ipcm n. 83 | September - October 2023

The smart journal for surface treatments

ISSN 2280-6083

ipcm digital on

® Special issue on

www.myipcm.com

ARCHITECTURE & DESIGN

2023

INTERNATIONAL PAINT&COATING MAGAZINE

14th Year - Bimonthly

N° 83 - SEPTEMBER/OCTOBER

www.futuraconvogliatori.com

A NEW FOCUS ON INNOVATION www.adaptacolor.com

More Content. 17-18 Ottobre More Exhibitors. 2023 Milano NH Milano Congress Centre More Innovations. Milanofiori, Assago, Italy

Registrati ORA

Per maggiori informazioni visita www.paint-coatings.it pci@step-exhibitions.com Tel: +39 334 891 8603

NEW!

ESPOSIZIONE • PROGRAMMA SCIENTIFICO • TECHFOCUS

POLYMER ACADEMY

Associazioni di supporto:

Organizzatori:

Media Partners:

THE STABLE ONE

DELTA-PROTEKT TC 502 GZ

®

Silver hybrid topcoat

  

DELTA-PROTEKT ® TC 502 GZ is a silver hybrid topcoat with excellent friction properties for use on metric components.

Very stable friction properties PTFE-free Strong process stability

INDUSTRIAL COATINGS

www.doerken.com

MORE?

CONTENTS SEPTEMBER/OCTOBER 2023

14

40

ANALISYS

FOCUS ON TECHNOLOGY

A Thermal Evaporator for Bilge Water Treatment Contributes to Ecologia Oggi’s Total Waste Recovery Project

07 EDITOR’S LETTER 08 BRAND NEW 18 HIGHLIGHT OF THE MONTH

A New Name, a New Brand, a New Ambitious Growth Strategy: Kansai Helios Italy’s New Course

24 ROAD TO 2025

32

Guide for Reliable Gloss Data

26 SUCCESS STORIES

72

Painting at Breath-taking Heights

48 WHERE WE HAVE BEEN 52 BRAND NEW

ADVANCEMENTS

AUTOCOATER 3000: A New Booth Concept

HIGHLIGHT OF THE MONTH

A New State-of-the-art Colour Bonding Technology Bring a Wealth of Product Enhancements at Sherwin-Williams: Higher Quality, Efficiency, and Sustainability in the Manufacturing of Metallic Powder Coatings

56 FOCUS ON TECHNOLOGY

Increased Productivity, Improved Quality, Faster Cycle Times, and Significantly Lower Powder Consumption: the Advantages of the New Vertical Coating Line Installed at Extrusax

Staying power When you need a protective coating to stay the distance, long after others have faded into memory, Interpon D3020 delivers. Its hyperdurable performance in all weathers and environments, from the hot desert sun to the freezing chill of the arctic rain, is matched by a fabulous array of colors and

coating performance when applied by an approved being a powder coating, it’s free of VOCs, creates little or no waste, and supports a more sustainable future.

architectural.interpon.com

CONTENTS SEPTEMBER/OCTOBER 2023

88

110

FOCUS ON TECHNOLOGY

A Hanging System that Improves Powder Coating Efficiency on Foxydry’s High-Tech Designer Clotheslines

104

ADVANCEMENTS

UCF Researcher Creates World’s First Energy-saving Paint – Inspired by Butterflies

64 FOCUS ON TECHNOLOGY

AREES Improves the Quality of Its Products with the Introduction of a State-Of-The-Art Shot Blasting and Powder Coating Plant

70 HOW IT’S COATED

Goodbye Grey, Welcome Colours

80 FOCUS ON TECHNOLOGY

114

NIR Coatings with a 5-Second Curing Cycle Specially Formulated for Marcegaglia’s Coil Coating Line

FOCUS ON TECHNOLOGY

Operative Word: QUALITY. A Long-Standing Partnership with a Powder Coating Manufacturer Enables LADAL to Finish Its High-End Aluminium Profiles for the Architectural Sector

FOCUS ON TECHNOLOGY

Mexall Upgrades Its Aluminium Profile Coating Plant with a Chrome-Free PreTreatment and Atomisation Cycle that Improves Performance and Reduces Water Consumption

96 FOCUS ON TECHNOLOGY

Allcolors: a Revolutionary System with a Bell Oven for Coating Aluminium Profiles up to 8 Metres Long

112 BRAND-NEW

Enduring.

Powerful.

Consistent.

Maximize the endurance and performance of your degreasing process UniPrep® cleaners, specially designed to operate at low temperatures, outlast conventional degreasing products by naturally degrading the organic soils introduced during the cleaning process.

Thereby, they reduce wastewater treatment burdens, lower energy consumption, and improve the overall carbon footprint. This offers modern paint applicators a highly sustainable and economical solution to replace conventional degreasing processes.

Advanced oil elimination vital to cost savings In combination with UniPrep® ISOtect, an easy-to-implement and easy-to-use turnkey oil elimination system, the efficiency of UniPrep long-life cleaning processes can be significantly increased.

The integrated cleaning system supports reduced chemical consumption and improved overall operational cost.

Long-life solution Low temperature operation Consistent performance Reduced wastewater treatment burden Improved running cost Reduced energy consumption

Atotech an MKS Brand info @atotech.com

www.atotech.com

CONTENTS SEPTEMBER/OCTOBER 2023

122

134

HIGHLIGHT OF THE MONTH

Science-based Decarbonisation Targets and a Focus on Innovation in Powder Coatings: PPG’s Growth and Sustainability Strategy

ADVANCEMENTS

Tintelligence™ is Ready to Transform the Paint Tinting Industry

128 BRAND-NEW

150 ASK JOE POWDER

138 ANALYSIS

152 ROAD TO 2050

The New Financial-Economic Era: Post-Globalisation

130

146

The “Ask an Expert” Column

EcoQPower Takes Paint Shop Energy Efficiency to a New Level

ANALYSIS

The New Trend Towards Ultra-Matte Colours in the World of Design and Architecture: Stardust’s View on Research, Production, and Application Issues

HIGHLIGHT OF THE MONTH

Research, Innovation, and Circular Economy in Paint Stripping: MECCRIOS Group’s Vision on its 32nd Anniversary

156 STANDARD & LEGISLATION - UCIF INFORMS Do System Certifications Still Bring Value for Companies in the Mechanical Engineering Sector?

158 MEETING THE INDUSTRY

THE POWER OF A PARTNER:

Working together for a more sustainable future Powder coatings from PPG

Sustainably advantaged solutions from a reliable partner PPG is a global coatings leader with 140 years of experience protecting and enhancing everything from cars and houses to packaging and industrial equipment. PPG’s powder coatings offer manufacturers and custom coaters sustainable solutions that combines stunning finishes with outstanding protection and performance.

Our coatings are just the start. The real plus is the total solution you get from a reliable partner. For more info, visit us at ppgindustrialcoatings.com.

The PPG Logo and We protect and beautify the world are registered trademarks of PPG Industries Ohio, Inc. ©2023 PPG Industries, Inc. All rights reserved.

EDITOR’S LETTER

Richiedi la versione in italiano a info@ipcm.it

M

etal architecture and powder coating.

A winning combination. An unbreakable association. A mutual exchange of inputs for innovation. A powerful push for research and development in the paint industry to meet the growing demands for outdoor durability and ageing resistance in an increasingly unpredictable climate while also fulfilling any designers’ dreams of colour and materials.

The dynamism underlying the relationship between the world of architecture – from designers and specifiers to manufacturers and coaters – and powder coatings is similar only to that existing between the automotive industry and liquid paints.

In Europe, when speaking of technologies for finishing metal architectural components – be they made of aluminium, steel, or extruded or sheet metal – powder coating is the first to come to mind, so much so it is established within the industry.

The European market simply does not consider any technological alternatives for the organic coating of architectural metalwork. In those rare times when we come across liquid-coated profiles, for example because they are intended for the US market, we find it hard to understand why that choice was made. Only in the coil coating sector does liquid paint still find its use, due to the specific mechanical strength properties required of the paint for post-processing the substrate.

