment to being seen as an aesthetic icon, almost a street

265 TWh (+14%) in 2022 and wind power has been confirmed as the

furniture element.

leading non-hydro renewable energy with over 2100 TWh produced, more than all other technologies combined1. However, as well as

How did the idea of enhancing the aesthetic value of wind

other energy generation devices such as for example solar panels,

turbines, an electricity-generating device, come about?

wind turbines are often at the centre of discussions because they are

“Enessere is a young company founded on the know-how acquired by

considered unsightly within the landscapes in which they are placed.

its team in the automotive electronics sector. From the very beginning,

Enessere (Vicenza, Italy) decided to revolutionise this perception by

we had an innovative project in mind, one that was unprecedented in

conceiving a new product with an innovative design and eye-catching

the field of energy: combining advanced technology for the production

colours, an object to be shown rather than hidden: a vertical micro-

of domestic electricity with attractive design to create a device that

wind turbine to produce clean domestic energy by exploiting wind from

guaranteed extremely high functional performance while being able to be shown in plain sight and not hidden away. Ten years after its

1

https://www.iea.org/energy-system/renewables/wind

foundation, we can say that Enessere has achieved its goal thanks to

© Enessere Srl

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HOW IT’S COATED

the careful study of its products’ structure, which is linear and sinuous,

design, and our paint supplier Lechler. In fact, we realised that giving

materials, and colours. Today, our small, 9 m-high wind turbines placed

customers the freedom to choose their preferred nuance often turns

in gardens, parks, mountain landscapes, and on waterfronts have

into a limitation and not an opportunity. Therefore, we decided to

become “totems of sustainability”, symbols that are proudly displayed

develop a palette from which everyone can select the most suitable tint

by our clients.”

depending on the specific landscape, creating a harmonic relationship between the turbine and the place where it is installed. The wings of

What are the special features that make your turbine special?

Enessere’s wind turbines have the colours of the sky and of clouds,

“First of all, the high-quality materials it is made of: wood, stainless

whereas their towers have warm and cold neutral colours matching the

steel, and carbon fibre. The first line of turbines we designed is called

trunks of the trees and the urban environment. We aim at proposing

“Hercules” and features a 316 stainless steel support structure and

material-inspired, natural, and “quiet” tints in the name of “chromatic

wings covered with a dense weave of Paulownia wood slats to ensure

silence”. Today, our towers in the colours of different materials

perfect aerodynamics. The tower of our second line, “Pegasus”, is made

(graphite, metal, titanium) can be combined with five wing colours

of S355 N steel to which we apply three coating layers to protect its

inspired by earthly and celestial elements (silk, sky, metal, copper, and

surfaces. The same paint, which can be customised in different colours,

space) in six different combinations.”

is also used to coat the wings, which feature a carbon structure just like the connecting struts that support them. Indeed, this possibility of

How are the turbines coated?

personalising it with the colour chosen by each customer is the second

“We outsource the coating phase. Our coater uses the same manual,

important feature of our product.”

spray application system utilised for automotive refinish applications.

In compliance with the ISO 12944 standard, our coatings meet the

Why does colour play such a strategic role?

requirements of the C5 class for very corrosive environments, as are

“Because it is also through colour that this type of product can

those where our generators are installed and exposed to high pollution,

be appreciated. In addition to their high functional performance,

humidity, and salinity conditions in seascapes. A three-layer coating

guaranteed by our consolidated experience, we have identified the

system is applied, consisting of a protective primer, the pigmented

colours that best suit our turbine blades together with Francesca

paint chosen by customers, and a clear coat for UV protection. The

Valan, an industrial designer specialising in colour, materials, and finish

finishing quality achieved is comparable to that of car bodies, uniform and pleasing to the eye, precisely because our wind turbines have to fit into particular landscape contexts, such as urban ones. That is also why we chose to use architectural paints that guarantee a service life of up to 25 years.”

You have offered something truly innovative to the market...

“I like to think that Enessere has not only “given beauty” to an object that has always been considered unaesthetic, but also succeeded in creating a “culture of sustainability” through colour, with turbines comparable to contemporary art sculptures – to be exhibited, rather than hidden. I think I can conclude that thanks to this innovative concept of renewable energy devices, we have finally managed to “colour wind”.”

© Enessere Srl

© Enessere Srl

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FOCUS ON TECHNOLOGY

Halved Colour Change Times and Tenfold-Reduced Powder Disposal Volumes: Nord Laser’s Experience Alessia Venturi ipcm®

An excellent partner in managing complexity.

This is how Nord Laser Srl (Reana del Rojale, Udine, Italy), a metalwork company specialising in the processing of pickled and galvanised sheet metal for a variety of industrial sectors, defines itself. After a years-long process of vertical integration of production, it can now offer a complete contracting service for advanced industrial metalwork machining, assembly, and coating. The investment it made in a new-generation Wagner powder centre in 2022 has increased its coating efficiency tenfold, with colour change operations being performed without manual intervention, fast and consistent turnaround times, accelerated production, increased volumes, and maximised finishing quality.

© Nord Group

In 2022 Nord Laser invested in a new application system, Wagner’s IPS powder centre, conceived with the same perspective as a machine tool to increase productivity, maintain high-quality standards, operate in a simple manner, and constantly reduce colour change times.

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“N

ord Laser’s key strength is the

© Nord Group

ability to simplify complexity through its strategic skills,

its customer-oriented, problem-solving approach, and its capacity to manage any critical issue developed over forty years,” explains Marco Bovolini, the president of Nord Group Spa, the holding company to which Nord Laser and other companies in the food, fitness, and mining sectors belong. “At Nord Laser, each project is the story of an ethical, technological, and innovation challenge. Over the years, we have structured it to be ready even for the most unexpected requests aiming at always satisfying our customers, also in terms of delivery speed and adherence to the planned processing times. Punctuality is an essential value for Nord Laser,” adds Bovolini. “Our idea of partnership is very concrete. It requires complete operational development plans and involves each customer at every stage, from co-design to objective sharing, including cyclic and tightly

The showroom of Canali System. This startup was created by Professor Vincenzo Canali, the inventor of a revolutionary biomechanical approach to training, and Nord Group, which had the idea to translate this sports philosophy into a product of excellence that is revolutionising the fitness world.

integrated monitoring activities. In Nord Laser, customers can find a complete, verticalised

© ipcm

service from a single source, thus avoiding all the disadvantages of long and complex supply chains.”

From analysis and production to coating and shipping, every stage is managed to guarantee excellent performance. It was precisely the coating operation that was the subject of a major capital investment in 2022 for switching to a new application system, Wagner’s IPS powder centre, conceived with the same perspective as a machine tool to increase productivity, maintain high-quality standards, operate in a simple manner, and constantly reduce colour change times.

From 1980s craftsmanship to 2000s integrated industrialisation Nord Group’s history began in 1984, when Alessandro Bovolini founded Bovolini Snc to carry out welding and light metalwork processes for the local market.

General view of the coating line designed by Imel and built by Nord Laser itself.

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© Nord Group

Over the years, the company has evolved to its current structure,

the case of Canali System, another of our Group’s companies. This

where the holding company Nord Group Spa owns four other firms,

means that the technical and quality specifications we have to meet

i.e. Nord Laser and three startups: Canali System in the fitness sector,

vary greatly depending on the sector for which the parts are intended:

North Group Mining in the mining sector, and Gabin in the catering

they range from purely functional specifications with high corrosion

sector. Meanwhile, Nord Laser’s evolution has involved moving from

resistance requirements to specifications where aesthetics are of

purely manual operations to an increasingly technological approach,

the essence. Our strategy has been to vertically integrate production

beginning with its first punching machine and continuing with the

in order to offer a complete service and a net reduction of all the

installation of laser cutting and many other advanced machines. Over

management costs of a conventional supply chain.

the years, it has made several investments in the vertical integration of

“With time, this approach has rewarded us so much that our customer

its production flow, up to the powder coating stage.

base is now changing, moving more and more towards industrial

“We are a contracting company, but we have a highly verticalised

companies. These new manufacturing requirements call for extreme

production cycle: we start with the raw materials, namely pickled or

production flexibility, definite lead times, and high quality. This, in turn,

galvanised metal sheets, and we supply machine parts or complete

has led us to sophisticate our management control tools. We have

systems, also performing the final plant acceptance phases, including

implemented a robust Enterprise Resource Planning (ERP) system for

on-board electrical equipment,” says Bovolini. “We like to call ourselves

production planning and management, an MES for data collection, and

“the production department of our customers”, which operate in

several other tools focusing on digitalisation and Industry 4.0 – like our

various fields, including the steel, energy, textile, air conditioning, and

latest investment, the Wagner IPS coating booth, which we believe is

machine tools industries, as well as the furniture and fitness ones in

the new benchmark in powder application.”

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FOCUS ON TECHNOLOGY

PASSION FOR MASKING SOLUTIONS www.global-mask.com

WHEELS

© ipcm

© ipcm

CUSTOM A three-year investment period with a focus on coating

devoted to painting. It is equipped with a coating line

Over the past three years, Nord Group has invested

6 metres in length, 2 metres in height, and 1 metre

around 5 million Euros in new technologies, renewing

in width.

designed by Imel in 2000, which can treat parts up to

its laser cutting and bending machines, creating a new in-house machining department, installing five robotic welding stations, and upgrading its paint shop with a state-of-the-art Wagner booth.

“Our production cycle includes laser cutting, punching, deburring, bending, machining, welding, coating, and assembly. The vertical integration of all these services is a winning business proposition and coating is a strategic part of it: as it requires skills, expertise, and substantial capital investment, not all manufacturing companies are willing or able to integrate this special process in-house,” notes Marco Bovolini.Nord Laser currently operates in four factories of about 5000 m2 each, one of which is

From the left: The Wagner spray booth, with two touch-up stations before and after the automatic coating phase, is part of the advanced IPS system.

General view of the Integrated Powder System (IPS) combining powder preparation, feeding, dosing, and colour change in a fully automatic plant.

Smart Boxer, the smart virgin powder feeding system, during a colour change operation. This is activated at the push of a button.

STANDARD

This system recently underwent two major updates. The first involved

drastic reduction in the disposal of spent powder, halved downtime

the pre-treatment process, which moved from 5 to 7 stages, including

required for colour changes, and improved coating film distension and

alkaline degreasing, mains water rinsing, phosphating, further

homogeneity. In a nutshell: extreme application efficiency.”

mains water rinsing, demineralised water rinsing, atomisation of a nanotechnology passivation product, and final demineralised water

The benefits of IPS

rinsing.

Nord Laser’s coating plant already had an automatic powder application

“The requirement behind this improvement was to pre-treat both

booth, which had undergone a minor upgrade of its electrostatic

of our raw materials to the same quality: as is well known, alkaline

generators to improve efficiency. However, the company’s spent

degreasing works best on galvanised sheets whereas phosphating is

paint disposal volumes were still very high, about 12 tonnes per year

ideal for pickled sheets,” indicates Marco Bovolini. “In addition, we were

against a total consumption of 80-90 tonnes. In 2021, it began to make

facing a few issues in the pre-treatment of galvanised sheets along their

contact with some potential suppliers of a new automatic application

laser-cut edges, at the separation between the galvanised surfaces and

technology and eventually chose to invest in Wagner’s advanced IPS

the cut ones. This is why we also introduced a deburring stage before

system, a complete, innovative, and fully automatic solution ensuring

chemical pre-treatment to radius their edges. Our coating process is

consistent finishing results. This entailed a new operator approach to

Qualisteelcoat certified. We guarantee high corrosion resistance (class

the coating cycle, a system meeting all 4.0 and IoT requirements, and

3C) on galvanised sheet metal with pre-treatment + one layer of paint;

the automation of tasks that used to be manual.

we can achieve class C4 with the application of two layers of powder,

“We were assessing two application benchmark systems at the same

but there is currently no demand within our market.”

level. Wagner’s IPS, however, changed the game,” says Marco Bovolini.

“This update on our pre-treatment process is very recent and

“Because of our focus on technological advancement and our desire to

validation with Qualisteelcoat is currently in progress,” adds Bovolini.

stay one step ahead of the competition, we opted for IPS. This solution

“The second upgrade, the one that has brought us huge benefits in

solved two problems that were very important to us: high powder

terms of coating efficiency, was the replacement of the old application

consumption, as we had reached a peak of 12-13 big bags of fine dust

booth with a latest-generation Wagner IPS system, which has led to a

to be disposed of per year, and the long downtimes required for our

© ipcm

One of IPS Master’s gun control modules.

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FOCUS ON TECHNOLOGY

colour changes, about 6 per day. When Wagner presented us with its IPS system, we immediately realised that this new-generation powder

NORD LASER, A CONCRETE PARTNER

centre could allow us to better manage paint consumption as well as our spraying patterns. The advantages in terms of production process management were decisive, rather than those related to aesthetics, which were of less interest to us since industrial products account for 90% of our coating volumes.

“All powder management units on the market have a high level of

50,000 m2 surface area of which 18,000 are covered 20 million Euros in turnover (year 2022)

automation; tasks are sequenced by the system and not managed by

100 customers in 2022

the operator. With IPS, the operators only have to clean the booth and

10,000 t of processed material

the cyclone: for everything else, they only need to press a button. This has enabled us to set a standard process time for colour changes with

130 employees

extreme precision and consistency,” explains Bovolini. “With the old

3-shift work

powder centre, we used to leave 12 load bars empty on the one-rail

2D/3D Solidworks software

conveyor to guarantee enough chain length for the colour change.

Sometimes, this was not even sufficient and the line would stop for up

Business Intelligence

to 30-40 minutes. With IPS, we have reduced the space on the chain for

Quality Certifications

colour changes to 6-7 load bars, i.e. 50% less than before, and we never need to stop the line. While maintaining the same performance degree

Lean Production

of the Imel line, the switch to the IPS system has enabled us to cut our

© ipcm

© ipcm

Operator intervention is reduced to cleaning the booth with compressed air.

With the Smart Feeding Technology, the powder is fed through a pressure container and an electronically controlled dosing valve and generates a soft cloud with little overspray.

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77

© WAGNER

© ipcm

A touch point controlling all the system.

From left to right, Carlo Salvadori from Imel, Alessia Venturi from ipcm, Nord Group CEO Andrea Montich, Nord Group president Marco Bovolini, Matteo Bovolini, and Venanzio Rosada from Wagner.

powder disposal volumes to 1 bag, i.e. a tenfold reduction compared

with a 0.5-bar VACUM unit and pressurised ultrasonic sieving,”

with the previous requirements.”

summarises Rosada. “It also offers the highest level of colour change

“It is undeniable that the old system was more wasteful as it was not

automation requiring no human intervention, centralised control of all

equipped with a parts detection bar, so that the paint guns, 6 on each

process steps, and real-time powder consumption tracking.”

reciprocator, were always on, with considerable dispersion of powder,” says Venanzio Rosada, Wagner’s sales agent for the Friuli Venezia Giulia

A new market benchmark?

region. “However, even if we had implemented a parts detection bar,

“We are still working to fine-tune the management of all the booth’s

we would not have achieved the same results in terms of consumption

parameters and understand in detail the behaviour of high-density

reduction, because IPS has a completely different approach in terms of

application for optimising paint penetration into 3D parts,” states Marco

overspray recovery and filtration, with a very soft suction and feeding

Bovolini. “For Nord Laser, halving our colour change times was crucial

mode that minimises the generation of fine dust. It is important to note

because our plant’s capacity is always saturated. It is undeniable that

that these data are related to products from the same powder coating

the investment required was very high, but I believe that the return on

suppliers, because particle size consistency also plays a key role in

investment is also going to be very high within a very short time. Not to

the creation of fine dust. In essence, IPS is a state-of-the-art powder

mention that this technology could become a new market benchmark,

management system that guarantees stable paint feeding conditions

with a very high future residual value.”

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ENDURANCE VERNICI E RIVESTIMENTI IN POLVERE POWDER COATINGS

IL PRIMER COPRI SPIGOLI THE EDGE COVER PRIMER

ENDURANCE La serie Endurance 16J0, realizzata con resina epossidica leggermente raggrinzata ed additivi ad effetto barriera e passivanti, garantisce un’eccellente copertura dei bordi e quindi un’eccellente protezione.

The Endurance 16J0 series, made with slightly fine textured epoxy resin and additives with a barrier and passivating effect, guarantees excellent edge coverage and therefore excellent protection.

Pulverit S.p.A. Italia Via Carlo Reale, 15/4 20157 Milano-Italy Tel +39 02 376751 email: pulverit@pulverit.it

Pulverit Polska Sp. z o.o. ul. Strefowa 16 43100 Tychy-Polska Tel. +48 32 329 14 11 email: biuro@pulverit.pl

Pulverit Deutschland GmbH Im Wert 3 73563 Mögglingen- Deutschland telef.: +49 7174 7193000 email: info@pulverit.de

www.pulverit.com

Pulverit Iberia s.l.u. c/ Caravis, 28, 1º 3ª 50197 Zaragoza Tel. +34 607163259 email: iberia@pulverit.it

ADVANCEMENTS

The Circular Economy’s Challenges to the Coating Industry and Chemtec’s Answers Carlo E. Guidetti Chemtec Srl, Corbetta (Milan, Italy)

info@chemtec.it

T

he world’s population has grown

resources (gas, water) and energy and as a

the current environmental context and the

exponentially in recent decades

generator of air and solid emissions.

need for change described above.

and it has now exceeded 7 billion

For some years now, the linear economic

development forecasts, it is going to reach

The shift from linear to circular economy

around 10-11 billion people in 2050. Around

The historically existing economic model,

regenerative. Here, the production model

54% of it lives in urban areas and this

referred to by scholars as “linear”, entails a

promotes the minimisation of environmental

percentage is going to increase to 64% in

very simple cycle: taking resources from the

resource use and emissions and the

2050. Cities, in particular, are responsible

planet, processing them to produce goods

consumption model is based on sharing,

for about 70% of anthropogenic emissions

(often using other resources and creating

reusing, repairing, and recycling existing

and contribute to generating about 70%

waste within the production cycle), selling and

materials and products to reduce waste

of total civil emissions, 50% of global waste

using the goods themselves, and disposing

and resource consumption. The differences

generation, and about 60% of greenhouse gas

of them at the end of their service life. This

between traditional and circular economic

emissions1.

traditional system is hardly compatible with

models are summarised in Figure 2.

people. According to various demographic

model has been countered by a new “circular” economic model, conceived to be

The “Country Overshoot Day” is the day of the year when each country goes into ecological debt, i.e. it finishes using all available natural resources for that year in relation to its regenerative capacity. It is, therefore, a true environmental accounting tool: devised by the Global Footprint Network, it uses biocapacity and ecological footprint data to determine when humanity will come to use more resources than it has at its disposal, both globally and locally. As can be seen from the diagram in Figure 1, all advanced economies on the planet consume their resources within the first few months of each year. These data tell us incontrovertibly that the world’s economic system is exploiting the resources of our planet too rapidly.

A global change is therefore required to set us on a path where our living needs are adapted to the available resources. In this framework, the manufacturing industry plays a very important role as a major user of natural Italian Circular Economy Stakeholder Platform, ICESP, 2019.

1

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© Earth Overshoot Day

ADVANCEMENTS

© Ellen MacArthur Foundation

The circular economy and the challenges for the industry

of a shift from the linear to the circular economy.

The circular economy model developed some years

key factors in the coming years for manufacturing

ago by the Ellen MacArthur Foundation shows that,

companies, at least in Europe and in all the world’s

in a circular system, every good is produced utilising

mature markets. Companies such as Freitag2 are

as much renewable energy as possible, minimising

cited by the economists as examples of firms that are

the use of natural resources and designing objects in

already taking advantage of this transition to create

such a way that they are at least partially repairable,

new business opportunities: Freitag manufactures

reusable, reconditionable, or recyclable through

bags and accessories from recycled truck tarpaulins,

simple operations. Some elements of this economic

PET bottles, and unexploded airbags. Even giants

model are already part of our system: let us think, for

such as IKEA3 have started to carry out major

instance, of the market for refurbished smartphones

initiatives to reuse their furniture and components.

or tablets.

In this new phase of the circular economic model, the

A few years ago, the International Organisation for

challenges facing the manufacturing industry can be

Standardisation (ISO) started a formal regulatory

summarised as follows:

process for the circular economy, with standards

• minimised use of environmental resources – water

currently being developed from the ISO 59000 series.

and natural gas

In Italy, the Italian Standardisation Body (UNI) has

• drastically reduced energy consumption from non-

adopted the technical standard UNI/TS 11820:2022,

renewable sources

which allows companies and organisations to

• no use of toxic substances in production cycles

measure their circularity rate by adopting shared

• reduced generation of discharges, waste water, by-

criteria; the current version of this technical

products, and solid waste.

specification includes 71 circularity indicators, divided

Any manufacturing company that would like to

into six categories: resources and components,

anticipate the changes imposed by this shift will

energy and water resources, waste and emissions,

inevitably have to set itself these goals.

It is therefore clear that we witnessing the beginning

2 3

https://www.freitag.ch/en www.ikea.com

EN 1527

H

el

m

A.

logistics, products/services, and human resources.

The ability to adapt to this change will be one of the

Hellas S

.

Chemtec’s responses to the economic transition

and avoiding frequent disposal. Chemtec is

nanotechnology processes to eliminate

currently investigating a solution to reuse such

or significantly reduce these issues.

Chemtec, an Italian company based in

sludge, turning it from waste into a by-product

TORAN 3, for example, is an alternative to

Corbetta (Milan) and specialising in the

for reuse as components in new systems.

phosphodegreasing that does not contain or

formulation, production, marketing, and

Paint-impregnated dry filters, on the other

use water, does not need to be heated, and

industrial application of chemical products for

hand, must be disposed of without the chance

does not generate sludge or waste water of

pre-painting surface treatment and industrial

of giving them a second life.

any kind. The processing oils eliminated in the degreasing stage are incorporated into the

water treatment (waste and process water), can act as a strategic partner to support its

Pre-treatment

operation, becoming an active component of it

customers in this transition.

The pre-treatment of metal surfaces before

and thus respecting one of the basic principles

coating is one of the most environmentally

of the circular economy, namely the reuse of

Overspray management

impactful phases of a finishing process.

waste products. PRONORTEC, on the other

In the field of overspray treatment, there

Traditional processes consume large

hand, reduces water, energy, and natural gas

are two technologies available: dry filters

quantities of water (hundreds or thousands

consumption by around 40-60% compared

and water curtain booths. Regardless of

of m3 per year) and huge amounts of natural

to traditional processes by exploiting organic

any economic evaluation, according to the

gas and electricity to heat or move the large

phosphorous compounds and, therefore,

principles of the circular economy described

volumes of aqueous solutions required for the

operating without the presence of any heavy

above, in many cases the latter are preferable

cleaning and phosphating stages. These create

metals such as chromium, nickel, zirconium,

to the former. Although water curtain booths

solid sludge to be disposed of periodically and

or titanium. The ease of use of these

do use water, through specific equipment

call for the replacement of the mass of liquid

solutions also ensures a very low percentage

and specially formulated chemicals (Figure

1 to 4 times a year on average. It is easy to

of production waste, thus increasing the

3) it is possible to turn the paint overspray

see why traditional cleaning and phosphating

efficiency and quality of industrial processes.

into sludge with a low water content (dry

processes hardly reflect the circular economy

residue of around 60-70%), thus purifying

parameters mentioned above.

Conclusions

the booth water constantly and continuously

Chemtec offers some highly innovative

The transition of the current economic model from linear to circular has already begun.

Several large companies have already adopted changes in asset design, production, and their supply chains to reuse and recycle their manufactured goods and minimise the use of environmental resources. Companies that have not embarked on these projects yet or are looking for solutions in this field can find in Chemtec and its technically innovative processes a reliable partner to jointly tackle the challenges posed to the coating industry by the circular economy.

The author would like to sincerely thank Professor Andrea Urbinati of Liuc University for his invaluable collaboration.

© Chemtec

The flotation plant developed by Chemtec.

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ADVANCEMENTS

More Options for the Coating of Components for Electric Vehicles Frank Siegel Walther Trowal GmbH & Co. KG, Haan - Germany

f.siegel@walther-trowal.de

The demand for sealing components made from elastomers is rapidly growing. A major reason for this increased demand is the e-mobility. To meet the requests of numerous coating job shops Walther Trowal has developed the new Rotamat R 100. Compared to its predecessor models the usable volume of this coater is practically doubled. In addition, the R 100 also allows the coating of sealing components with a wider range of materials such as different types of oil, wax and slow drying lacquers.

R

otamat coaters have established themselves as the ideal solution

Larger components and higher production volumes

for coating sealing components made from elastomers, such as

For their drive trains and accumulator batteries e-vehicles require

O-rings, with anti-friction lacquers. Rotamat machines are also

numerous sealing components. These are not only utilized for the

used for coating thin-walled metal rings - for example, shaft seal rings -

accumulator cells but also for cooling purposes. Even components like

with a bonding agent.

control modules for e-vehicles have their own cooling systems with

© Walther Trowal

Walther Trowal achieves the required dosing precision of the coating materials by utilizing ultra-modern sensor technology and an electro-pneumatic valve.

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ADVANCEMENTS

© Walther Trowal

© Walther Trowal

The new Rotamat R 100 allows the coating of components with diameters of up to 300 mm.

On the right, Rotamat coaters in the final assembly stage at Walther Trowal in Haan.

heat exchangers, where elastomer sealing elements with sizes of up

Utilization of more types of lacquer

to 300 mm are utilized. At coating job shops, already handling millions

Several technical features in the new Rotamat coater now allow

of components, this technological trend created the need for coating

the application of a wider range of lacquers. Some lacquer types,

systems with higher processing capacities. To meet this demand Walther

respectively, coating media demand quick, sometimes even abrupt,

Trowal developed the new Rotamat coater R 100. With a usable volume

cooling of the work pieces after the coating process. To achieve this

of 160 liters and a payload of 100 kg it can process about 1,000 sealing

Walther Trowal added a bypass for the exhaust air coming from the

rings in one single batch. Compared to its predecessor model R 85 it

drum. It allows the air to bypass the heating unit after the spraying

coats twice as many components – within the same cycle time and with

operation and guides ambient air into the drum. This prevents

only marginally higher energy consumption and space requirements.

any residual heat from the heating unit from reaching the coated

The first R 100 will be delivered shortly to a coating job shop in Italy.

components. Therefore, they are not sticking to each other and are

The diameter of the rotary drum in the R 100 is 1,000 mm. To

discharged from the drum as single pieces. The result: A higher yield of

completely cover the entire internal drum space the machine is

work pieces in “1a quality”. Walther Trowal generally equips the Rotamat

equipped with two spraying systems.

coaters with a four-stage exhaust air system. It consists of a Papp

Processing of more oil and wax types

labyrinth filter, a filter mat and two pocket filters. Therefore, solvents contaminating the exhaust air can never reach the environment. This

Another technological trend is the increased use of oil and wax for the

solution has proven its effectiveness and reliability in many coating

coating of sealing components. For example, in medical engineering

applications. With some lacquer types the overspray requires a longer

lacquers are being displaced by silicone oil as the predominant coating

time for curing and becoming dry dust. To prevent sticky lacquer mist

material for high value sealing elements. For obvious reasons: silicone

from passing through the filter and migrate to the exhaust air system

oils are more compatible with the human body. Since they are applied in

of the machine user, Walther Trowal has further optimized its filtration

thin layers, but require a highly homogeneous surface coverage, precise

technology. If needed, fresh air is added to the exhaust air, which causes

dosing within a tolerance of a few grams is essential.

the residual lacquer particles to dry abruptly. The resulting dust particles

Walther Trowal achieves the required dosing precision of the coating

are safely retained in the Rotamat filtration system – a significant benefit

materials by utilizing ultra-modern sensor technology and an electro-

for occupational safety and the environment.

pneumatic valve. This guarantees that the precise quantity of coating material reaches the component’s surface within a given time period.

Higher degree of automation

The result is a consistent coating thickness and long-term quality of the

The automatic drum inclination is another important step towards full

applied coating material on the component.

automation of the Walther Trowal coating systems. A manufacturer

international PAINT&COATING magazine - JULY/AUGUST 2023 - N. 82

85

© Walther Trowal

© Walther Trowal

The Rotamat R 100 coater can safely coat elastomer sealing components with diameters of up to 300 mm.