The same is also true for all the markets colonised by European technology, such as the Arab Emirates, North Africa, and the Far East. Europe (especially Italy and Spain), however, is home to the companies that have pioneered the application of powders on aluminium profiles.

Conversely, at the global level, the United States market is the one where powder coatings are used the least, even more so in architecture, a sector where AAMA specifications, in particular AAMA 2605, provide for tests and requirements that are still very much focused on liquid coatings, despite covering both technologies. Less advanced technological development than in Europe, together with an environmental awareness that has not fully blossomed yet, means that powders (which are VOC-free as well as recoverable and recyclable) still hold a minority share of the market.

The trend, however, is reversing: this is what ipcm® picked up during its third attendance at Fabtech, the leading event in the US for the metal processing and finishing industry as well as the place-to-be for the paint and coatings sector, which this year took place in Chicago from 11 to 14 September.

Several European technologies were presented, with precise marketing and communication strategies contributing to the spread of powder coatings and fostering the technological change they call for. The information, research, development, training, and product validation work being done by ChemQuest Powder Coating Research with the help of Kevin Biller, by now a regular guest of this magazine with his Ask Joe Powder column, also proved strategic.

Many of these topics are also explored in depth on this issue of ipcm®, including a focus on “Architecture&Design” as well as offering the usual technological insights into the world of surface treatments.

Alessia Venturi Editor-in-chief Direttore Responsabile

international PAINT&COATING magazine - SEPTEMBER/OCTOBER 2023 - N. 83

07

BRAND-NEW

A Pioneering Design Engineer, Revolutionizing the Abrasive Blasting Industry Jason McKenna, CEO of Apollo Blasting Ltd & Apollo Blasting LLC, launches a new revolutionary dual induction technology for the abrasive blasting industry.

J

ason McKenna, CEO of Apollo Blasting Ltd & Apollo Blasting LLC,

provides the following benefits over older welded pressure pots:

has designed and developed world first dual induction technology,

• No pressure vessel - no moisture contamination with abrasive

revolutionising the abrasive blasting industry – globally, technology

media, eliminating the need for a compressed air dryer in most

built upon 13 years of prior engineering R&D of testing and validating

blasting applications.

abrasive blasting equipment.

• Infinite productivity - Apollo blasting systems can be filled with

Jason established his first contract abrasive blasting cleaning

abrasive during use, allowing 24/7 production, unlike pressurized

business, Media Blasting Solutions back in 2010, and used various

blasting pots.

types of blasting systems for contract blast cleaning on buildings,

• Apollo Blast pots are typically 50% lighter than older "welded"

engineering structures and machinery for customers across the

pressure blast pots.

UK. It was through issues seen with pressure blasting equipment,

• Single "multi-core" hose, combines all the control lines,

(downtime on job sites), that motivated Jason to design and

eliminating extra cable tied remote lines or water lines.

manufacture an alternative, more reliable solution for blasting

• 30% lighter blast hose, compared to 1" (25mm) pressure blast

contractors.

hose, reduced operator fatigue and increased productivity.

Jason McKenna went on to design and developed the world’s first

• Bullet proof reliability - ensuring productivity and profitability.

non-pressurised hopper (dual induction blast pot) Global Patent

• Reduced overheads: 35-37% less air consumption, compared to

Pending: Patent Application # PCT/EP2020/058157 - his new

welded pressure blast pots, (based on the same blast nozzle size),

technology has been sold and exported to over 15 different countries

50% faster cycle times - saving our customers thousands per year!

across the world, harnessing the best of his prior technological

It’s simply revolutionary new technology for the abrasive blasting

achievements.

industry.

Jason McKenna’s, new revolutionary dual induction technology,

For further information: www.apolloblasting.com

© Apollo Blasting

08

N. 83 - SEPTEMBER/OCTOBER 2023 - international PAINT&COATING magazine

© Apollo Blasting

BRAND-NEW

Microban® Launches Ascera™, a New Nature-inspired Technology for Polymers and Coatings Microban introduced Ascera™, its latest innovative antimicrobial technology designed for use in olefin polymers and solvent-based coatings.

M

icroban International has introduced its latest groundbreaking technology – Ascera™. This patentpending, next-generation antimicrobial technology uses

an active ingredient inspired by nature and designed for use in olefinic polymers and solvent-based coatings.

Ascera is sustainable, metal-free and less toxic than alternative technologies and provides the lifelong antimicrobial product protection that Microban is known for around the world.

Known for its antimicrobial and odour control technologies, Microban is committed to developing solutions that support product sustainability by extending their useful life. Ascera exemplifies the company's commitment to sustainability by © Microban

offering long-lasting product protection while maintaining critical attributes, such as ease of incorporation, safe handling and good chemical, thermal and UV stability. Ascera will work for the expected life of the product when applied to Microban standards,

research. This is the first of an exciting series of nature-inspired solutions

effectively inhibiting the growth of odour-causing bacteria to

that we will be launching in the next few years for different market

prevent stains and premature aging of the finished product.

segments and material types.”

“Microban has always led the antimicrobial industry with

“Our R&D teams are laser-focused on developing a range of cutting-edge

technological innovations that contribute to product sustainability,”

technologies that are nature-inspired for the different market sectors

said Dr. Souvik Nandi, Vice President of R&D at Microban

we serve. Our partners look to us first for what is next. Ascera will help

international. “In the past decade, regulatory and environmental

leading brands to create clean, odour-free and high value end-use

groups have put increasing pressure on many antimicrobial

products, which their customers will choose to support sustainability and

additive providers. As a result, Microban has invested significant

live a clean and refreshing lifestyle”, concludes Michael Ruby, President of

resources in identifying naturally occurring solutions that are more

Microban International.

sustainable and effective. We are very proud to roll out Ascera, which represents the culmination of many years of intensive

For further information: www.microban.com

COATING SYSTEMS AND APPLICATION TECHNOLOGY FROM ONE SUPPLIER Your trusted expert for automatic coating machines for metal parts, plastic parts, glass and many more will be happy to advise you on an individual coating solution. www.sprimag.com

BRAND-NEW

Tecnofirma Opens a New Branch in the United States Tecnofirma expands and announces the opening of the new American branch Tecnofirma America Inc..

A

fter Diamond Machinery Equipment Co. Ltd, Beijing (2011)

There will be also a spare parts warehouse which allows

and Tecnofirma Deutschland GmbH (2021), Tecnofirma

immediate availability of critical components and a dedicated

has established Tecnofirma America Inc. in Charlotte,

hot line service.

North Carolina. Today Tecnofirma can count on 4 different

Tecnofirma design and production departments remain in

branches in the world in the most strategic areas for its market.

the Italian headquarters in Monza. Machines and systems for

The new company is born to be the reference for the surface

cleaning, impregnation and coating business units continue to

treatment industry in the USA, Canada and Mexico (USMCA).

be designed and engineered every day by the Italian team at

It will guarantee an on-site service, following the customers

the historic plant in Viale Elvezia 35.

from the commercial phase to after-sales assistance, and a well-equipped laboratory to validate the right technical cycle based on the user needs.

For further information: www.tecnofirma.com/en

© Tecnofirma

10

N. 83 - SEPTEMBER/OCTOBER 2023 - international PAINT&COATING magazine

BRAND-NEW

Europolveri Obtains the ISO 45001 Certification Europolveri's constant commitment to guarantee the excellent quality of its products has been rewarded with the ISO 45001 certification.