On the right, a plastic sealing ring before (left) and after coating (right) with an anti-friction lacquer.

of sealing components reported that he had to frequently adjust

pressure control system improves not only the overall process stability,

the drum inclination during the coating process. He noticed that the

but it also simplifies the coating operation.

components not yet coated displayed different tumbling characteristics than the components already coated. To date the inclination of the

About Walther Trowal

rotary drum was activated by an electromechanical drive but had to be

For more than 90 years Walther Trowal has produced and sold modular

initiated manually. In the new Walther Trowal Rotamat coaters the drum

and custom-engineered solutions for the most difficult challenges in the

inclination is fully automated, and the respective process parameters

field of surface treatment and refinement.

are part of the PLC processing programs for the various work piece

While initially focusing on mass finishing, over time Walther Trowal has

categories. The machines now automatically adapt the drum inclination

continuously expanded its product portfolio. Today the company offers

to the required coating buildup on the work pieces and are, therefore,

a broad range of mass finishing, shot blasting and coating equipment

running fully automatically during the entire coating process. Even with

for surface refinement, cleaning and drying of a variety of work pieces as

applications requiring multiple changes of the drum inclination the only

well as coating of mass-produced small parts.

manual operations are the loading and unloading of the rotary drum.

Walther Trowal develops and implements complete surface treatment

Higher process stability

solutions: By linking and automating various processing modules Walther Trowal adapts the respective process technology to the specific

With the new control system for dosing the coating material Walther

requirements of the customers. This also includes peripheral equipment

Trowal was able to further improve the process stability of the Rotamat

such as process water cleaning and recycling systems. Comprehensive

coaters. The new system automatically adjusts the pressure so that

services like processing trials with the customers’ work pieces or the

under different operating conditions the specified amount of coating

global repair and maintenance service are rounding off the company

material is precisely applied to the surface of the components. In

program.

addition to the sophisticated temperature management and the exact

Walther Trowal serves customers in a wide range of different industries

fresh air flow, the new pressure regulator ensures optimal conditions in

all over the world, for example, automotive, aerospace, medical

the rotary drum during the entire coating operation. However, the new

engineering and wind power.

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HIGHLIGHT OF THE MONTH

Brief Notes on the Development of Sustainability-oriented Technologies through Automation, Energy Efficiency, Digitalisation, and AI Used in Industrial Coating Processes Alessandro Soba Verind Spa, Rodano (Milan) – Italy

alessandro.soba@verind.it

Part of the international Dürr Group, VERIND designs innovative technological solutions by integrating knowhow, industrial systems engineering, equipment, and specific eco-technologies for paint, coating, and waste water treatment processes. A common element of all economic developments is energy (and its consumption), which has always been seen as the engine of progress itself. Any industrial process can be analysed in terms of energy, efficiency, and environmental friendliness with a technological approach that directs the production process to minimise raw material consumption, improving the overall energy balance and thus waste and costs. © Dürr

T

he final stage of a production process is generally a surface finishing operation. This has a significant impact on the environment in terms of emissions, creation of special waste,

and water pollution. It is also an energy-intensive manufacturing stage with high energy consumption, which further impacts the environment by reducing natural resources.

Technological innovation, automation, and processing of data derived from field sensors, supplemented by digitalisation and AI: this is the mix of skills that Dürr brings into play to meet today’s sustainability criteria.

With this in mind, innovative engineering choices are now being made more and more often for highly productive and environmentally friendly coating lines, with the following aims: • Reducing the energy consumption of individual processes • Reducing global CO2 emissions

• Reducing consumption of products used and raw materials • Reducing liquid and gaseous discharges • Increasing efficiency and quality • Optimising the cost per unit produced • Integrating automation and digitalisation • Increasing efficiency through flexibility.

Through innovation and applied research, the Dürr Group has developed, in particular, important technologies for the automotive and industrial sectors.

HIGHLIGHT OF THE MONTH

© Dürr

The paint feeding system EcoSupply P.

EcoBell electrostatic technology

to the considerable increase in the variety of colours

This rotary atomiser with 2- or 4-needle technology

required by the automotive and commercial vehicle

and a compact external loading unit, ideal for use

sector as well as the industry in general, the scraping

on both automotive and general industry lines,

technology has been used for a long time now both

guarantees maximum finishing quality, minimum

for handling special or customised colours and for

coating product consumption, and quick colour

colours to be applied on small batches. EcoSupply P

change times. It especially allows saving paint in high

allows saving paint and cleaning products, especially

quality and high productivity processes, thanks to

in production lines where frequent colour changes

the electrostatic effect that ensures high transfer

are required. Unused paint in the pipes is recovered

efficiency values.

in the paint drum and reused.

EcoSupply P technology It is a standardised, modular paint feeding system

EcoPaintJet - OFA (Overspray Free Application) technology

with scraping technology that can be used for

High customisation: this is the prevailing demand

water- and solvent-based coating applications. Due

of the market. Examples of this are the creation of

FORNITURE TECNICHE PER LA VERNICIATURA INDUSTRIALE

Via Fermi, 9 Zelo Buon Persico (LO) Tel. 02 90 66 92 40 r.a.

info@guerrasrl.it www.guerrasrl.it

two-tone car roofs or the application of striped designs on various

© Dürr

products. EcoPaintJet is an innovative system for automated, overspray-free coating, a perfect combination of robots, measuring systems, and applicators that guarantees selective paint application. Equipped with sensors, its measurement system monitors the surface to be coated and sends data to the plant’s management software, which constantly calculates in which tracks the applicator is to be guided and how much paint is to be dosed.

It allows saving paint in production lines devoted, for example, to two-tone surfaces. It eliminates overspray and the need for masking operations and it reduces process energy consumption.

In summary, this technology enables to perform highly sustainable processes.

Coating process digitalisation with DXQ The goal is to apply efficiency measures at all phases of the coating process to systematically increase productivity, reduce unit costs while maintaining the highest quality, and improve sustainability. DXQ is a powerful industrial tool offering solutions for the operation, analysis, and control of modern industrial plants.

It allows large volumes of data to be processed and analysed to optimise processes, thus guaranteeing optimised energy consumption, higher production rates, and smart spare parts ordering to minimise the impact of preventive maintenance.

Commitment to sustainability Dürr also expressed its concrete commitment to sustainability by joining the “Business Ambition for 1.5 °C” coalition, a global initiative by Race to Zero and UN Global Compact, and by presenting its Sustainability Report according to the GRI standards as well as its ECOVADIS sustainability rating document.

EcoPaintJet is the innovative system for automated, overspray-free coating.

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P

o

w

de

r

i

n

s

i

d

e

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 have always been a guarantee of high resistance also in difficult enviroments.

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

info@europolveri.it - www.europolveri.it

ADVANCEMENTS

Eliminate Masking from Coating Operations with Lasers Guillaume Jobin Laserax, Quebec – Canada

gjobin@laserax.com

Laserax has developed an innovative laser solution which can replace the manual masking operations of the areas that need to be protected before coating.

M

asking is widely used in coating operations to cover or protect

costly, but they are typically applied manually, which is labor-intensive

certain areas of a part that should not be coated. Common

and can lead to inconsistent results due to manual errors.

techniques include the application of specialized masking

For many manufacturers, masking has become a necessary evil to

tapes, plugs, caps, and fixtures to protect specific areas from powder

ensure quality for sequential processes. For welding, surfaces must

coating, e-coating, and other types of coatings.

be free of contaminants that could penetrate the welds. For assembly,

Masking can be a time-consuming process, especially for complex

screws and bolts adhere better to bare metal surfaces than to coated

geometries. It is also expensive. Not only are masking consumables

surfaces.

© Laserax

Today’s laser systems provide micron precision. That enables them to remove coatings from specific areas without impacting other areas: this image shows well the selective nature of laser process.

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ADVANCEMENTS

Laser alternative to masking

the underlying metal. This process is done

Selective removal

There is another option. Laser coating

using a laser system, which generates laser

Today’s laser systems provide micron

removal is an innovative process that enables

beams that carry huge amounts of energy.

precision. That enables them to remove

manufacturers to eliminate masking from

A portion of this energy is absorbed by the

coatings from specific areas without impacting

coating operations. Instead of manually

surface, causing it to heat up.

other areas. For example, lasers can be used

1

to remove coatings from areas to be used for

masking areas that need to be protected

welding or assembly without removing the

before coating, manufacturers can simply coat

The speed of laser coating removal is affected

the entire part, and then use a laser to remove

by the type of coating, its color, and its

coating from other areas.

the coating from specific areas.

thickness. For example, thicker coatings will

With their smaller spot size, single-mode lasers

Lasers feature highly-efficient precision

take a longer period of exposure to the laser

are more precise than multi-mode lasers and

control, reducing errors and ensuring parts

or require multiple passes. Also, different

are best suited when specific, repeatable

are ready for the next phase of production.

types of coating have different ablation

shapes need to be cleaned, especially

thresholds, and different colors absorb laser

when working on more delicate or sensitive

light at different ratios.

materials.

Laser coating removal: how it works Coatings and metals have an ablation

Manufacturers need a laser coating removal

threshold2 — the temperature at which they

solution adapted to their needs. Depending

Speed of process

vaporize into dust and fumes.

on the operation and materials used, higher-

Lasers will significantly speed up the process

Lasers can be used to bring coatings to their

powered lasers may be needed to accelerate

by eliminating manual or machine masking.

ablation temperature to eject them from

the ablation process.

For manufacturers, this translates directly

metal surfaces. Since the ablation threshold

into more efficient throughput, efficiency, and

of metals is much higher than that of coatings,

The benefits of laser coating removal

coatings can be removed without damaging

Laser coating removal offers several key

With their larger beam size, multi-mode

benefits compared to traditional methods of

lasers are ideal for processing larger areas.

masking.

They can also reach higher laser power levels

https://www.laserax.com/blog/coatings-removal 2 https://www.sciencedirect.com/topics/engineering/ ablation-threshold 1

productivity.

than single-mode lasers, allowing them to deliver more energy at once for faster coating removal.

No damage Abrasives can cause damage to the bare metal surfaces, especially if it is soft or thin.

Laser coating removal is a great alternative when abrasives create defects. As a noncontact process, it eliminates the risk of mechanical damage to the substrate. Unlike abrasive methods, it is possible to remove coatings without affecting surface roughness.

Improved adhesion Laser cleaning can remove coatings and, at the same time, create a surface texture that increases friction. This improves the adherence of mechanical fasteners during assembly. It can also be used to improve the

© Laserax

bonding of adhesives.

The laser process generates laser beams that carry huge amounts of energy.

A portion of this energy is absorbed by the surface, causing it to heat up.

international PAINT&COATING magazine - JULY/AUGUST 2023 - N. 82

93

© Laserax

© Laserax

EV stator connector tabs, before and after epoxy powder coating removal.

Consistent, repeatable processes

Enhanced safety

Masking is marred by imprecision, especially when handled manually.

Today’s laser solutions are extremely safe. With a laser safety enclosure

No matter how careful operators are, there will always be some level of

and a dust extraction system, operators do not need to wear PPEs near

deviation between applications.

lasers. They also do not need to handle any dangerous chemicals or

Even experienced and well-trained operators suffer from errors due 3

to the repetitive nature of masking. Lasers don’t make errors. They are

materials for use with the laser.

computer programmed and are equipped with tools to adjust the laser

Limitations of laser coating removal

process based on deviations.

Laser coating removal offers attractive benefits. However, there are some challenges that manufacturers should know about in using lasers.

Easier automation

Limitations include:

Lasers are easier to automate than alternatives. Unlike abrasive

• Thicker coatings: laser coating removal works well with coatings that

blasting , there are no dust contaminants to manage, little maintenance

are 300 microns or less. But when coatings are thicker, the process may

is needed, and the process is fully managed by a computer controller.

require several laser passes making it less efficient. The process can still

4

be done, but it will take more time.

Lower operating costs

• Does not work for all coatings: clear coats and certain types of

Compared to alternatives, lasers have significantly lower operating costs.

translucent coatings or varnishes do not absorb the laser’s light

Once they are programmed, they do not require operators and use no

efficiently. They are simply bad candidates for laser coating removal.

consumables. They are extremely low maintenance and are incredibly

• Heat generation: some materials may be sensitive to the heat from the

durable.

laser, creating the potential for damage or discoloration.

• Fume filtration: a fume filtration and extraction system is needed in the

More environmentally friendly

laser enclosure to prevent toxic fumes from being released into the air.

Laser coating removal does not use harmful chemicals or generate

While lasers are low-maintenance equipment, they still require manual

hazardous waste. Pulsed laser systems also have a low power

filter replacements.

consumption and are extremely energy efficient, minimizing the

• Large areas: if the coating that needs to be removed covers a large

environmental footprint. Lasers also work in a compact space, often

area, multiple lasers may be needed to meet cycle times. This quickly

reducing the space required for manufacturing and further reducing

drives up costs and can negate the business case for purchasing a laser.

energy consumption.

• Complex shapes or complete parts: laser coating removal may not be the best solution to clean complex shapes or complete parts, as

https://www.assemblymag.com/articles/97027-top-5-human-errors-in-manufacturing 4 https://www.cdc.gov/niosh/topics/blasting/default.html 3

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adjusting the laser angle often may not be mechanically possible.

• Open space cleaning: performing laser coating removal in an open

ADVANCEMENTS

space is challenging because laser safety

By embracing laser coating removal,

measures are difficult to apply. Typically, laser

manufacturers can unlock the potential

processing is done in a class-1 laser safety

for significant advancements in efficiency,

enclosure to contain the laser beam and its

quality, and productivity. Lasers represent an

reflections.

innovative way to manage coating operations

An innovative solution for coating operations In today’s manufacturing environment where it’s increasingly difficult to recruit and retain a

and offer a promising future that paves the way for automation and improved quality control, delivering a competitive advantage in

About the author

much of the masking and cleaning process

Trained as a Mechanical Engineer, Guillaume

to overcome labor shortages. Finding such

Jobin has more than 10 years of experience

efficiencies will be increasingly important for

in automation and control. He is Supervisor

manufacturers. A recent report from Deloitte

of Application Specialists at Laserax, where he

and the Manufacturing Institute reports

oversees the team that analyzes clients’ needs

that 2.1 million manufacturing jobs could go

and that designs the right laser solutions for

unfilled in the US by 2030 .

them. He is also a member of the Corporate

https://www2.deloitte.com/us/en/insights/industry/ manufacturing/manufacturing-industry-diversity.html

5

© Laserax

the marketplace.

high-quality workforce, lasers can automate

5

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ART WITHIN SURFACES

The Symbiosis of Industry and Design in the Exhibition “Red in Italy - I Colori del Rosso nel Design Italiano” Edited by Hill + Knowlton Strategies for Campari Group

The Italian Ministry of Enterprises and Made in Italy presented “Red in Italy - I Colori del Rosso nel Design Italiano”, an exhibition project devoted to red throughout the history of Italian design conceived by Campari Group and sponsored by Altagamma.

T

he exhibition “Red in Italy - I Colori del Rosso nel Design Italiano”

series of objects that symbolise Italian design and spur many possible

(i.e. Red Colours in Italian Design) was inaugurated at Palazzo

aesthetic and cultural comparisons. “This event and the inauguration

Piacentini, the headquarters of the Ministry of Enterprises

of the “Red in Italy” exhibition are particularly significant for Italy, at

and Made in Italy in Rome, on 31 May. It was conceived by Campari

a time when our country has shown more growth than many other

Group, one of the major international players in the spirits sector,

Western economies. And the credit goes to our companies,” said

and sponsored by Altagamma, the foundation established in 1992

Minister of Enterprises and Made in Italy Adolfo Urso during the opening

to bring together the best companies from the high cultural and

ceremony. “Today, we can see many examples of Italian excellence

creative industry that strive to promote Italy’s excellence, uniqueness,

here, from food to fashion, from design to cars, recognised worldwide

and lifestyle around the world. This project, designed and curated

for their high quality and value. We would like to thank Altagamma and

by Francesca Valan with the staging by FG Confalonieri, is aimed at

Campari Group for this important project that contributes to spreading

exploring all things red (whose history and evolution was analysed by

Italianness and our products of excellence around the world.”

an article1 in the previous issue of ipcm®, Ed.) through the display of a

“The “Red in Italy” exhibition weaves a common thread among the most

https://www.ipcm.it/en/open/ipcm/2023/81/178-180.aspx

© Mauro Serra

1

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ART WITHIN SURFACES

iconic objects manufactured by the numerous Altagamma member

art, culture, and sociology – as did the rich and surprising history of this

companies that embody the Italian lifestyle and our country’s creative

colour, which has evolved together with the expression of Italianness

and aesthetic skills,” stated Stefania Lazzaroni, General Manager of

all over the world. The exhibition thus explores several Italian designer

Altagamma. “Altagamma has been promoting Italian excellence for

objects, guiding the visitor along a true immersion in colour at the

over thirty years now, representing a sector worth 144 billion Euros,

discovery of the many Italian products of excellence characterised

around 7.4% of Italy’s GDP. We feel honoured to be at the side of the

by red shades. In addition to the unmistakable Campari red, present

Ministry of Enterprises and Made in Italy and of Campari Group, one our

with a limited-edition bottle created especially for the exhibition, other

member companies, for this high cultural-value project involving so many

iconic reds are on display here, including those of companies Artemide,

well-known design, automotive, and fashion brands. This is a virtuous

Brembo, Driade, Ducati, F.I.L.A. Fabbrica Italiana Lapis ed Affini, Ferrari,

example of institutional cross-sectoral cooperation, a distinctive trait of

FontanaArte, Orsoni Venezia 1888, Gruppo Cimbali, Gufram, Magis,

our foundation, and of talent enhancement.”

Moleskine, Alessi, Museo Kartell, Opinion Ciatti, Poltrona Frau, Rossignoli,

“After a début in Brussels in 2019, we are proud to have brought “Red in

Salvatore Ferragamo, Serralunga, Smeg, Stilnovo brand of Linea Light,

Italy” to Italy, where it all began, and we would like to thank the Ministry

Tecno, Trenitalia, Venini, and Zanotta, as well as Panzeri as the technical

of Enterprises and Made in Italy and the Altagamma foundation for

sponsor for the exhibition lighting system.

believing in this project,” said Sascha Cumia, the Managing Director of

The “Red in Italy” exhibition created by Campari made its début in

the Southern Europe, Middle East, and Africa division of Campari Group.

Brussels in September 2019, with the aim of promoting the iconic

“This exhibition confirms Campari’s prominent role as an Italian company

Italian brands that have contributed to the symbolic construction of

of excellence appreciated worldwide, among the most recognisable

Italy’s image in the world. Curated by Valan and FG Confalonieri with

symbols of our lifestyle. It also emphasises the role of our Group as an

the coordination of Galleria Campari, this project was inspired by the

active participant in the promotion of culture in Italy and abroad.”

success of the exhibition “I colori del Rosso” (i.e. The Colours of Red),

The exhibition starts with Campari’s iconic red, which inspires a

organised at the Galleria Campari spaces in Sesto San Giovanni (Milan)

reflection on the red hues that have characterised civilisations on a

in 2015 on the occasion of Expo Milano.

global level, to tell the story of the creations of some of the most famous

The Rome edition of “Red in Italy”, hosted by the Ministry of Enterprises

designers of the 20th and 21st centuries, who have contributed to the

and Made in Italy, was open to the public on Saturdays 3, 10, 17, and 24

symbolic construction of Italy’s image abroad by interweaving design,

June 2023.

© Mauro Serra

© Mauro Serra

© Mauro Serra

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© ipcm

FOCUS ON TECHNOLOGY

CEB Invests in Flexibility and Repeatability Through Robots Capable of Self-Generating Powder Coating Programmes Gabriele Lazzari ipcm®

During the most difficult years of the economic crisis, CEB has distinguished itself by investing in improving the quality and speed of its production lines. Seven years after the installation of a new powder coating plant, it further enhanced its performance with two CMA Robotics robots capable of self-generating three-dimensional coating programmes through the AXPS-BOX system.

C

EB S.p.A. is a company specialising in the processing of iron and stainless steel sheet parts for the production of electrical equipment such as cabinets, enclosures, and control desks,

founded in 1980 in Montebello Vicentino (Vicenza, Italy). Its professional experience, technical skills, flexibility, and in-depth knowledge of manufacturing dynamics and market needs have made it highly competitive through the offer of a diverse and complete range of solutions to customers all over Italy, supplying both mass-produced and customised units to be installed indoors and outdoors and able to meet any requirement in the metallurgical, metalworking, and food industries.

In addition to guaranteeing excellent safety and resistance properties to protect electrical circuits in the long term, CEB’s cabinets are also required to have finishes with a high aesthetic level and matching the main colours of the structures in which they are located. This is why in 2016, the company equipped itself with a modern powder coating plant

FOCUS ON TECHNOLOGY

© ipcm

The power&free overhead conveyor supplied by Futura Convogliatori Aerei.

designed and built by Imel to cope with growing market demands,

degreasing at 55 °C, rinsing with mains water, rinsing with demineralised

which was the subject of an in-depth article1. In addition, to further

water, passivation with Chemetall’s nanotechnology product Oxsilan®,

improve the quality of its offer and its lead times, it has recently

and final rinsing with demineralised water) and before entering the

installed two GR-680 articulated robots with their corresponding

drying oven at 110° C.

software package and the exclusive AXPS-BOX system, which uses

Designed, built, and installed by Imel, the coating system is equipped

three-dimensional scanning technology to allow identifying not only the

with 2 Gema MagicCylinder® EquiFlow automatic booths with their own

type of workpiece entering the booth but also its incline degree and

reciprocators for rapid colour change operations.

its position and adapting the automated coating programme and its

These apply epoxy and polyester powder paints to the sheets that make

trajectory accordingly.

up CEB’s cabinets, intended for outdoor use and therefore subject

Upgrading the powder coating plant

to harsh environmental conditions. However, due to their complex geometry, manual pre-processing used to be often necessary in the

An operator hangs the parts onto the 31 load bars (with a maximum

past. Indeed, this coating plant and all other recent technology upgrades

capacity of 5,500 x 1,000 x 2,200 millimetres and 500 kilograms) of the

have enabled CEB to increase its production capacity: this has also

Futura Convogliatori Aerei two-rail overhead conveyor (with a speed

translated into a growing demand for complex-shaped enclosures,

of 2 metres per minute) so as to facilitate their draining following the

panels, and boxed parts with multiple cavities, curves, and angles. The

spray pre-treatment process performed in a 5-stage tunnel (alkaline

booth applying different tints is equipped with quick colour change

“A system for applying powders that guarantees high productivity, paint savings, and consistent quality for large components, M. Fumagalli, in ipcm®_International Paint&Coating Magazine no. 39.

1

features and Venturi-technology injectors, whereas the single-colour application booth is equipped with OptiSpray AP 01 paint feed pumps.

international PAINT&COATING magazine - JULY/AUGUST 2023 - N. 82

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© ipcm

CEB panels at the entrance to the spray pre-treatment tunnel.

© ipcm

Overview of the coating plant provided by Imel.

The two articulated robots from CMA Robotics’ GR-680 series were

solutions, which performed different tests to better understand CEB’s

recently installed on the latter.

needs. Two 6-axis electronically controlled articulated robots capable

“The coating process of these components starts with a pre-finishing

of self-generating three-dimensional coating programmes through the

phase on their inner surfaces. This was carried out by two specialised

AXPS-BOX system were thus installed in June 2022. Like the entire range

operators, who, however, after a few hours of work, experienced a

produced by CMA Robotics, the GR-680 robots are designed to spray

physiological drop in performance, either decreasing the speed of their

both powder and liquid paints on metal, wood, and plastic surfaces

movements or increasing the distance between the spray gun and

and they are certified to operate in ATEX areas by a specialised external

the workpieces. However, we want our coating quality level to be high

body. Another peculiarity is the special configuration of their wrists,

and, above all, consistent. Therefore, this caused delays for the entire

which, by rotating each axis through 360°, makes it easy to reach any

production, as well as wasting materials. We talked with Gema and Imel

point on the workpiece to be coated.

about the issue and they suggested we turn to an articulated robot

Each robot can mount several guns or rotary bells at the same time and

manufacturer to find the best solution for our requirements,” says CEB

integrate perfectly with any airflow and paint control device through

owner Silvano Biasin.

the internal control system, which has extremely sophisticated yet

Robots capable of self-generating coating programmes

user-friendly software and diagnostic tools. “The 2D self-generation of coating programmes is a well-established feature for treating doors,

The company, therefore, sent some samples to the Pavia di Udine

windows, and frames, but the design of a 3D system for coating boxed

(Udine, Italy) site of CMA Robotics, a manufacturer of automated paint

profiles was also new to us. At CEB, the components entering the

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FOCUS ON TECHNOLOGY

coating booths are hung onto the conveyor with varying incline degrees depending on their size and weight: therefore, a normal scan would not have allowed the robots to correctly carry out the programme assigned to each type of part,” explains Marco Zanor, sales director at CMA Robotics. “However, we were not discouraged at all: after some trials, we managed to develop a tailor-made solution to meet all CEB’s needs. The 3D part-scanning device placed at the booths’ entrance does not only detect the shape of the incoming component but also its incline degree and its position. The AXPS-BOX system then uses pre-set rules to automatically self-generate the paint programme that ensures the coating is applied evenly to all its interior and exterior surfaces.”

In this way, also following the further coating operations occurring inside the Gema booths,

© ipcm

Gema’s booth and OptiCenter powder management unit.

© ipcm

The guns for powder coating application.

© ipcm

The 3D part detection unit at the entrance to the booth.

all products leave the system with a homogeneous coating layer and

extended periods of time. The two robots have enabled us to maintain

can be taken to the curing oven, where they dwell for 25 minutes at

a speed of 17 load bars per hour with components that can reach up to

180 °C, and then to a storage buffer for cooling at room temperature.

2.20 metres in height. In addition, the operators previously employed

Finally, the operators unload the parts, which are ready to be

for this coating phase are now assigned to the assembly and packaging

assembled, packed, and shipped.

one. This means that we have not only speeded up our coating

Consistent and repeatable coating even with complex geometries

operation but rather our entire production flow,” notes Matteo Biasin,

With this investment, CEB has therefore improved its production flow

the production manager of CEB.

and the quality of its coated components. Previously, it was necessary

“We did not know the full potential of this new system, but we decided

to stop the chain or carry out post-finishing operations after assembly.

to rely on the professionalism of CMA Robotics and this paid off. In

“Now, our production rate is constant and the applied coating film

your last article, I stated that the productivity of our new coating plant

is more uniform even on complex-shaped parts. As mentioned, the

was still difficult to assess as it had only been operating for a while,

physiological fatigue inherent in activities like manual spraying makes

but that some aspects, such as powder saving and coating speed and

it difficult for operators to faithfully repeat the exact same gesture for

efficiency had already clearly improved. The same applies to this new

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© ipcm

The GR-680 coating robots supplied by CMA Robotics.

investment: our CMA robots have only been fully operational since the end of September 2022, but we have already seen an increase in the quality of the applied film and a reduction in the resources used.

In fact, together with Imel, we are already studying how to lengthen the conveyor chain to create more storage buffers and expand the loading and unloading area. Imel’s technicians just helped us modify our line to accommodate the two robots and proved to be willing to listen to our needs and quickly implement the most appropriate solutions. This new upgrade could enable us to further increase the profitability of our entire powder coating plant,” says Silvano Biasin with satisfaction.

HIGHLIGHT OF THE MONTH

Seven Quality Tests for Coating Processes According to Argos ST Edited by Argos Srl Cambiago, Milan (Italy)

In order to verify the high quality of the coating processes it carries out, the Foresi plant of the Argos ST Group can generate measurement reports at its customers’ request, using three main methods: cross-hatch test for checking adhesion, thickness measurement, and gloss measurement. Four additional performance assessments can only be performed by certified laboratories, namely the continuous and alternating salt spray tests, the prolonged immersion test, and the accelerated ageing test.

C

hecking the quality of its coating processes at the request of customers. This is one of the activities of the Argos ST Group’s Foresi plant, a leading company in the

field of surface treatments, including three types of industrial coating processes: cataphoresis (or e-coating), powder coating, and liquid coating, also with high-temperature liquids. These treatments are instrumental in preventing corrosion of materials such as iron, steel, and other alloys while ensuring greater resistance; specifically, coating with high-temperature liquids enables any metal part subsequently subjected to particularly high temperatures to maintain a good seal.