L

ast month of May Europolveri, a company

once again looks to the future and is committed

specialising in manufacturing powder

to real changes. This is a considerable result

coatings for 40 years, achieved another

since it was achieved starting from an already

successful goal, the ISO 45001 certification,

established path, demonstrating the attention

confirming the company's concrete commitment

that Europolveri has always paid to quality,

to offering its workers and stakeholders a safe

environment and safety. Europolveri thus wants

environment, through the adoption of a proper

to act as an organizational role-model that

management system for safety and health in

reflects its historical choices, whereby together

the workplaces. Achieving this goal represents

with the continuous search for qualitative

the conclusion of a long journey that began in

improvement, it gives equal respect and attention

1993 with the ISO 9001 certification for quality,

to man and the environment.

then continued in 2014 with the ISO 14001 certification for environmental protection.

The implementation of the integrated

For further information:

certification represents a highlight of great

www.europolveri.it/en/philosophy/

importance in the company’s identity, which

certifications/

FORNITURE TECNICHE PER LA VERNICIATURA INDUSTRIALE © Europolveri

Via Fermi, 9 Zelo Buon Persico (LO) Tel. 02 90 66 92 40 r.a.

info@guerrasrl.it www.guerrasrl.it

BRAND-NEW

Sherwin-Williams Presented Three New Services at FABTECH 2023 At FABTECH 2023 Sherwin-Williams showcased FASTtrack, Stocked Powder Program and E-commerce Store to deliver fast, convenient, and reliable support to its clients.

T

he General Industrial Coatings division of Sherwin-Williams

John Morey, the U.S. marketing director of the General Industrial

attended FABTECH, the international trade fair dedicated to

Coatings division of Sherwin-Williams. “We provide paint and

metal forming, fabricating, welding, and finishing that took

coatings expertise when and where its partners need it. With liquid,

place from 11th to 14th September 2023 at McCormick Place in

powder and electrocoat technologies, as well as a full spectrum of

Chicago (Illinois, USA).

colour and gloss options, we have the products and the people to

The global manufacturer of paints and coatings presented its

help customers overcome all their coatings challenges. These new

wide portfolio of finishing solutions for the metal industry, as

services further expand the ability to meet customer needs”.

well as three new services specifically developed to deliver fast,

The personnel of Sherwin-Williams hosted also giveaways

convenient, and reliable support to businesses of all sizes:

throughout the show. As a matter of fact, visitors had the chance

• FASTtrack: a new service for customers that need liquid products

to win a Color Reader Pro: a small and portable device that links to

in a 24 to 48-hour turnaround time

thousands of colours produced by the company via Bluetooth and

• Stocked Powder Program: a programme with more than 475

simplifies colour matching.

products in stock and ready to be shipped, for users needing

In addition, Tabitha McLeish (global director of powder coatings)

accelerated delivery and streamlined processes

shared insights and expertise on powder coating and pre-treatment

• E-commerce Store: a new online shop allowing small to

by presenting real-life challenges and troubleshooting approaches,

medium-sized businesses dealing with powder coatings to order

while Michael Bauer (E-Coat application engineer) discussed the

directly.

latest advancements in e-coat technology, exploring the recent

“These new programs and technologies are a direct result of

innovations in pre-treatment and application processes.

conversations we have had with FABTECH attendees in the past.

We listened, we addressed the challenges and we are excited to having brought advanced solutions to this year’s show,” has stated

© Sherwin-Williams

12

N. 83 - SEPTEMBER/OCTOBER 2023 - international PAINT&COATING magazine

For further information: https://shorturl.at/lruwK

BRAND-NEW

Efficient Drying Using a Heat Pump Harter, a German company that has been developing, manufacturing, and selling energy-saving drying systems for industry for over 30 years, consolidates its technology and confirms itself as a point of reference on the market.

U

nacceptable drying results are often

terms of quality and time.

the reason why many operators

To begin with, Harter offers to test the items to

approach the proficient drying system

be dried in their in-house pilot plant station to

manufacturer Harter. Issues include items left

see how they respond to drying. In these tests,

wet, staining, and stringent cycle times. Cracking

the parameters controlling successful drying are

and cratering are frequently challenges in paint

determined. Potential buyers may thus satisfy

drying applications. And processors switching

themselves of the potential that lies in this

from solvent to water-based paints are faced with

technology.

drying for the first time. Furthermore, companies must replace energy squandering equipment

Low temperatures, dry air

previously tolerated.

Heat pump based condensation drying uses

Harter and their heat pump based condensation

temperatures between 20 °C and 90 °C. The

drying have established themselves as problem

extremely dry, unsaturated process air is

solvers in the market. The South German

precisely passed over or through the items to be

company developed their alternative drying

dried. This ensures both quick and gentle drying.

technique more than 30 years ago. Their

Paint coats dry uniformly from the inside out.

energy-efficient technology was much ahead of

Water on surfaces is quickly removed. Staining is

its time, then. It has become red-hot, today –

an issue of the past. Reduction of cycle time or

more than ever. Operators using this technology

expansion of capacity have often been achieved.

do not only save energy and money galore, they

The drying solutions are always customized and

also obtain substantial improvements in

perfectly meet the requirements of the specific product or process.

Drying is accomplished in a closed air system which means that there is no exhaust air involved. Constant parameters ensure consistent quality and, thus, utmost process reliability – irrespective of the seasons and the climate. And, energy and carbon savings set the agenda, today.

As of 2017, German, Austrian, and Swiss users of this efficient and energy-saving heat pump technology qualify for government subsidy.

COMPLETE SOLUTIONS FOR For further information:

© Harter

HANGING AND MASKING

www.harter-gmbh.de/en/

www.rostirolla.it

© BYK

ANALYSIS

Guide for Reliable Gloss Data Edited by BYK-Gardner GmbH Geretsried, Germany

info.byk.gardner@altana.com

U

niform and consistent gloss are an essential quality criterion

the end-user will perceive it as a defect. Therefore, gloss limits

for a variety of products. Therefore, gloss needs to be

and tolerances are defined based on application and customer

objectively measured. Only what can be objectively measured,

expectations.

can be controlled and can be optimized which is of importance in

The technical performance of the gloss meter used to objectively

product development as well as in production control. Especially in

measure gloss is essential to obtain reliable data. Therefore,

case of multi-component products a uniform gloss is an expression

BYK-Gardner glossmeters are developed with focus on excellent

of “high quality”. Variations in gloss look like something is wrong and

technical performance under any circumstances.

14

N. 83 - SEPTEMBER/OCTOBER 2023 - international PAINT&COATING magazine

© BYK

ANALYSIS

© BYK

Fig. 1: Short- and long-term repeatable gloss data with BYK-Gardner micro-gloss: ±0.2 GU.

Fig. 2: Inter-instrument agreement of BYK-Gardner micro-gloss instruments: ±0.5 GU.

Technical performance: essential for reliable data Repeatable gloss data Goal is to meet the target value within a defined tolerance. Therefore, the glossmeter used should deliver repeatable measurement results i.e., excellent short- and long-term repeatability (Fig. 1).

Otherwise, you do not know whether the gloss change is due to a glossmeter drift or a true product Reproducible gloss data from glossmeter to glossmeter Reproducibility is as important as repeatability as every production is part of a supply chain

© BYK

variation.

Fig. 3: Temperature stability between 10 °C – 40 °C – 10 °C.

process. Gloss values need be communicated and exchanged within a supply chain. Gloss levels of

reproducibility because you do not know what the

various production facilities or several production

temperature conditions are at different production

lines need be consistent to achieve a uniform gloss

sites.

Otherwise, a multi-component product will look like

A glossmeter needs “health check”

patchwork and the various component suppliers

Production environment is often rough and

will always discuss who delivered the “part with the

dusty which can affect the performance of your

correct gloss level”.

glossmeter as optics can accumulate dust on the

Gloss measurement independent of

lenses. Therefore, the “health status” of the used

temperature changes

gloss meter is an important factor and needs to be

Depending on the season temperature in the

checked. The BYK-Gardner micro-gloss instruments

production area can change. The temperature

have an “auto-diagnosis” which checks the actual

during day and night shift can be considerably

performance of the instrument and gives you

different. The temperature in the lab might be

instant feedback:

controlled at 23 °C, while in the production area the

• Auto-diagnosis is OK

temperature is much higher due to baking ovens or

• Please clean standard

other production machines.