Measuring the quality of coating processes: Foresi’s tests There are three types of checks that Foresi adopts to assess in-house the quality of its coating processes: cross-hatch test for checking adhesion, thickness measurement, and gloss measurement.

• Cross-hatch adhesion test: a method that uses a special comb tool and a standardised tape to determine the peel strength of paints and coatings with respect to the substrates by creating a right-angled grid on their surfaces. More precisely, the grid incisions performed must be the same distance apart both vertically and horizontally, reaching down to the substrate. By applying the adhesive tape over the entire incision area and then vigorously removing it, it is possible to visually determine the outcome of the test. If no squares have detached from the grid, if the detachment is limited to 5% of the area and to the intersections of the cuts, or if the paint has detached along © Argos ST

the edges of the cuts and at the intersections in 5-15% of the The main activities of Foresi include cataphoresis, powder coating and liquid coating.

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area, the coating process carried out is deemed successful. On the other hand, if the paint has peeled off along the edges of

HIGHLIGHT OF THE MONTH

the cuts or in the squares in more than 15% of the area, depending on

•The salt spray test is a standardised test to check how well a surface

the extent of the damage, the surface needs to be scraped partially or

coating protects the substrate from corrosion. Corrosion resistance

totally before re-coating.

tests on cataphoresis layers last less than 500 hours, whereas test times

• Thickness assessment: the coating’s thickness can be measured on

for combined cataphoresis and powder coating applications extend

both smooth and rough surfaces using special instrumentation.

beyond 500 hours. The test is carried out inside a chamber where

• Gloss measurement by reflectometer (BYK-Gardner Micro-TRI-

the test salt solution (5% NaCl) is atomised at 35 °C; the resulting mist

Gloss): for a coating process to be considered of good quality, it must

creates a particularly corrosive environment, which allows measuring

necessarily guarantee constant and uniform gloss, whatever the

the degree of corrosion of the sample by the end of the test. During the

treated surface. Especially in the case of multi-component products, a

test, some partial outcomes can be recorded to monitor the progress of

uniform gloss degree is proof of the high quality of the treatment and,

the corrosion process.

consequently, of the end material obtained. In order to measure gloss

• A specific method called alternating salt spray test is similar to the

objectively, a glossmeter is therefore used, which can be employed on

one just described, but it is based on the alternation of phases when

paints, plastics, and even mirror-like metals.

the material is exposed to salt spray and phases of rest, simulating the stress to which the treated part is going to be subjected over time. Such

Four other useful tests for verifying the quality of treatments

alternation can be programmed by the climatic chamber to perform several cycles with a different duration.

Four additional assessments can be performed by certified laboratories

• The adhesion test is carried out by soaking the treated part in water

to check the quality of the coating treatments performed: the salt spray

for 24-48 hours. After this time frame, the paint’s adhesion degree can

test to monitor corrosion resistance, the cyclic corrosion tests, the

be assessed.

adhesion test carried out after 24-48 hour water immersion, and the

• Finally, the accelerated weathering test makes it possible to reproduce

accelerated ageing test.

– in the laboratory and within a very limited time frame – the damage

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© Argos ST

© Argos ST

© Argos ST

© Argos ST

From top left, clockwise: The Foresi headquarters; Foresi carries out numerous tests to verify the quality of the surface treatments; Cross-hatch test for checking adhesion; Product painted in the Foresi factory.

that the material would suffer if exposed to sunlight, rain, and dew

About Argos Surface Technologies

for several months or years. Special UV lamps are used, so that the

Created by the Gradiente II private equity fund, the new Argos Surface

materials to be tested are subjected not only to high and controlled

Technologies Group was born in 2020 from the merger of major players

temperatures, but also to moisture.

in the metal surface treatments and coatings industry, with the aim of

“Coating processes undoubtedly contribute to excellent aesthetics,

creating a leadership position in the sector. In 2020, the Group started

but they also play an important functional role,” commented Guido

with the acquisitions of Argos, Impreglon Italia and Aalberts ST. In 2021,

Ghilardi, the managing director of Argos ST’s plants in Gonzaga e

it acquired the Emilia-based TSM (today Argos TSM) and Lualma Anodica

Borgaro Torinese. “Although we are not a laboratory that can carry out

(today Argos Lualma) and in 2022 the Bergamo-based TEC.RI.MET Srl, the

official tests and issue certifications, we do perform tests at the request

Mantua-based FORESI S.p.A., and the Turin-based Rotostatic. The Group

of our customers at our premises, which enable us to monitor the

now boasts nine plants: Gonzaga (Mantova), Origgio (Varese), Cambiago

effectiveness of our coating processes. This is a very important activity

(Milan), Calcio (Bergamo), Opera (Milano), Monteveglio (Bologna), Imola

for us, because it allows us to guarantee the high quality of our work

(Bologna), Minerbio (Bologna), and Borgaro Torinese (Torino), with more

and, if necessary, to take any corrective actions.”

than 300 employees and a turnover in excess of €50 million.

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© T&G

General view of the Euroimpianti Komby plant, the latest acquisition of T&G Verniciatura Industriale in Castione di Loria.

FOCUS ON TECHNOLOGY

T&G: The Loyalisation of the Coating Plant Engineering Partner to Support the Company’s Growth Alessia Venturi ipcm®

A coating contractor needs three things to grow: entrepreneurial spirit, specialisation in a few niches, and the right plant engineering partner. In its twenty-year history, T&G (Castione di Loria) has managed to combine all of them, in particular relying on Euroimpianti’s expertise for its equipment.

A

n entrepreneurial spirit is a mindset focusing on change,

and choices and for the effects they will have on one’s business. Not

innovation, and continuous improvement. Audacity and risk are

everyone has it – not even many entrepreneurs. But there are also

synonymous with entrepreneurship. Having such an attitude

people who, on the contrary, have entrepreneurial spirit to spare,

means taking responsibility (and therefore the risk) for one’s ideas

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such as partners Enrico Troisi and Luca Girolimetto, two friends and

FOCUS ON TECHNOLOGY

colleagues who founded T&G Verniciatura Industriale in 2002 after an experience as coaters at another local company.

In twenty years, Enrico and Luca have never shied away from the challenges posed by the market and they have made many bold investments to build what T&G is today: a leading liquid and powder coating contractor in the machine tool and automation sector, with three factory halls in Castione di Loria (Treviso, Italy), three powder coating plants, several liquid painting booths for the application of corrosion protection products, an automatic shot blasting machine, and a manual sandblasting cabin.

In addition to the resourcefulness of its two founding partners, T&G achieved such success also thanks to its ongoing partnership with © ipcm

coating plant engineering company Euroimpianti and the total trust placed in its owner, Gianluca Baruffaldi, who has always supported T&G’s growth by offering advice and consultancy on all things paints.

With time, this partnership has led T&G to install the complete range of industrial coating equipment manufactured by Euroimpianti: first the Eurocar system, then the Euro90 automatic plant with a one-rail conveyor, and finally, a few months ago, a “hybrid” Komby system with an automatic load bar drive unit designed by Railtechniek.

“Each of the modular lines in Euroimpianti’s range was well suited to meet our growth needs at a particular point in our journey,” notes Enrico Troisi. “Guided by Gianluca’s experience, we have chosen the most suitable system from time to time, modifying it or hybridising it to personalise it and adapt it to our production flow.

Currently, our equipment enables us to meet a multitude of coating requirements from the mechanics and automation sectors, which are very flourishing in our area (around the city of Galliera Veneta,

© ipcm

Editor’s note), with many manufacturers of heavy machinery, from drill rigs to pasta production lines, relying on contractors to paint their components.”

The history of T&G Founded in 2002 and operational since March 2003, for the first five years T&G only offered liquid coating services in a small, 400 m2-wide factory. In 2008, the implementation of a powder coating process marked a turning point and the company moved to its current site in Castione di Loria.

“My encounter with Gianluca Baruffaldi and the beginning of our powder coating-oriented partnership dates back to that year, with the purchase of our first plant, Eurocar 5, capable of coating parts up to 10 metres long. This system enabled us to powder-coat both smaller and larger components, thus completing our offer in addition to the application of liquid products, especially corrosion protection ones. In 2008, we also purchased a manual sandblasting cabin to further improve the quality degree of both liquid and

© ipcm

From top: T&G coats large parts for leading heavy machinery manufacturers.

The coating booth of the Eurocar plant.

General view of the Euro90 automatic system.

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© ipcm

© ipcm

The Euro90 plant’s automatic powder application booth and the OMSG Tunnelblast 3000x3000 automatic shot blasting system.

powder coatings through mechanical pre-treatment.

customers as much as possible towards powders, limiting liquid coating

“In 2013, we decided to invest further to expand our range of surface

to corrosion protection systems only.”

treatment services,” adds Luca Girolimetto. “In two years, we bought a new building next to the first one to accommodate an OMSG automatic

Three plants for three different coating requirements

shot blasting plant, a Tunnelblast 3000x3000 system featuring a manual

Eurocar is the plant in Euroimpianti’s range for the semi-automatic

touch-up booth, 16 turbines, inverters, and a digital control panel. In

industrial coating of large metal parts that, due to their size, are difficult

2016, we decided to move our static liquid coating booths to a third site

to handle with a traditional overhead one-rail conveyor. In fact, it makes

and upgrade them with additional booths with a wall filtration unit, an

use of a special step-by-step roller handling all types of workpieces and

internal air intake plenum, and an exhaust air extraction and purification

consisting of two one-rail tracks connected by a load bar system, which

system. At the same time, we revamped the manual sandblasting cabin,

shifts forward automatically through steps that are specifically timed for

equipping it among other things with an opening roof, to enable the use

the various processing phases throughout the coating cycle. “Eurocar is

of our overhead crane for handling the increasingly heavier products we

available in various sizes depending on the maximum length of the parts

were treating.”

to be treated. We chose model 5, handling components up to

“We have grown together with our customers and their surface

10 m in length,” says Enrico Troisi. “However, after installing the Komby

treatment needs,” says Enrico Troisi. “What changed was above all the

plant, we revamped the Eurocar one by replacing the booth, compacting

size of the workpieces. At one point, the Eurocar plant was no longer

the line, and downsizing it to a size 3, i.e. with a maximum piece length

sufficient. Therefore, we invested in an automatic Euro90 system, which

of 6 metres. As the new Komby machine can coat large and very large

enabled us to quickly coat ever-larger batches of small and medium-

parts, we could turn the Eurocar one into a medium-sized, faster plant

sized workpieces. Finally, in 2022, we installed a third powder coating

performing frequent colour changes.

plant for very large-sized components, as the maximum part dimension

Euro 90 is the plant for the industrial powder coating of semi-finished

that could be handled by the Eurocar one was beginning to limit our

and finished metal parts fully automatically, built with standardised

further growth. We could have diverted these volumes to our liquid

components for fast delivery and excellent value for money. The

application plants, of course, but our business strategy was to drive our

machine installed by T&G can accommodate a maximum part size of

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© ipcm

Heavy metal structures at the entrance to the shot blasting machine.

3000 x 2000 x 80 mm and it is equipped with a one-rail conveyor, a chemical pre-treatment tunnel, a demineralisation plant, an automatic application booth, and drying and curing ovens. “This investment allowed us to increase our number of customers by enabling us to coat long series of parts quickly and efficiently,” indicates Luca Girolimetto. “We will soon add a second automatic in-line booth, to devote one to our standard colour and one to quick colour changes.”

In the early 2020s, T&G was faced with a problem: the sizes of the machines built by its customers were getting bigger and bigger and its Eurocar plant, handling workpieces up to 10 metres in length, was no longer sufficient. This was the reason behind its most recent investment: a Komby line for manual coating, extremely adaptable to the most diverse metal parts, suitable for small production runs and touch-ups thanks to the possibility of loading different components with different dimensions and colour requirements on its overhead conveyor at the same time. Furthermore, its modular construction allows it to be upgraded and modified with additional modules over time. T&G chose a Komby model with two modules, namely paint application and curing, defined as “hybrid” because it has a fully automated one-rail conveyor for handling large and heavy workpieces instead of a manual directional roller. Its overhead trolley moving transversely to the fixed rails can carry up to

4,000 kg, distributed among two parallel workpiece-carrying bars. The load bars are 12,000 mm long. This handling system was designed by Dutch company Railtechniek, which also built four automatic feeders on board the trolley to allow inserting the load bars from both sides of the plant according to pre-set programmes for different work cycles.

Conclusions “Throughout our careers as entrepreneurs, our priorities have always been investing in our company, pampering our customers, and retaining them by solving their problems – in short, providing a high-quality service,” says Enrico Troisi.

“Today, we have 45 employees and we specialise in the coating of automation systems and industrial machinery in general. In this niche, having always opted for mechanical © ipcm

pre-treatment has played an important role, through both manual sandblasting with Garnet and automatic shot blasting with mixed iron grit. Moreover, since staff training is a critical aspect for companies like ours, we believe that once operations have been optimised for a handful of target industries, it becomes uneconomical to go for others. T&G is an all-round contractor, specialising in highquality surface treatments and in the application of both powder and liquid coatings with a wide range of equipment to meet the most diverse requirements: we are proud of what our small business idea has become.”

© ipcm

From top: Railtechniek designed a unique handling system for T&G’s Komby plant, which makes the transfer of parts between operating modules fully automatic.

The Komby plant’s manual coating booth. © ipcm

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From left to right, Enrico Troisi, Alessia Venturi, and Luca Girolimetto.

Super durable powder coating

in anodized look

TIGER Drylac® Series 68 underscores the high demands of the architecture and facade industry on the performance of building envelops worldwide.

The super durable product portfolio includes numerous anodized effects for smooth finishes in matte or flat matte aesthetics.

Your advantage: Not only aluminum, also steel and galvanized steel can be finished in a refined anodized look: cost-effectively, environmentally friendly and in just one coat.

©Envato_Elements

www.tiger-coatings.com

© AkzoNobel Aerospace Coatings

ART WITHIN SURFACES

AkzoNobel Helps Southwest Celebrate Hawaiian Culture with Imua One Edited by AkzoNobel Aerospace Coatings Hamburg – Germany

The Boeing 737 MAX 8 aircraft of Southwest® Airlines was coated with several colours to capture the Hawaiian cultural concept of Imua.

T

here are special liveries, and there are liveries that are special – to

The aircraft took 17 days to complete from a team of up to ten painters

an airline and the people it serves.

who worked in shifts in Spokane. The design used more than 90 gallons

So when Southwest® wanted to celebrate the fourth anniversary

of paint comprising 16 different colours.

of serving the Hawaiian Islands, it wanted to create a unique design that

First the aircraft was painted black all over and a coat of Mica applied.

captured the Hawaiian cultural concept of Imua, which means forward,

A clearcoat set the Mica in place and was then sanded to give greater

and the strength, courage, and spirit of the islands’ people.

adhesion for the special colours that were to follow. Pre-mask stencils,

For the design of Imua One, the airline partnered with Oahu-based

expertly crafted by Solo Graphix, were then applied, with only very slight

Osaki Creative Group, and received guidance from Herman Piikea Clark,

adjustments required. The ease with which the stencils could be used,

the Kanaka Maoli/indigenous Hawaiian artist, designer and researcher.

combined with the speed of the paint material set-up, enabled the

The design, on a Southwest Boeing 737 MAX 8, features a range of

project to be completed two days ahead of schedule.

stunning colours including bold blues, warm reds and a sunrise yellow,

After the front design (pre-masking) was applied over the black it was

with gradients and vignettes to symbolise the transition from night to

scuffed, and the blue and purple added, along with a further coat of

day and reflect the history of Pacific travel using the sun, the moon and

mica. The design was sealed with a clearcoat. The skilled paint team

stars to navigate.

expertly handled the challenge of blending the orange of the after-

To bring its designs to life, the airline turned to AkzoNobel, for the

section design to deliver the desired effect For the middle section, the

quality of its aerospace coatings, and the expertise of its Technical

design blends (red to orange and purple to red) were completed at

Services Team.

the same time. Both the after-section and the mid-section designs also featured a further coat of Mica sealed with a clearcoat.

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ART WITHIN SURFACES

Custom-built painting installations With the design work completed, the airplane was unmasked,

Macchine e impianti realizzati su misura

scuffed down, blown off for debris and tacked, and then three coats of clear were applied. The tail was worked on, and one final clear finish applied. Throughout the entire program, the paint went on with ease and no re-working was required.

Shot blasting booths Cabine di sabbiatura

Mike Suhara, AkzoNobel Aerospace Coatings, says the team’s expertise was crucial to the success of the project: “The most challenging part of the project was choosing a Mica that would work with the different basecoats,” he explains. “We also had to develop five basecoat colours in less than our standard time, as well as an additional colour created on the spot during the customer visit. This took a huge effort from the colour development team in Troy.”

Happily, the extra effort involved was worth it, for Mike says that in

Washing tunnels Tunnel di lavaggio

the light of day the airplane takes on a life of its own: “The design flows and the colours make it work so well,” he continues. “It is amazing to see and once you learn the meaning of the symbols and what they mean to the people of Hawaii, it means something special to all of us.”

Liquid painting installations

Impianti di verniciatura a liquido

Scan or click the QR Code to see the coating process of the Boeing 737 MAX 8

Powder painting booths

Cabine di verniciatura a polvere

© AkzoNobel Aerospace Coatings

Curing ovens

Forni di cottura

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

© VISAVU/Iveco Group

ADVANCEMENTS

The Latest Generation of CONDOROIL Stainless’ Dialysis Cells Edited by CONDOROIL Chemical Casale Litta (Varese), Italy

info@condoroil.it

Dialysis cells are essential for cataphoretic coating. Condoroil Stainless, a division of the Condoroil group, has developed a new cell concept with innovative features, ready to meet any market requirement.

F

ounded in 1972 by Franco Zavattoni, chemical company

which may impact the cells while oscillating, choose this option.

CONDOROIL currently has a portfolio of 3,000 products,

• “super” length: when necessary, the length of the active membrane

16 registered patents, and an innovative range of recovery,

can exceed 4 metres, especially if bus, truck, or earth-moving equipment

regeneration, and waste minimisation technologies to match its

components have to be immersed in the tanks.

chemical formulations. Its plant in Casale Litta, in the province of Varese

• beyond-standard features: the T1 and T2 cells, with anode diameters

(Italy), covers a total area of 10,000 m , of which 4,000 are covered, and

of 1.5” and 2” respectively, are suitable for general industrial applications;

consists of 5 buildings with a production capacity of 10,000 tonnes/year.

they offer an excellent membrane-to-anode ratio and the longest possible

Its technical division devoted to research and assistance employs on

service life. The demand for this type of cells is going increasingly hand

average 35% of its entire workforce and its chemical laboratories are

in hand with the demand from the automotive sector for T3 and T5 cells,

its main flagship. Specialising in chemical solutions for the industrial

which have anode diameters of 3” and 5” respectively and ensure the

coating sector, the company offers a diverse portfolio ranging from paint

added advantage of having fewer connections than the smaller ones.

2

strippers to water purification agents, from pre-treatment solutions to electrophoretic coating products. For the latter field, in particular,

Dialysis cell features

the Condoroil Stainless division produces state-of-the-art dialysis cells

Condoroil’s cells are equipped with ion exchange membranes and

already in use worldwide.

they are built by using wrapped and welded polymer sheets, with low

CONDOROIL Stainless’ dialysis cells

deformability and electrical resistance but long service life and high current intensity characteristics. With its minimal thickness and therefore

Condoroil has already installed a large number of cells both in Italy

limited electrical resistance, this generates little heat, which is the

and abroad, proving that the features developed by its R&D division

primary cause of premature ageing of the membrane itself. Its limited

can meet a truly wide range of different customer needs. Such

expansion also prevents any short circuits between the membrane and

characteristics include as follows:

the electrode. Whereas in conventional cells the water flow enters the

• protection: a “semi-rigid” mesh placed around the membrane protects

electrode by physically touching it, in Condoroil’s cells it flows through a

it against accidental impact and therefore against damage. Typically,

plastic tube closed at the opposite end with a plug to prevent the liquid

users needing to immerse sharp-edge parts in their cataphoresis tanks,

from flowing back into the electrode.

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ADVANCEMENTS

In these tubular cells, the electrolyte is flushed from the top into the electrode and, rising from the bottom, allows any excess to leave the cell.

In the event of electrode failure, this eliminates the risk of the creation of a preferential water path that would result in the electrolyte building up in the space between the electrode and the membrane.

A further advantage is that, in the event of failure and/or breakage, it is not necessary to replace the full unit: these cells enable to replace the electrode alone while keeping the membrane. Another benefit relates to the fact that the standard solution was developed with an open top for easy inspection and simple maintenance. Especially in the case of pressurised cells, however, a “Closed Top” alternative is also available, with the application of a lid that is connected to the water circuit and the electrical cable. © CONDOROIL

Once again, the Condoroil Stainless division of the Condoroil Group proved itself up to the demands of the market, capable of researching and finding dialysis cell solutions that meet the most diverse and complex requirements while optimising a product that is fundamental for

© CONDOROIL

From left to right: The semi-rigid mesh around the membrane protects it against accidental impact; Especially in the case of pressurised cells, the alternative “Closed Top” type allows connecting the lid to the water circuit and the electrical cable.

cataphoretic coating processes.

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117

© Adobe Stock

COLOUR STUDY

Deceiving Green Monica Fumagalli ipcm®

From a venom-based pigment to a flag for ecological movements: green, the quintessential colour of nature, is one of the most difficult tints to synthesise and, perhaps for this reason, it is also associated with capriciousness and deception. Positivity and negativity of a colour with many nuances.

G

reen is the colour of sustainability and ecology par excellence,

Obtained from the combination of yellow, the colour of joy, and blue,

so much so that it is now common, particularly in technical

the colour of tranquillity, green nevertheless remains a positive colour

communications for the manufacturing industry in which we

precisely because of its connection with nature: it evokes feelings such

work, to see companies defined as “green”. However, this is a misleading

as rebirth, freshness, vitality, and peace. Green promotes relaxation,

mental association with the world of nature and what is “clean” and

which is why environments with elements in this hue are seen as

sustainable: as green is one of the most difficult colours to synthesise,

peaceful, capable of nourishing our minds and even – it is believed –

its production process is actually among the most complex and polluting

improving concentration. It is also the colour of hope, vitality, fertility,

ones, and the same is also true for its disposal. As chemist Michael

and abundance. In traffic lights, it gives us – literally – the green light,

Braungart stated in an interview with the New York Times a few years

understood as the go-ahead, as opposed to red, which obliges us to

ago, “The colour green can never be green, because of the way it is

stop. However, it is also the colour of envy, the medieval devil, disgust,

made. It’s impossible to dye plastic green or to print green ink on paper

and venom. In some cultures, it is associated with money (dollars are

without contaminating them. Ironic, isn’t it?”

green) or the lack of it (in Italian, for example, “essere al verde”, literally

1

“being to the green”, means “being broke”). Green has been appreciated 1

https://www.nytimes.com/2010/04/05/arts/05iht-design5.html

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since ancient times but, precisely because it is difficult to produce, it

COLOUR STUDY

has always also been one of the most problematic colours for artistic

Shades of green in the Middle Ages

production.

Whereas during the Late Roman Empire, newborn babies were wrapped

The origin of the word “green”

in green mats to wish them good luck, in the Middle Ages this colour was chosen by girls seeking husbands and then, once married, as a wish

The ancients considered green (in Italian verde, in French vert, in

for motherhood. However, perhaps because of its dye instability due to

Spanish and Portuguese verde, and in German grün) to be a shade

the difficult composition process, at that time green was also associated

of colour associated with yellow. This is revealed to us by the Indo-

with deception and cunning and, therefore, to the devil, to witches, and

European root ghel, which also meant “bright”, “shining”, and the Proto-

to the most frightening fantastic animals such as dragons, monstrous

Germanic word gewalz, which indicated both tints. This gave rise to the

snakes like the hydra and the basilisk, and mermaids.

Latin terms galbus (“pale green”) and galbinus (“yellow”).

From its earliest days, the colour green has also been associated with

The first to separate these two colours were the Greeks: in ancient

Islam because of a sentence in the Quran that states that those who are

Greek, the same Proto-Indo-European root evolved into khloròs, a word

in paradise will “wear green garments of fine silk”. Therefore, mosques

associated less ambiguously with pale green, later becoming itself the

are decorated in various colours but almost always with predominant

root of “chlorophyll”.

green tones and the tombs of Sufi saints, connected to the mystical

The English word “green” derives from the Proto-Indo-European ghreh-

dimension of Islam, are covered in green silk.

2

and the Proto-Germanic groniz, which also, not at all coincidentally, gave origin to the verb “to grow”.

The Italian, French, Spanish, and Portuguese names followed the same

© Gennadii Saus i Segura

path: they came from the Latin viridis, which later became virdis, which in turn was related to the verb vireo, i.e. “to sprout”, etymologically also connected to “vigour” and “vegetation” (from the Proto-Indo-European root weg-).

Green in ancient history In contrast to blue and red, there is no trace of green in prehistoric paintings, perhaps because colours found in nature, of which we can no longer find any trace, were used on cave walls. The first evidence of the use of this colour dates back 5000 years, when the ancient Egyptians chose it to represent the vegetation and fertility of the Nile, which flooded the land with its waters making it lush. The Egyptian deity Osiris was often depicted with green skin to symbolise rebirth and fertility.

Palettes of green facial makeup have been found in some tombs of the time, made from malachite, a green mineral rich in copper that was pulverised and used as a pigment: the Egyptians had the custom of making up the edge of their eyes with green dye to protect themselves from evil. The same belief also applied to the dead: small green amulets in the shape of scarabs, made of malachite, have been found inside tombs, probably left for the very purpose of protecting the deceased.

In addition to malachite, pigments such as verdigris and Egyptian green were used to obtain the green tint: verdigris was a compound of copper acetate, obtained from the corrosion of metal, whereas Egyptian green was a mixture of malachite, azurite, and other minerals that was prepared synthetically. To become green, on the other hand, fabrics were first dyed yellow with saffron-based pigments and then soaked in blue dye made from the woad plant’s roots.

2

www.linkedin.com/feed/update/urn:li:activity:7001092899694129152

“Arnolfini Portrait” by Jan van Eyck (1434-35), oil on oak panel, National Gallery, London.

international PAINT&COATING magazine - JULY/AUGUST 2023 - N. 82

119

© MARVEL

© Pixar Animation

The Incredible Hulk of the Marvel comics.

The character Disgust in the Pixar film “Inside Out”.

That is also why the tribe of prophet Muhammad had a green banner

The Romantic movement of the late 1700s, finally, sanctioned green as

and why almost all Islamic countries use this colour in their flags.

the colour of nature, ecology, and the environment, as it has been up

In Western history, green retained its controversial appeal even in the

until today.

15th and 16th centuries. Its association with good omens was confirmed in the famous “Arnolfini Portrait” by Jan van Eyck (1434-35), in which the

Fun facts

woman is not pregnant, as one might guess due to the shape of her

According to some theories, before Coca-Cola’s marketing move4,

dress, but is thought to have been depicted in that position and with

Santa Claus’ original suit was green to recall the “secular” origin of this

green clothes as a propitiatory rite for numerous offspring.

figure, linked to the tradition of elves distributing gifts in some Northern

Venomous green

European countries. According to the folklore of Ireland, the green island par excellence, green is the favourite colour of fairies.

The turning point in the popularity of this colour in the art world and

As for the negative connotations of this colour, the creators of the

beyond occurred in the Victorian era, with the custom of obtaining

Pixar film “Inside Out” chose green for the character Disgust, alongside

green dye by adding arsenic, the highly toxic substance believed to

Joy (yellow), Sadness (blue), Anger (red), and Fear (purple); again, the

be the cause of the deaths of many people who handled books, toys,

ambivalence of green is however once again confirmed by this very

and decorative objects or merely lived in rooms painted with it3. Both

character who, within the emotional concept of the film directed by

Scheele’s green, developed in 1775 by Swedish chemist Carl Wilhelm

Pete Docter and Ronnie del Carmen, also has a positive value because

Scheele, which was an immediate success due to its intensity and

she allows the protagonist to protect herself from physical and social

resistance to light, and the Paris green or Schweinfurt green, consisting

contamination.

of arsenic and lead, with which Impressionist painters fell in love during

A final oddity brings us back to the problems associated with the

the 19th century, are believed to have been responsible for poisonings

realisation of this colour: do you know why the Incredible Hulk’s skin is

that cost the health or lives of many who came into contact with their

green? According to the well-informed, in the original portrayal of the

toxic green pigments. Just to mention one of the most famous cases,

Hulk, Stan Lee wanted him to be grey, but due to some printing issues

Napoleon Bonaparte’s residence in exile on the island of St. Helena,

in early copies of Marvel comics, his figure turned from grey to the

Longwood House, had its walls painted in this colour. In his “Theory of

green we are used to seeing in comics and films today.