• Optics need cleaning

Therefore, it is essential that the glossmeter used

recertification

is not influenced by temperature changes and the

The auto-diagnosis is your insurance for reliable

gloss data is independent of the temperature

measurement data.

(Fig. 3).

Send in for service /

stability is as important as repeatability and

The answer is easy: micro-TRI-gloss. The universal

EN 1527

el

H

conditions, data cannot be compared. Temperature

High gloss, semi gloss, matt - what geometry is best?

If gloss values are only stable within laboratory

m

A.

within defined tolerances (Fig. 2).

Hellas S

.

© BYK

© BYK

Fig. 4: Standardized geometric conditions.

Fig. 5: Specular gloss values dependent on measuring angle.

In order to get a representative value of your product finish a minimum of 3 readings should be taken. And to evaluate the uniformity of your product’s surface finish the average with “std. dev. or range (min – max)” should be recorded.

The micro-gloss instruments offer a statistic mode that can be defined by the user (Fig. 6).

A single reading does not give a true picture of the uniformity which is particularly important when evaluating larger surface areas. © BYK

Fig. 6: Micro-gloss display of statistic mode.

Gloss measurement digitalized Everyone is talking about digitalization. Why do you still write down gloss values or enter data manually in Excel?

The micro-gloss instruments come with the software smart-

glossmeter to measure high, medium and low gloss finishes

chart which allows you to transfer, save and analyse the data

accurately. Three different illumination angles (Fig. 4) are

in easy-to-interpret trend charts. The saved data can be used

required to achieve good differentiation of the entire range from

for production monitoring with documentation in standardized

high to low gloss surfaces:

reports as PDF-file or for transfer to other programs. Always

- 20° high-gloss surfaces - 60° semi-gloss surfaces - 85° low gloss

ready for audits and optimization.

surfaces range of applications with gloss values between 10 and 70 gloss

Micro-TRI-gloss: the intelligence in gloss measurement

units. If gloss data is higher than 70 GU or lower than 10 GU,

The features of the Micro-TRI-gloss are:

this measurement geometry is no longer effective in showing

• Repeatable

differences as shown by the flat portion of the curve. Thus, the

• Reproducible

60° geometry would show little or no difference in this range,

• Temperature Stable

while visually there is a clear difference (Fig. 5).

• Auto-Diagnosis

The 60° illumination is used as a general geometry for a wide

How many measurements should be taken or the importance of statistics Here our answer is “ONE reading is like NO reading”.

16

N. 83 - SEPTEMBER/OCTOBER 2023 - international PAINT&COATING magazine

• Statistics • Gloss measurement digitized • High to low gloss finishes • Unsurpassed.

HIGHLIGHT OF THE MONTH

A New Name, a New Brand, a New Ambitious Growth Strategy: Kansai Helios Italy’s New Course From an interview with Bine Pangršič Managing Director and President of the Board of Directors of Kansai Helios Italy

At the beginning of 2021, ipcm® first visited Helios Coatings Italia, which at that time was formed by the merger of two sister companies – Ecopolifix, an Italian powder coatings producer, and Helios Italia.

Today, the company is part of the Kansai Helios Group, which belongs to Kansai Paint, one of the ten largest paint manufacturers in the world. In August, we returned to the Riese Pio X plant to discuss the medium-term development paradigm of the company, meanwhile renamed to KANSAI HELIOS Italy, and how it intends to implement it.

“K

ansai Helios Italy represents the result of a two-year long development and integration

process in order to position the company as a system supplier for industrial coatings and additionally as a strong pillar for the Kansai Helios Group on the Italian market,” states Bine Pangršič, Managing Director and President of the Board of Directors of Kansai Helios Italia, at the beginning of our interview. “We left behind the approach that characterised the company in the past, based on specific niche segments and service offerings, to enter a completely new dimension: a new corporate name, a new market focus, and a new, ambitious growth project. In the course of integration processes like this, it is first necessary to identify the strengths and weaknesses of the original business and the path taken in the past. Then, it is important to understand which direction to take in the present, in terms of both strategic vision and development goals. Finally, it is necessary to reflect on the future, defining the market

The new brand image of Kansai Helios Italy on the boxes pictured at one filling line at Kansai Helios facility in Riese Pio X (Treviso, Italy).

©ipcm

18

N. 83 - SEPTEMBER/OCTOBER 2023 - international PAINT&COATING magazine

HIGHLIGHT OF THE MONTH

©ipcm

©ipcm

Bine Pangršič, Managing Director and President of the Board of Directors of Kansai Helios Italy.

Kansai Helios Italy replaced almost all the mixers with state-of-the-art machines.

Currently, we are in this third phase of our transformation,

Tell us about the current production and commercial set-up of Kansai Helios Italy.

and we are slowly entering the fourth one, which will define

Bine Pangršič: “We still own two production sites. The one

the “4.0 version” of Kansai Helios Italy, when everything will be

where we are today, in Riese Pio X (Treviso), is the largest and

digitalised and automated and production will be completely

it produces around 7500 tonnes of thermosetting powder

paperless – a complete revolution in the way things are done

coatings. The second one is in Tezze sul Brenta (Vicenza) and

compared with today,” explains Bine Pangršič.

it produces around 2500 tonnes of thermoplastic powders. In

“The new name, Kansai Helios Italy, is in line with the group’s

addition to these production plants, we also have an already-

strategy, which envisages that all companies belonging to

existing trading office in Gorizia, from which we sell products

it not only carry Kansai Helios internally, but also represent

from Kansai Helios Group’s other ranges, especially decorative

it externally. It may seem like a small change from our first

paints, car refinishing products, and adhesives, and a brand-

meeting two years ago, but it has meant a lot to us because

new hub in Piacenza, which will be representative of what

it also enabled us to rebrand our products in the powder

Kansai Helios Italy stands for. We aim to become a unique

coatings sector, and changing from Ecopolifix to Kansai Helios

and exclusive point of sale in Italy for all coating technologies

Italy, which was still in use until a few months ago, and thus

produced by the Group. With the Piacenza hub, we will initially

starting to distinguish ourselves in terms of both quality and

serve only nearby regions and then, depending on the segment,

strategy. First of all, this production and commercial site is

gradually expand to the entire North-West Italy. We all together

now part of a global multinational coatings group. Secondly,

currently have 110 employees. Last year, we sold more

we have a completely different technological know-how and

than 9000 tonnes of paint in 28 different markets, with Italy

an entirely new, state-of-the-art approach to infrastructure

accounting for just over 50% of total sales.”

position and the corporate mission one wants to achieve.

and production processes. Last but not least, we want to than in the past. This rebranding operation was therefore

What is the new industrial coatings sales strategy of Kansai Helios Italy?

necessary to show the market and all our stakeholders

“Our main goal is to become a major supplier of integrated

that we have taken a different direction. Kansai Helios Italy

coating systems, including liquid, powder, cataphoresis

is no longer just a manufacturer of powder coatings: while

technologies, gelcoats as well as adhesives and sealants to

maintaining its specialisation, it now also represents the

industrial customers and contractors, which are our main target

entire portfolio of solutions that the Group can offer in Italy

groups. Our entire strategy, including our ongoing marketing

and abroad, through synergies with other segments and

activities with ipcm®, is in line with this approach. We see the

close connection with other subsidiaries.”

coordination among their different product segments as a key

offer a completely different and updated set of technologies

international PAINT&COATING magazine - SEPTEMBER/OCTOBER 2023 - N. 83

19

©ipcm

In the last three years Kansai Helios Italy added another production line, bringing the total number from 6 to 7, and revamped all the existing ones.