Colours”, it was Goethe who first described green as “soothing” and thus recommended for use in rooms intended for rest and conviviality.

3

https://www.focus.it/cultura/curiosita/verde-arsenico-timore-mistero

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4

https://eosmarketing.it/en/did-coca-cola-invent-santa-claus/

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

BRAND-NEW

Swimming Across the Strait of Messina: The Verind Team’s Latest Feat Sport is about unity, sharing, and effort to achieve a common goal: this is also the experience of Matteo Minelli, Claudio Orlando, and Francesca Orlando from Verind, who completed the crossing of the Strait of Messina by swimming after a year of training together.

O

n 12 June, Verind accounting & controlling senior manager

a somewhat wild idea come up while chatting at work soon materialised

Claudio Orlando, his daughter Francesca, and Verind general

into the common goal of swimming across the Strait of Messina in 2023.

manager Matteo Minelli crossed the incredible blue waters of

His daughter Francesca, a very sporty girl, joined us at a later stage.”

the Strait of Messina, where the myth of Scylla and Charybdis still lives

“For the safety of swimmers, since the Strait is characterised by heavy

on. Their swim started on Sicily’s coast, near Torre Faro, and ended on

nautical and merchant vessel traffic, such an experience cannot be

Calabria’s beach of Cannitello, right in front of the church.

organised independently but requires the support of sports clubs that

During the crossing, the weather conditions changed abruptly and a

take care of the organisation, provide the support boats that follow the

severe thunderstorm raged for almost the entire time, only ceasing

groups of swimmers, and fix a date for the crossing in agreement with

when they approached the Calabrian coast as the sun came out. In

the port captaincy. Claudio and I chose 12 June,” adds Matteo Minelli.

total, as confirmed by Matteo Minelli’s GPS watch, which also recorded

“Unfortunately, the weather was not favourable, as the day started with

the exact route followed, they swam 4,375 metres in 1:26’:04”, with

overcast skies, which then turned into light rain and ultimately into a

3,444 strokes.

storm that hit us during the crossing. There were only a few of us, so

“I am passionate about open water swimming but, living in Milan, the

we swam alone, each side by side with a support boat. The briefing

options for practising this sport are few,” says Matteo Minelli. “My

was very simple: swimming by following the boat with our eyes and

colleague Claudio Orlando shares this passion with me, and what was

avoiding looking underneath so as not to get dizzy from the deep,

© Verind

The itinerary followed by Matteo Minelli during the crossing.

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© Verind

Matteo Minelli under the rainstorm.

dark blue waters of the Strait. We finished the crossing with a time perfectly in line with our pool training, without even feeling excessive fatigue. We reached the Cannitello beach under the sun, where we were presented with the Diploma certifying the completion of the challenge. We are all very happy with this experience but also with the whole journey we took together to get ready.”

“Our aim was to achieve a common goal and we attained it through training and perseverance: we have worked side by side for many years and this experience has united us even more. As soon as I touched the Calabrian shore, I thought that our team had managed to connect the two Italian coasts well before the construction of the

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

bridge over the Strait,” states Matteo Minelli with a smile.

For further information: www.verind.it

© Verind

The team before the crossing.

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



BRAND-NEW

KANSAI HELIOS Austria Awarded Anna Gruber with the Sponsorship Prize KANSAI HELIOS Austria awarded its sponsorship prize to Anna Gruber, who successfully completed the bachelor degree in Applied Chemistry at the IMC Krems University.

D

uring the bachelor degree ceremony of the IMC Fachhochschule

promising future job opportunities for graduates. The Wien-based

Krems (University of Applied Sciences of Krems), KANSAI HELIOS

subsidiary (formerly Rembrandtin Lack GmbH) became part of the global

Austria awarded its sponsorship prize to Anna Gruber, who

KANSAI PAINT Group in 2017. Its core competencies include modern

successfully completed her bachelor degree in “Applied Chemistry” and

corrosion protection systems, innovative industrial coatings for the ACE

showed exceptional enthusiasm and initiative while writing her thesis.

segment and the railway vehicle industry as well as high-temperature

The prize was presented by Hubert Culik – the managing director of

resistant coatings and road marking paints. Currently, it has 190

KANSAI HELIOS Austria – and Dr. Uwe Rinner, the Head of the Institute.

employees, more than a quarter of which working in the Research &

KANSAI HELIOS Austria has been supporting the English-language

Development department. The sponsorship prize allows to support

bachelor degree programme “Applied Chemistry” of the Austrian

future professionals that might help the company to continue its growth.

university for many years, as it is managed by professors from the academic sector and the chemicals industry focused on a solid and practice-oriented basic training in the field of chemistry, thus providing

For further information: www.kansai-helios.at

© KANSAI HELIOS Group

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© Forplan AG

The recently introduced Planetary Motion Technology by Forplan AG has significantly improved the process for removing excess coating from dipped parts.

ADVANCEMENTS

New Dip-And-Spin Technologies Reduce Material and Labour Costs in the Metal Coating Process Tim Hanna STC Dip Spin – Kalamazoo (Michigan), United States

thanna@prab.com

Recent supply chain disruptions and material shortages have strained almost every corner of the North American manufacturing sector, and the coatings industry has been no exception. From price hikes to order delays, the effects of a materials shortage are hard to understate. And if that has not been bad enough, persistent labour shortages continue to challenge manufacturing workforces.

A

resource is precious, cutting back on material waste and

Labour savings, increased throughput, reduced downtime

operational inefficiencies is vital to the continued success of any

According to the National Association of Manufacturers, companies

t a time when every drop of coating material and workforce

coating operation. New advancements in coating technologies make

report that it is 36% harder to find the right talent than it was just a few

that possible.

years ago, despite a high unemployment rate.

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ADVANCEMENTS

© Forplan AG

Due to an improved and innovative curing process this new equipment requires 35% less floor space than traditional dip and spin systems.

It is predicted that the skills gap could result in 2.1 million unfilled

Reducing coating consumption

trades jobs in the U.S. by 2030. When every worker is more valuable

The recently introduced Planetary Motion Technology by Forplan AG

than ever, dedicating multiple people to the same task constrains

has significantly improved the process for removing excess coating

production capacity. Advanced coating systems automate the entire

from dipped parts. The process starts with automatic weighing

coating process—from the start of part loading to unloading—requiring

capabilities to ensure consistent load sizes, with one batch consisting

minimal operator oversight. The systems take care of part dipping,

of two baskets of equal weight. Together these baskets are submerged

excess coating removal, curing, transfer to and from the dipping

into the coating, tilting and rotating at the same time to ensure all parts

unit, and more, and are highly programmable to meet the individual

are coated.

needs of the operation. This allows coating operations to free up their

After the system dips the parts into the coating material, the baskets

workforces for other responsibilities, combatting the rising difficulties

rotate around themselves in a planetary fashion at high speeds. This

associated with the labour shortage. Automated part coating systems

engineering feature results in consistent coating and ensures that the

also save time. Advanced systems include state-of-the-art touchscreen

parts inside the baskets are moving and re-orientating themselves

control systems that make running the equipment easy for operators.

for the best possible coating thickness. Excess coating material is

Additionally, automated dip and spin short and consistent cycle times

recovered and returned to the dip tank for future use. The planetary

of approximately 2 minutes help keep production moving. In the event

motion technology is shown to reduce coating material consumption by

that a mechanical problem occurs, remote troubleshooting can help

up to 30%.

accelerate a solution that minimizes equipment downtime.

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127

Space saving and lower carbon footprint

learn about the economic and environmental benefits of new planetary

Due to an improved and innovative curing process this new

dip-and-spin technologies.

equipment requires 35% less floor space than traditional dip and spin systems and can save 285 tons of CO2 compared to other common

equipment. Typical ROI for these types of systems is less than one year.

Conclusion Demand in the coatings industry is booming. According to the “Paints and Coatings Global Market Report 2021,” the global paint

About the Author Tim Hanna serves as the Vice President of Business Development and Sales Manager for STC Dip Spin/PRAB. With industry experience spanning over 30 years, Tim has extensive knowledge of the parts coating industry and the needs of its customers.

and coating market is projected to reach $258.45 billion in 2025 at a

About STC Dip Spin

compound annual growth rate of 4%. As demand increases, it’s likely

STC Dip Spin built its first dip spin coating machine in 1965. That machine

that the cost of coating materials will rise. Fortunately, innovative part

is still in operation today. Since then, STC has worked to create the most

coating equipment can be the key to saving process time, labour,

reliable and consistent pieces of coating equipment possible. In 2020, STC

and material costs. Advanced coating systems not only help position

partnered with Forplan AG, Brugg, Switzerland, which offers a variety of

coating operations to weather future challenges spurred by economic

coating systems for mass-produced parts—both for bulk items and rack

turbulence, but they put them in a favourable position to maximize

parts. Regardless of industry or operational needs, STC provides a wide

growth. To take the first step toward more sustainable and steady

variety of trusted equipment backed by comprehensive warranties and in-

production, consult with a trusted industry expert or manufacturer to

depth expertise, tailored to fit the client’s needs every step of the way.

The baskets rotate on themselves to "centrifuge" the dipped parts.

lan AG

© Forp

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sataluminium.com SAT | Surface Aluminium Technologies Srl | Via Antonio Meucci, 4 37135 Verona | Italy | ph +39 045 8280601 | sales@sataluminium.com

SPECIALIZED TRAINING

Research, Technology, and Innovation for a Sustainable Industrial Future Alessandro Soba Verind S.p.A. – Milan

One of the most important objectives for laying the foundations of a more modern and sustainable industrial future is to consolidate the relationship between industry and academia: the seminar held at Politecnico di Milano, with the contribution of Verind S.p.A. and PPG S.r.l., for the university course in Advanced Organic Coatings was a perfect example of this.

M

ay and June saw the end of the second semester at Politecnico

In particular, they examined a few industrial concepts applied to the

di Milano, Italy’s leading university for technical and scientific

automotive and industrial sectors:

education and one of the top fifteen universities in the QS

• production of paint products and assessment of the quality of the

World University Rankings in the Engineering & Technology category1.

applied film, with PPG;

The students of the Master’s Degree in Materials Engineering and

• technologies and equipment for applying paint products, with Verind.

Nanotechnology, aimed at training new technicians with a broad

The seminar held in English by Alessandro Soba from Verind S.p.A.

spectrum of knowledge in the fields of production, processing, and

(Dürr Group) and by Francesca Di Costanzo from PPG S.r.l. (Quattordio,

application of materials as well as in the more innovative field of

Alessandria) for the Advanced Organic Coatings teaching course was

nanotechnology, also had the opportunity to meet a few companies

a concrete example of the possible interaction between students and

from the surface finishing industry.

businesses. Led by Raffaella Suriano, associate professor at Politecnico’s

https://www.topuniversities.com/university-rankings/university-subject-rankings/2022/engineering-technology 1

Department of Chemistry, Materials, and Chemical Engineering “Giulio Natta”, the students were particularly interested and asked numerous

© PPG

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SPECIALIZED TRAINING

questions both during and at the end of the seminar.

of the PPG plant in Quattordio, were able to see how certain defects

“I illustrated Dürr’s most innovative application technologies,” explained

typical of coating (craters, pinholing, sagging) and certain critical features

Alessandro Soba, “such as the EcoBell electrostatic device, the EcoDose

are checked and tested during quality control operations.”

2k electronic dosing system using Coriolis mass flowmeters for 2k and

“Such a synergy between university and industry,” noted Raffaella

3k coatings, and the PIG and Robot Process Arm systems, all of which

Suriano, “was made possible thanks to the collaboration with PoliEfun,

are solutions aimed at achieving consumption savings and higher

an association of the Politecnico di Milano university that promotes

efficiency in the painting process. Thanks to videos showing surface

business culture in the surface treatment sector2. PoliEfun encourages

coating devices and plants used in the automotive and general industry

the involvement of industrial players with the academic world also

sectors and to presentations of specific equipment for automatic and

through in-person and online masters courses such as ISM10 (Industrial

manual coating, we addressed several topics related to environmentally

Short Master), now in its tenth edition, and TST2022, the digital

friendly application technologies with a view to sustainability, efficiency,

conference that last year dealt with topics such as the circular economy

and process digitalisation.”

and the development of sustainable bio-derived coatings obtained by

“I presented PPG as a global leader in paints, coatings, and speciality

recycling industrial agricultural waste such as tomato peels."

materials,” explained Francesca Di Costanzo, PPG’s Colour Science

“Thanks also to the support of PoliEfun, the School of Industrial and

Application and Quality Control Manager, “whose goal is to “protect

Information Engineering of Politecnico, and the degree course in

and beautify the world” through its two industrial segments devoted to

Materials Engineering and Nanotechnology, in this academic year

Performance and Industrial Coatings.”

2022-23 the Advanced Organic Coatings teaching course has devoted

This company’s mission includes three major drivers: Innovation,

40% of its lecture hours to laboratory teaching, in order to further

Sustainability, and Colour. The subject matter explored with the

strengthen the skills and technical-scientific knowledge of future

students was the Automotive OEM Business, with all the product lines

engineers with practical experience and experimental tests.”

included in the paint cycle of a car body, their functions, and of course their distinguishing feature: colour.

“Thanks to continuous classroom interaction” added Di Costanzo, “the students, together with some representatives of the Quality Control Lab

2

https://www.poliefun.com/

© PPG

© Verind

international PAINT&COATING magazine - JULY/AUGUST 2023 - N. 82

131

STANDARD & LEGISLATION - UCIF Informs

ESG Criteria: From an Added Value to a Market Requirement Manuela Casali, UCIF – Italian Surface Treatment Equipment Manufacturers’ Association, Milan, Italy

I

info@ucif.net

nterest in ESG, an acronym for Environmental, Social, and

protection in terms of both company infrastructure and design of

Governance, is not a recent phenomenon. Environmental and

increasingly green plants. The letter S identifies the values related to the

social transformations have long been the focus of companies

corporate activities’ social impact, considering not only the relations with

and organisations. ESG issues were already being discussed back in

employees, collaborators, suppliers, and customers, but also with the

2005, although only recently do we have an abundance of data at our

area in which the company operates, the community, and the people.

disposal to enable us to compile reports and statistics.