and one of our great strengths. We offer a new way of selling

all, it identified powder coatings as one of the crucial areas of

complete painting technology packages as coordinated and

development for the entire Kansai Helios Group. Therefore,

interconnected. This is also a great advantage for our industrial

the first issue we had to address was the improvement of

customers, which will always know who to turn to for any

our production capacity, which would limit us quickly on that

problem and, on the other hand, will always find in us a partner

growth path.

able to interface with both pre-treatment suppliers and coating

The general paradigm behind our mid-term management plan

plant manufacturers to solve their issues. We are becoming a

was to move from being a good company to becoming a great

full system supplier that is aligned with its customers’ wishes

company. This approach came from the Japanese mindset,

and needs. Our industrial metal coating business started from

and it was up to us to figure out how to implement it. Kansai

scratch in Italy three years ago. The fact that we have grown the

Helios Italy chose the two ways that seemed most effective to

company from its origins of only offering architectural coatings

us: having the right people in the right position and knowing

and refinishing coatings to its current form, where we offer not

exactly what we want to do and what we are capable of doing

only powder coatings but also cataphoresis and liquid products

well in order to focus exclusively on that.

with endless combinations of uses, is the result of the people who

We therefore decided to invest heavily in three areas:

work for us. We are proud, that over the past two years, numerous

infrastructure, production machinery, and personnel. We

technical and commercial experts have come on board Kansai

first invested in the development of the existing staff through

Helios Italy and joined our family.”

training and refresher courses to bring our people to a

Can you outline the industrial development plan of Kansai Helios Italy for our readers?

higher professional level than before and then we hired new specialised professionals to strengthen our team even further. As far as infrastructure is concerned, we first bought

“In 2021, Kansai Helios designed a mid-term management

the premises that we only had for rent and afterwards we

plan that gave precise indications on the path to be taken as a

also acquired the adjacent building to secure the necessary

company but also on the path of our industrial segments. Above

space for expansion. With the right people in the right place

20

N. 83 - SEPTEMBER/OCTOBER 2023 - international PAINT&COATING magazine

HIGHLIGHT OF THE MONTH

©ipcm

Alenka Leghissa, Managing Director and Member of the Board of Directors and Bine Pangršič, Managing Director and President of the Board of Directors in front of the new powder coating extrusion line.

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

and owning the necessary infrastructure, we finally started a much more complex and ambitious development project, which is going to continue over the next five years leading to the construction of a new state-of-the-art, fully digitalised, automated, and paperless factory.”

Can you give us some more technical details about this project? ”Only this much - large parts of the production and warehousing are being automated, from raw material storage to handling and dosing across the entire production chain to the finished product. It will give us and our customers new possibilities in new dimensions in regards of production flexibility and product availability. It is a true investment not only in the production location Italy and the Italian market, but also into a segment that will become increasingly important within our group and in general. This year, Kansai Helios Group successfully closed the acquisition of CWS Lackfabrik, where also CWS Powder Coatings in Germany belongs to. This has made us the fourth largest European powder producer, with production locations in Germany, Italy, Slovenia and Serbia covering the entire Europe from the German speaking area, Benelux and Northern Europe, to Italy, Spain, France, and Poland as well as strategical markets in Central and Eastern Europe with practically no overlaps”.

We can say that the project of Kansai Helios Italy is twofold: on the one hand, it focuses on infrastructure and investment and, on the other hand, on business transformation and development. ”Exactly. We took a big step forward in the development of the

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



General view of the warehouse of the finished products at Kansai Helios Italy’s Riese Pio X plant.

©ipcm

company. We thoroughly analysed the global powder market

deep matt Qualicoat Class 1 architectural paints. Today, Kansai

to understand its current needs and expectations in terms of

Helios Italy holds 22 different quality approvals, which puts us in a

products and services. We therefore streamlined our portfolio

privileged position compared with our competitors. Finally, we are

and restructured our own standard offer. Now, we can readily

placing great emphasis on customer service through maximum

supply around 1,000 products from our warehouses in more

product availability, short delivery times, and continuous technical

than 650 different colours and textures that are part of the main

assistance.”

international standard products and immediately available at any

In fact, it has already grown significantly thanks to the

What critical issues do you anticipate in the implementation of this comprehensive development project?

investments made over the past years. Only in the last three

”One of the biggest challenges will be to implement this process

years we added another production line, bringing the total

without interrupting production. But we can draw on a broad

number from 6 to 7; we revamped the existing extrusion plant

wealth of experience within our group and have the chance to once

and replaced two grinding mills; we replaced almost all the

again demonstrate the strengths of our global organization”.

given time and delivered within 24 hours.

Our goal is to double our production capacity to 15,000 tonnes.

mixers with state-of-the-art machines; and we are implementing

traceability within a year. A further area of development in the

As a general question, how do you see the future of powder coatings? Do you think they will gain other market shares of liquid technology?

short term is our bonding system, considering that bonded

”Well, of course, a lot depends on the overall movement of the

special-effect powder coatings will experience the greatest

global economy, and now we are somehow in a downward trend,

development in the mid-term future, driven by demand from

especially in Europe. But if you look at future predicted growth

sectors such as design, architecture, and automotive. Of course,

rates, you will see that we have predicted higher growth rates in

we are also working intensively on reviewing and optimising all

powder coatings than in other segments. We expect in the future

our processes and service and information tools.

that the increase in powder consumption will be higher than the

With regard to future product developments, we are focussing

one in liquid coating due to the sustainability and eco-friendly

on sustainability, an example is low-temperature cure powders

nature of powder coatings. At present, we are seeing a lot of

and powders formulated using recycled or natural raw materials.

potential in Western Europe markets, such as Spain, where we have

Currently, several products from standard offering, such as

recently implemented our distribution channel and local stock that

Leatherette Qualicoat Class 1, are produced in low-bake quality.

is giving already excellent results”.

a new manufacturing execution system (MES) that will enable us to achieve a paperless production process and full product

Another R&D focus is that of thin-textured, soft touch, and

22

N. 83 - SEPTEMBER/OCTOBER 2023 - international PAINT&COATING magazine

REDDER THAN EVER

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ROAD TO 2050

Watch out for VOCs! Edited by Lechler Spa Como, Italy

The growing attention towards the topic of sustainability implies greater corporate awareness and the need to verify the suitability of its products according to methods recognised, measurable and shared at an international level.

T

he Indoor Air Comfort (IAC)

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regards the Paints and Varnishes sector

Organic Compounds) emission criteria

Comfort conformity result in the highest level

and, more specifically, the requirement

established by the European Community.

called GOLD, in line with the most stringent

2.5.13 (point b - heavy metal exemption)

The products from the Lechsys Hydro

international environmental certification

and the requirement 2.5.1 (VOC emissions

line HYDROFRAME COAT PVC FLEX,

protocols.

limit). The fact that Lechler is a UNI EN ISO 14001 certified company and the evidence of particularly low indoor VOC emissions (measured according to the UNI EN 16516 standard), also make these products compliant with additional CAM rewarding criteria defined in paragraphs 3.2.1 and 3.2.8.

Compliance with the CAM and IAC Gold requirements allows for compliance with the main international protocols regarding the emission of VOCs and with Green Public Procurement (GPP), i.e. the system that evaluates the possibility of including environmental qualification criteria in the application that Public Administrations express when purchasing goods and services.

Furthermore, IAC Gold and

© Getty Images

24

N. 83 - SEPTEMBER/OCTOBER 2023 - international PAINT&COATING magazine

CAM compliant products

ROAD TO 2050

© iStock

and materials contribute to obtaining

conformity to VOC requirements

that, through the control of VOC

credits for achieving the American LEED

such as Contract, Habitat Interior,

emissions, want to demonstrate in a

and WELL building certifications and the

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concrete and measurable way the carbon

English BREEAM, recognised throughout

intended for works of public and private

footprint of their products and improve

the world.

procurements, designed according

their PSI (Product Sustainability Index),

The IAC Gold and CAM compliant

to the requirements of the main

an important parameter of the so-called

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environmental protocols.