Lastly, the letter G for Governance relates to a difficult subject, that of

What has changed substantially, however, is how companies today

corporate management, which traditionally, in Italy, is seen as an aspect

communicate their relationship with ESG criteria and their added

to be kept “confidential” and not communicated to the outside world,

value, to the point of making them not only a reputational issue but

except for the obligations imposed by law. The issues under observation

also and above all a commercial one. By realising that an increasing

here include, for example, executive compensation, shareholder rights,

number of consumers are directing their choices according to ethical

and transparency in decision-making.

criteria, businesses have immediately responded by monitoring and

Are these new topics? Certainly not: there has been what we called

defining parameters that can even contribute to compiling actual

“sustainable investment” before. The big difference between ESG-

rankings of the most virtuous organisations. It is easy to imagine

driven investment and sustainable investment, however, lies in the

how from a parameter initially used by large companies to be more

measurability of the former: every effort made and every action

attractive in the marketplace, we are increasingly moving towards the

performed should have a positive and economically measurable return

focus on the same criteria and parameters by smaller organisations to

for investors and beyond – nowadays the focus is more and more on

demonstrate their environmental, social, and ethical commitment.

the community and the environment. In addition, apart from being

What is the state of the art in the mechanical industry?

measurable, the results produced should be understandable and clear.

The outcomes of the environmental and social policies of a company or organisation working according to ESG criteria should be evident,

Whether larger or smaller, there is now a growing conviction today

bringing concrete improvements and data to support the actions taken.

that companies that can produce positive environment and society-

In the medium term, the collection of all this data is going to allow

related results are also better performers in terms of business results,

ranking companies based on what they declared compared to what they

in the long run. The letter E for Environment encapsulates various

did. In fact, this is why it is more and more established that a virtuous

environmental criteria and values, with companies being assessed

company capable of producing positive results for the environment and

according to their environmental behaviours: for them, this means

society is also an organisation capable of achieving excellent business

planning future investments and projects with a view to environmental

results in the long run.

© Adobe Stock

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1 8 Y 19 D E O C T U B R E

POWERED BY

MEETING THE INDUSTRY

News and Developments in the Aluminium Business at the 12th Aluminium Two Thousand The next edition of Aluminium Two Thousand, which is organized in collaboration with ICEB World Congress, will take place from 19 to 23 September 2023 at the Royal Hotel Carlton in Bologna (Italy).

M

ore than 80 highly qualified “aluspecialist” speakers from

millions of products. Fast forward to the end of 1988: having just

companies, universities and associations all over the world

come back from Paris Interfinish congress, I was talking with a long-

are coming together (as they have been doing every two

term collaborator of Italtecno, journalist Velello Muratori, and another

years since 1990) to introduce the most innovative technologies and

business partner of mine and we decided to organize ourselves a

applications in the aluminium field to a specialised, international

congress that would give due credit to this noble metal. We set the

public.

date of the first edition, March 1990, and the title, Aluminium Two

Aluminium Two Thousand has become an irreplaceable networking

Thousand, because of the nearing Y2K.

occasion for all operators of the aluminium business (be it extrusion,

We had no way of knowing whether ten or a hundred people would

foundry, melting, finishing or exhausted water treatment).

have come to the Raffaello Hotel in Modena, and yet more than two

But how did it come to be? We asked its creator, Walter Dalla Barba,

hundred came, despite the odd Arab refusing to attend due to a lack

CEO of Italtecno Srl (Fiorano Modenese), president of Interall and of

of five stars hotels in the city.

the Aluminium Two Thousand World Congress.

Still, this made me realise we had attracted a high-end public and that

Walter Dalla Barba: “In the 80’s I used to attend international

our congress had to meet those expectations. We called in managers

congresses about surface treatment and extrusion techniques, and

and businessmen from the most important businesses in the field,

I wondered why aluminium was only treated as one among many,

both from Italy and other manufacturing countries. And we were

despite it being the third most common element after oxygen and

successful – not just with the scientific part, but also with the side

silicon and the most used metal (right after iron) to manufacture

activities we had planned: to get to north-west Sardinia, where we

© Interall

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© Interall

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MEETING THE INDUSTRY

would spend the following two days and nights, we had booked

technology and its analysis through FEM simulation. When did

an entire Meridiana flight, but it was so full we had to leave some

the collaboration with ICEB first start?

people out. Ever since 1990, all the activities we’ve offered – from

Walter Dalla Barba: “It all began in 2003, when researchers from the

gala dinners to sightseeing tours, from activities for those just

Engineering Department of the University of Bologna came to our

accompanying to cooking classes (which Americans seem to really

congress, which was in Rome that year. Now, ever since the 6th edition,

enjoy) – have gained more and more following”.

we also host the International Conference on Extrusion and Benchmark, an event attended by researchers from all over the world which

Who are the congress speakers?

previously used to alternate between Bologna and Berlin. This is why

Walter Dalla Barba: “According to topic, we have called in

I’m proud of my contribution, not just for enabling the highly desirable

technicians from extrusion, anodizing, coating and melting

exchange between universities and manufacturers in a constructive,

companies, but also economists, like professor Cesare Garzia

friendly setting, but also for bringing to Bologna the excellence of

from Bocconi university, who are going to present their analysis of

aluminium studies”.

the trends and outlook of the aluminium business as well as the overlap with general economy.

What’s this year’s program?

We’ll talk about the different fields of application for extruded

For three whole days we’ll hold three parallel sessions to delve into the

aluminium, about the issues with implementing various alloys

details of all topics. Each paper has been examined by the congress

and about applying aluminium to architecture, automotives,

scientific committee in order to only select the most innovative studies

transportation, costume jewellery and furniture. We have indeed

and researches, the most recent manufacturing applications and the

seen at the Salone del Mobile (Milan furniture expo) that aluminium

most interesting case studies.

is trending for home and office interior design. We’ll leave a lot of

At the same time, to ensure the best possible stay in Bologna, we’ll have

space to innovative technologies and scholarly research”.

entertaining side events every night: a gala dinner, an exclusive concert, a tour for accompanying people, a technical tour and a final, beautiful

About that, you have managed to have business and

social tour through the charming historical cities surrounding Bologna,

university meet through the synergy with the International

including Ravenna, capital of the Roman Empire from 408 to 476.

Conference on Extrusion and Benchmark (ICEB), the biggest event in Europe for the newest development of extrusion

For further information: www.aluminium2000.com

© Interall

international PAINT&COATING magazine - JULY/AUGUST 2023 - N. 82

135

MEETING THE INDUSTRY

Chicago – A FABTECH Kind of Town The next FABTECH edition will take place from 11th to 14th September in Chicago (IL, United States). led presentations that cover a wide range of technical topics for all finishing professionals. “It’s amazing how much the FINISHING Pavilion & Conference have grown since we became a part of FABTECH back in 2010,” notes CCAI Executive Director Anne Goyer. “The growth has been phenomenal since CCAI became the FABTECH Finishing partner and we are happy that the FINISHING Pavilion & Conference is set to exceed our pre-pandemic numbers as pre-registration numbers are very strong.”

Training and education have always been at the forefront of CCAI’s mission. The conference program at FABTECH is the perfect platform for CCAI to showcase the expertise and knowledge of members and enlighten those who are new to the finishing industry or those who want to sharpen their skills and gain new insight. CCAI’s FINISHING Conference track features 27 sessions, encompassing a broad spectrum of technical presentations, from basic to advanced, addressing topics of interest for everyone involved in finishing technologies.

Another highlight of the show will again be offered as CCAI marks its sixth edition of the FAB to FINISH Production Experience. The program gives attendees a first-hand opportunity to see a part produced from fabrication to finishing. Attendees can observe a souvenir part being laser cut and bent, then follow a production route to participating CCAI Corporate Member exhibitor booths to experience the part being cleaned, powder coated, and cured. Some routes will feature selective plating, while others will include coating thickness measurement. Each year the program grows in popularity as exhibitors and attendees alike want to participate.

FABTECH 2023 Finishing Conference Program and Finishing Pavilion Exhibitors Take time to review the current FINISHING Conference Program and list © CCAI

of FINISHING Pavilion exhibitors found on the show website. To view the

F

FINISHING Conference Sessions, select the “Conference” tab at the top

and gain insights into finishing and manufacturing trends that will help

website or select the Exhibitor Directory on the FABTECH website to

you prepare for what’s ahead. Everything you need for your finishing

view the floor plan or search the exhibitor list. Note that the FINISHING

operations can be found all in one place in September.

Pavilion and Conference sessions are located in the Lakeside Center

In their 14th year as a FABTECH partner, CCAI’s FINISHING Pavilion

East Building.

ABTECH returns to McCormick Place in Chicago, IL, from

of the home page and scroll down to SESSION DETAILS. Be sure to enter

September 11-14. There is no better opportunity to explore the

promotion code FINISHING30 to save 30% on your finishing sessions.

latest technology, share knowledge, network with industry peers,

You can view the complete list of FINISHING exhibitors on the CCAI

and Conference continue to thrive and offer great innovations and critical information on all aspects of industrial surface finishing.

FABTECH provides a wealth of technology solutions, along with expert-

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For further information: www.fabtechexpo.com

2023 Anticipating

Leading Trade Fair For Metal Working Industry

Exhibitors

Visit countries

In Asia-Pacific

The Smart Manufacturing Industrial Cluster

Visits

Exhibiting Area (sqm)

Accelerating Global Expansion And Growth Forums / Shaping The Future Of Metal Fabrication

Enquiry Organizer

+886-2-2595-4212 E-mail : imt@kaigo.com.tw

MEETING THE INDUSTRY

Current and Future Trends in Organic Coatings at the Conference Organised by the University of Trento The future of organic coatings at a conference that brought together paint manufacturers and applicators and academia: the Department of Industrial Engineering at the University of Trento confirmed its strategic role in the research and scientific dissemination of the most up-to-date information to support the industry.

The first session of the day was opened by Lorenzo Soldavini from PPG Italia (Milan), who presented a talk about “High-performance powder coatings for corrosion protection”.

Maria Alba Fusco from Liberty Magona (Piombino, Livorno, Italy) gave a speech about “Reinventing steel for a sustainable future”, emphasising the importance of this material as a sustainable choice, thanks to its 100% recyclability, and of the research and development of energysaving solutions, such as the one her company designed together with the Laboratory to keep building roofs cool through the coating of a special coil.

“Alternative cataphoresis applications” was the topic of the report © ipcm

A

presented by Gian Luca Gazzola from Arsonsisi (Lainate, Milan).

The first session of the conference ended with a presentation by conference about “Organic coatings, the solution for protection

Giovanni Ciafrè from Renner Italia (Minerbio, Bologna), “Wood coatings:

and aesthetics: trends and innovations in the sector” was held

a matter of aesthetics, protection, and application”.

on 20 June at the Department of Industrial Engineering of the

After a coffee break and a visit to the stands of the event sponsors,

University of Trento (Italy).

CO.FO.ME.GRA, Liberty Magona, Nikon, Merck, and Pintarelli

Moderated by Professor Stefano Rossi, the head of the Coatings &

Verniciature, the second part of the conference continued with the talk

Industrial Corrosion Control Laboratory, which has been collaborating

“What evolution can we expect for traditional building and corrosion

with companies and research centres at the national and international

protection coatings?”, presented by Gianfranco Di Tanna and Luciano

levels for over thirty years, it was aimed at taking stock of the situation

Pau from the AITIVA Association of Piacenza.

of organic coatings and understanding and discussing with several

Tiziana Pintarelli from Pintarelli Verniciature (Lavis, Trento) highlighted

companies’ representatives what are the most complex challenges

some of the problems encountered in the daily work of a coating

expected to be faced by this sector in future.

contractor in her talk about “Paints, the applicator’s point of view”.

“Protection and aesthetics are longer enough,” stated Rossi during his

Before the lunch break, the two reports by Stefano Corrado from Merck

introductory speech. “Today, coatings are required to do much more:

(Milan) and Francesca Valan from Valan Studio (Milan) concluded the

reduce their environmental impact by becoming increasingly green,

second session, dealing respectively with “Pigments and colours in

use raw materials from natural or recycled sources, add properties

motion, a brief journey between emotion and innovation” and “Colour

other than simple corrosion protection by increasingly becoming “smart

sustainability: timeless colours”.

coatings”, and create an infinite range of effects through colour and

In the afternoon, speakers and participants were able to visit the

texture to the point of encompassing not only the sense of sight but

Department’s laboratories, equipped with the most advanced devices

also that of touch. To make the best use of paints not only based on

for the electrochemical characterization of surfaces and coatings, for

their protective characteristics but also on their aesthetic-perceptive

accelerated ageing, surface abrasion resistance and microstructural

ones, it is necessary to be aware of the infinite possibilities that this type

characterization.

of coatings offer. This is why the Laboratory felt the need to organise this event together with some industrial partners.”

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N. 82 - JULY/AUGUST 2023 - international PAINT&COATING magazine

For further information: https://rb.gy/kv3uv

More Content. 17-18 Ottobre More Exhibitors. 2023 Milano NH Milano Congress Centre More Innovations. Milanofiori, Assago, Italy

Registrati ORA

For everything you need to know visit www.paint-coatings.it pci@step-exhibitions.com Tel: +39 334 891 8603

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EDITORIAL BOARD Prof. Massimiliano Bestetti:

Prof. Stefano Rossi:

Department of Chemistry, Material and Chemical Engineering, Politecnico of Milan – Section of Applied Chemistry and Physics

Material Engineering and Industrial Technologies, University of Trento - Product Design

Prof. Paolo Gronchi: Department of Chemistry, Material and Chemical Engineering, Politecnico of Milan – Chemical Engineering Section

Dr. Fulvio Zocco: Environment and quality

Kevin Biller: ChemQuest Powder Coating Research

EDITOR IN CHIEF / DIRETTORE RESPONSABILE

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2023

INTERNATIONAL PAINT&COATING MAGAZINE

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14th Year - Bimonthly N° 82 - JULY/AUGUST

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