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STUTTGART 26-28/09/2023 HALL STAND

10

E36

SUCCESS STORIES

Painting at Breath-taking Heights Vollert developed a particularly space-efficient paint shop on two levels for machine and plant constructor KraussMaffei. The workpieces are moving on a crane track at a height of twelve metres. The walk-on painting and working area for the workers is located six metres high on the first floor, and the space underneath can be fully used – protected by a rock-solid fall protection for large parts with weights of up to 30 tons.

© Vollert

© Vollert

Logistics area below, paintshop above: Vollert developed an extremely space-saving two-floor paintshop for large parts of up to 30 tons for KMT KraussMaffei.

26

N. 83 - SEPTEMBER/OCTOBER 2023 - international PAINT&COATING magazine

SUCCESS STORIES

T

he components of the plants for producing and processing

logistics paths in the existing hall made us think of a two-level plant,

plastics that are painted above-ground in the new Parsdorf

though without being certain of its feasibility in detail – in particular

plant of KMT KraussMaffei Technologies near Munich

in light of work safety. After all, employees keep on working in the

(Germany) weigh up to 30 tons. That’s not the end of it either

logistics areas and on workstations on the ground floor as well.

since some machine parts can reach weights of up to 100 tons.

Together with Vollert’s experts, we developed the two-level concept

Those, however, are painted manually rather than in the circulation

with fall protection in order to optimally meet our needs,” explains

procedure. “KraussMaffei set us multiple tasks to solve at once since

Wuyang Li, project manager at KraussMaffei.

special large parts need to be painted manually while transport automated – and the entire filter and painting technology had

First double-floor paint shop for parts weighing 30 tons

to be placed very space-savingly in an existing hall, too,” Jochen

The heavy-duty and intralogistics specialists at Vollert planned a

Keinath, head of finishing technology sales at Vollert Anlagenbau

two-level system with conveyor technology above, integrating it

from Weinsberg, reports. “The limited space and highly frequented

into the existing hall at the new Munich/Parsdorf production site

and coating of parts weighing up to 30 tons are to happen partly

© Vollert

Special catching nets secure the work area on the ground floor against falling workpieces with weights of up to 30 tons in an emergency.

international PAINT&COATING magazine - SEPTEMBER/OCTOBER 2023 - N. 83

27

SUCCESS STORIES

© Vollert

© Vollert

Several input and output stations transport workpieces from the ground floor twelve metres up to the height of the crane track on the first floor.

of KraussMaffei as a free-standing steel structure. The ground floor now holds the manual paint shop for large parts with up to 100

There is a total of 26 workstations here, including cleaning, paint and drying booths, along with storage places for sequencing and cooling. The manipulator in the background takes care of workpiece distribution. A catching basket (red) underneath the load additionally secures the workpieces.

however, make this plant at KraussMaffei’s facility stand out.”

paint supply, as well as the filter and washing technology for

A single manipulator constitutes the entire conveyor technology

extraction of the paint mist for the paint booths above. “These

The conveyor technology’s special feature is that no chain

filters are usually installed in the basement underneath the

conveyors or directly driven goods carriers are needed for

booths,” Jochen Keinath explains. “That wasn’t an option here for

transport at all. A single manipulator is all it takes to distribute the

constructional reasons. Therefore, we put the booths for cleaning

workpieces among various workstations. For this, Vollert installed

and painting the workpieces at first-floor height.” Vollert planned

a crane track at a height of twelve metres for the distribution

and delivered the plant and heavy-duty conveyors, including streel

manipulator to run on along a length of 80 metres to serve the

structures, from a single source. The painting technology comes

workplaces and paint booths on either side. The manipulator has

from Heimer Lackieranlagen from Bielefeld. “As far as we are aware,

stationary friction wheels to move the goods carriers forward and

this is the first double-floor paint shop of this kind world-wide. We

push them on and off at the various workstations. The paint and

have designed plants on multiple levels a few times before in the

drying booths thus can make do without any live drives.

area of prefabricated concrete plants; maximal loads of up to 25

The system starts out on the ground floor, where workpieces at

workpieces at 30 tons each and the accessible level underneath,

sizes of up to 4.8 m length, 2.4 m width, and heights of up to

tons, storage places and walkways along with the paint warehouse,

28

N. 83 - SEPTEMBER/OCTOBER 2023 - international PAINT&COATING magazine

SUCCESS STORIES 2.8 m are suspended in goods carriers individually or in groups. The

Florian Gruber, responsible for operation of the paint shop at

carriers are designed as double-track goods carriers for better load

KMT KraussMaffei, is very happy: “The new system has some great

distribution to handle the heavy weights. Three input and output

advantages for us. Several input and output stations let us serve

stations are available to insert the workpieces into the plant and

three different end assembly segments from a single system in a

remove them from it again. After merging, a lifter moves the goods

value-flow-oriented manner. We are now also perfectly flexible in

carriers up twelve metres to the height of the manipulator crane

terms of process design for our diverse parts families, as well as

track, which takes them over for further distribution.

for sequence planning thanks to multiple sequence storages. Our

Maximal flexibility in the process

previous system – a strict circulation system – hardly allowed us to set priorities. Now, we can act highly flexibly and supply even

On the first floor, the system comprises 26 stations, including four

pressing service orders immediately. At the same time, we were

masking ones, one cleaning booth, two wet paint booths, and four

able to clearly increase the cycle time with the new paint shop.”

drying booths. The remaining areas are storage places used for sequencing, interim storage, buffering, and cooling the workpieces.

Rock fall protection as fall arrestor

The special plant layout makes it possible to advance individual

The plant’s fall protection concept is another special feature.

workpieces, overtake them, or keep them back for rework at any

Workers’ walkways must be protected from falling workpieces in

time without interrupting the plant flow. This ensures a cycle time

emergencies in order to permit full use of the space underneath

of 45 minutes. The storage places are targeted automatically by

the paint shop and the workpieces suspended overhead. It’s not

the Vollert system’s control unit after the workpieces are fed in, as

a simple task at weights of up to 30 tons, through the Vollert

well as in the further coating process. Transport in the walk-in work

specialists had a special idea here, too. Jochen Keinath: “We use

booths and masking stations takes place after acknowledgement by

special nets that are usually used for rock protection and to protect

the workers.

from falling boulders. They secure the space underneath the

SUCCESS STORIES

© Vollert

Relocation of the cleaning, paint, and drying booths to the first floor leaves enough space on the ground floor for manual painting of large parts of up to 100 tons, as well as for storage places, walkways, and the paint warehouse.

The paint booths at KraussMaffei are located on the first floor, the paint supply, filter and washing technology for extraction of the paint mist on the ground floor underneath.

© Vollert

conveyor now – and they can catch falling loads of up to 30 tons.”

About Vollert Anlagenbau GmbH

To make the safety system rock-steady without interruption, a fall

As a specialist for heavy loads and large parts, Vollert Anlagenbau

protection barrier designed as a catching basket underneath the

GmbH is developing turn-key intralogistics concepts for the

manipulator and moving along with it additionally supplements the

aluminium and metal industries. As a general contractor and full-

safety concept.

service provider, its performance range comprises state-of-the-art

“The rock fall net is, of course, special. Our staff like it a lot since

material flow, warehouse, and packaging technology, both as stand-

it reflects our commitment to employee safety, which enjoys the

alone solutions and integrated into a larger logistics environment.

highest priority for us. We want to exclude all dangers from the

Whether fully automatic mega high-bay facilities for aluminium

very first here. We discussed all potential risks for our employees

coils, smart material flow systems for the leading aluminium strand

with Vollert in advance of the plans already, trying to find solutions.

manufacturers, the world’s highest-performing storage and retrieval

Vollert’s concept with the catching basket travelling along and

machines for storing sheet blanks, automatic crane systems for

the safety nets eventually convinced us. The employers’ liability

50 tons and more, or cutting-edge surface coating plants – Vollert is

insurance association also reacted very positively to this,” reports

involved in all of them.

project manager Wuyang Li.

Plant and machine solutions by Vollert are used in more than

“With the new plant at KraussMaffei we have implemented a

80 countries around the world. Dedicated subsidiaries reinforce

particularly space-saving layout that optimally uses the available

sales activities in Asia and South America on top of this. Vollert has

area. Arranging it on two levels allows us to greatly reduce the

a workforce in excess of 300 employees at its corporate seat in

footprint without having to cut down on speed. Partial automation

Weinsberg.

simplifies and accelerates processes while at the same time ensuring damage-free transport,” Jochen Keinath concludes.

30

N. 83 - SEPTEMBER/OCTOBER 2023 - international PAINT&COATING magazine

For further information: www.vollert.de

HP series

the Pulverit Opus Magnum HP SERIES - HIGH YELD/PENETRATION PRODUCTS SERIE HP - PRODOTTI AD ALTA RESA/PENETRAZIONE FEATURES The HP series is specifically designed to uniform the thickness of powder applied on all parts of the painted support.

CARATTERISTICHE La serie HP è pensata specificatamente per uniformare lo spessore di polvere applicata su tutte le parti del supporto verniciato.



BENEFITS Reduction between 15% and 30% of the powder required to paint the support.

The HP series considerably reduces the “orange peel” effect due to the accumulation of powder in the parts adjacent to the critical points and minimizes the accumulation effect on the edges.

CARATTERISTICHE Riduzione tra il 15 % e il 30% della polvere necessaria a verniciare il supporto.



La serie HP riduce notevolmente l’effetto “buccia di arancia” dovuto all’accumulo di polvere nelle parti adiacenti ai punti critici e minimizza l’effetto di accumulo sui bordi.

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www.pulverit.com

Pulverit Iberia s.l.u. c/ Caravis, 28, 1º 3ª 50197 Zaragoza Tel. +34 607163259 email: iberia@pulverit.it

© Spray S.A.

ADVANCEMENTS

AUTOCOATER 3000: A New Booth Concept Oscar García, Spray S.A. - Barcelona (Spain)

W

oscar.garcia@spray-sa.com

hen it comes to coating, many companies find

deal with a high variety of component shapes. This is a major issue

themselves dealing with large batches of parts, mainly

because every time they switch to a batch composed of workpieces

with complex 3D geometries and with numerous welding

with a different geometry, they are forced to stop production

spots or areas as well as difficult-to-reach surfaces, which require

so that the operators can adjust the fixed automatic guns. This

them to be equipped with fixed guns for manual retouching as well

process, which depends on the complexity of the parts to be

as automatic guns mounted on reciprocators. Most of these firms

coated next, takes an enormous amount of time, which of course

only apply one colour but, on the other flip of the coin, they often

also entails significant costs. This situation might seem theoretical,

32

N. 83 - SEPTEMBER/OCTOBER 2023 - international PAINT&COATING magazine

ADVANCEMENTS

© Spray S.A.

Overview of the AUTOCOATER 3000 coating system.

fictitious, or trivial, but it is actually a serious problem for these

• Increased production volume through improved application

companies, which lose hours of work every day to carry out batch

speed.

changes, without any cost-effective solution in sight.

• Reduced idle time when adjusting the angles of fixed automatic

This is what we were also told by the company that allowed us to write

guns.

about its success case provided that it remained anonymous. When we first made contact with this firm, we immediately identified its

In detail, the idle time required for the operators to reset the

production problems and its requirements for improving its workflow.

angles of the stationary guns was around 60 minutes, depending

Production issues

on the type of parts. However, having to stop production with each new batch, the average production time loss was 3 to 4

• High average idle time for adjusting the angles of fixed guns during

hours per day. Moreover, the adjustments performed by the

batch change operations.

workers were not perfect; therefore, it was necessary to resort to

• Very difficult and burdensome manual touch-ups.

manual touch-ups, resulting in a heavy workload and a reduction

• Inability to increase productivity.

in the efficiency of the operators responsible for such retouching

Production improvement requirements

phases.

In this situation, increasing productivity was a big challenge.

• Fully automatic coating of any type of component without manual

However, together with all the company’s requirements for its new

retouching.

line, this turned into a goal and, as a result, into the project for a international PAINT&COATING magazine - SEPTEMBER/OCTOBER 2023 - N. 83

33

© Spray S.A.

© Spray S.A.

Big Bag automatic gun feeding system.

A detail of the reciprocator and the fully sealed plant.

new coating system that, also supported by its accessory equipment,

in particular.

met the company’s needs while avoiding additional costs. From

• Reorganising the automatic guns, using 28 of them with an

the very beginning, we took advantage of numerous resources and

alternating vertical movement together with 22 fixed ones.

designs to achieve this objective and ultimately initiate a global project

• Achieving an idle time for the adjustment of the fixed guns’ angles

for the development of our new AUTOCOATER 3000 coating booth,

of 1 minute per batch change, compared with the previous 60

which we called “encapsulated” due to its special layout, as described

minutes.

below.

• Implementing an automatic angle adjuster for the 4 axes of each

The project

stationary gun to coat difficult-to-reach areas without any manual retouching.

To define the basis of this project, we laid out all the requirements

• Raising production speed to 8 m/min, i.e. a 60% increase

and problems presented by the company and defined the following

compared with the past.

targets: • Designing a new high-productivity booth with the highest possible

The philosophy behind AUTOCOATER 3000

transfer efficiency and creating new accessory devices that

We could define the AUTOCOATER 3000 as an “encapsulated

considerably reduced powder and energy consumption. The new

booth”, since there are no openings for the automatic guns (fixed or

AUTOCOATER 3000 proved to be the right machine for this last aspect

mounted on the reciprocators) nor stations for manual retouching.

34

N. 83 - SEPTEMBER/OCTOBER 2023 - international PAINT&COATING magazine

ADVANCEMENTS

© Spray S.A.

Custom-built painting installations Macchine e impianti realizzati su misura

Shot blasting booths Cabine di sabbiatura

Washing tunnels Tunnel di lavaggio

Liquid painting installations Overview of the accessory systems.

Impianti di verniciatura a liquido

It only has openings corresponding to the parts’ silhouettes and an upper opening for the conveyor. It also has the typical pre- and post-finishing stations located before the booth’s entrance and after its exit, but they are only used when problems occur in the application area.

More in detail, the openings for the vertical sliding of the guns

Powder painting booths

Cabine di verniciatura a polvere

positioned on the reciprocators on both sides of the booth are sealed with a belt or a mobile polyurethane band, which moves up and down together with the internal support bar on which the automatic guns are mounted (completely inside the booth), thus covering 95% of the opening areas themselves. Likewise, the grooves are equipped with compressed air nozzles to ensure a perfect seal. This design significantly reduces the air extraction

Curing ovens

Forni di cottura

volume, as no airflow from the automatic guns’ or touch-up stations’ openings can spoil the powder cloud inside the booth, which in turn limits overspray.

Based on our experience, reducing the distance between the automatic guns improves transfer efficiency and reduces blow-

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

off among the guns themselves, ultimately improving finishing consistency. This leads to the possibility of increasing the number of guns while limiting the length of the booth. We thus reduced the automatic gun pitch’s conventional value from 400 mm to 165 mm. Furthermore, during coating or when cleaning the inside of the booth, there is no risk of powder leaking through the openings and, therefore, there is only a minimal possibility of contamination in the environment around the booth.

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

Accessory systems

number of “swing-wing” filter cartridges, which ensure efficient

The significant reduction of air extraction volumes leads to the use

cleaning of 95% of the surface area, and the reduction in the size

of accessory systems with smaller dimensions and capacities, such

of the metal extraction piping and in the fan motor’s capacity. All

as the cyclone and the absolute filter unit, to the reduction in the

this entails a cut in the initial investment required. The use of a smaller fan motor also reduces energy costs.

Mounting the automatic guns directly opposite each other and

© Spray S.A.

offering the possibility to point them left or right and up or down guarantees more optimal coating angles. Their synchronised, alternating vertical movement helps create a denser powder cloud in the intermediate area of the booth, which improves penetration in all difficult-to-reach areas and therefore increases the coating’s quality on components with complex 3D shapes and many welded areas that are difficult to access. In short, the AUTOCOATER 3000 considerably improves transfer efficiency and coating quality.

AngleFlex 100 As mentioned, two of the basic objectives of this project were to reorganise the guns and to achieve an idle time for the AngleFlex 100.

adjustment of fixed guns of 1 minute per batch change. This

© Spray S.A.

The inside of AUTOCOATER 3000 with its fixed and mobile guns.

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N. 83 - SEPTEMBER/OCTOBER 2023 - international PAINT&COATING magazine

ADVANCEMENTS

company treats a large variety of parts in terms of both shape and size and most of them used to require a high number of manual touch-ups, so it was impossible to speed up the production line because the operators could not keep up with such a heavy workload. The firm had already installed more fixed automatic guns to reduce the amount of manual retouching required but, as already emphasised, each batch change entailed a production stop for adjusting the fixed guns that took an average of 60 minutes.

Depending on the production schedule, this resulted in a loss of 3 to 4 hours every day.

To meet the need for reduced idle times, we designed AngleFlex 100, a device that automatically adjusts the angles in the 4 axes of each stationary gun. With AngleFlex 100, every product series is matched with pre-set parameters for changing the angular positions of the fixed automatic guns on their 4 axes, via 4 servomotors.

Now, for each batch change, the operator only has to validate the

© Spray S.A.

4-axis rotation angle.

programme number matched with the set of parts to be coated and all fixed guns get positioned in the selected configuration within 1 minute. The use of AngleFlex 100 has eliminated 99% of

Mobile controller MobileKon 200

the retouching work necessary. The correct positioning of the fixed

MobileKon 200 is an industrial hand-held tablet linked to AngleFlex

guns has also largely improved coating transfer efficiency and quality

100, through which the operator selects and stores the angle values

consistency, guaranteeing savings in terms of powder consumption.

of each of the fixed guns. It also manages the configuration of the

We create chemistry that makes lines love curves.

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Brilliant gloss and innovative colors transform contours into dynamics and design into emotion. Lines and curves are united and edges and contours are brought to life. When color and shape come together, and paint evokes passion, it’s because at BASF, we create chemistry. www.basf-coatings.com

The MobileKon 200 tablet device.

© Spray S.A.

two reciprocators, the System Control Unit (SCU), and the

Cons of the AUTOCOATER 3000 system

electro-pneumatic guns’ Gun Control Modules (GCUs). It enables

• The Autocoater can change colour quickly, but in this peculiar case

the operator to work comfortably close to the spray guns and

the numerous automatic angle adjusters and guns cause a long

batches of parts during the adjustment phase without blind spots,

cleaning time.

for more optimal, sounder spray angles.

• Its purchase cost may seem slightly higher than that of a ColorQueen booth, but the savings provided by reducing its size and

To conclude this article, we would like to summarise briefly the main

using smaller accessory systems compensate for this perfectly.

advantages of the AUTOCOATER 3000 and its accessory systems and, of course, its possible disadvantages.

Pros of the AUTOCOATER 3000 system • Eliminating and limiting the openings reduces the air extraction

While thanking the company that allowed us to write this article, we cannot end it without listing the goals achieved and the words of appreciation received.

volume (depending on the design). This results in the use of

Goals achieved with the AUTOCOATER 3000 project

accessory devices (cyclones, absolute filters, and so on) with a

• Idle time for adjusting fixed gun angles: 1 min

smaller size and capacity for a more competitive and energy-

• Increase in production time: 3.5 h/day (on average)

efficient line.

• Manual touch-ups: 0

• Drastic reduction in the risk of powder leakage during the coating

• Parts per load bar: +10%

and cleaning, resulting in a cleaner working environment.

• Production speed: (8 m/min), +60% (previously: 5 m/min)

• Reduction of the space between the opposing automatic guns,

• Product quality: more consistent

resulting in greater transfer efficiency for different part batches.

• Increase in production capacity: x2

• Together with the considerable reduction in the automatic guns’ pitch, the elimination of the touch-up stations allows the size of

“Unsurpassed fully automatic product finishing”, “increased

the booth to be reduced, thus also limiting the space required for

production”, “full satisfaction with both the plant and the pre- and

system implementation.

after-sales services” are the best words, chosen by this well-pleased

• Increased profitability through reduced operating costs thanks

company, to conclude this article.

to the lower energy consumption of the extraction system and to limited powder dispersion.

• Operator control via tablet of the entire coating system.

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N. 83 - SEPTEMBER/OCTOBER 2023 - international PAINT&COATING magazine

®

© AdobeStock

FOCUS ON TECHNOLOGY

A Thermal Evaporator for Bilge Water Treatment Contributes to Ecologia Oggi’s Total Waste Recovery Project Monica Fumagalli ipcm®

Recovering waste instead of sending it to landfill: the European Union’s action plan to halve the amount of non-recycled waste is shared by Ecologia Oggi, an Italian company specialising in ecological services that has recently integrated an Eco-Techno thermal evaporator specifically designed for treating different fractions into its multifunctional waste management plant at the port of Gioia Tauro.

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FOCUS ON TECHNOLOGY

© Gioia Tauro Port Authority

The port of Gioia Tauro is reached by an average of 13 container ships per day.

W

aste collection on ships is a thorny issue from both the

source of pride not only in Italy but also at the European level. The

operational and management-related point of view.

goal we have set ourselves since our company’s foundation is not

Alessio Guarascio, the vice president of Ecologia Oggi

only to treat and dispose of waste but to recover it with a view to

Spa (Lamezia Terme, Catanzaro, Italy), a company specialising in

the circular economy concepts, which should be the ultimate goal

integrated ecological services, explains: “Every ship has a specific

of this entire sector.” About two years ago, Ecologia Oggi decided

section, called the bilge, corresponding to the lowest portion of the

to integrate its centre within the port of Gioia Tauro with an

hull, in which the waste produced by the vessel is collected. Here,

evapoconcentration plant for the treatment of liquid waste and of a

it is important to operate in compliance with the international law

fraction of the bilge water collected. It chose Eco-Techno (Busnago,

regulated by the MARPOL Convention1, aimed at preventing and

Monza e Brianza, Italy), a company specialising in treatment

minimising pollution of the marine environment by ships.

solutions for waste water purification and recovery, as a partner to

“Our company was given the concession for the collection and

develop a project that would meet its particular operational needs.

management of ship-generated waste and cargo residues reaching Calabria and the National Research Council of Italy (CNR), we thus

Ecologia Oggi’s vision: environmental education and social commitment

developed a project for a multifunctional centre for the storage and

Ecologia Oggi S.p.A. was founded in 1987 by Eugenio Guarascio,

treatment of hazardous and non-hazardous waste, which is now a

its current president, who, together with his sister Ortenzia and

the port of Gioia Tauro. In cooperation with the University of

his two sons Alessio and Fabio, has led this business from the MARPOL is the main international convention covering prevention of pollution of the marine environment. https://www.imo.org/en/KnowledgeCentre/ConferencesMeetings/pages/Marpol.aspx

1

complex region of Calabria to become a company of excellence in the waste-to-energy sector with projects often taken as a model international PAINT&COATING magazine - SEPTEMBER/OCTOBER 2023 - N. 83

41

© AdobeStock

Ecologia Oggi was given the concession for the collection and management of ship-generated waste and cargo residues reaching the port of Gioia Tauro.

even abroad. “We have a strong connection to the local community where our family and our company were born and grew up. For more than thirty-five years, we have been providing door-to-door waste collection services, dealing with the entire cycle of disposal and recovery of hazardous and non-hazardous waste (including special, medical, and hospital waste and on board ships), and operating facilities throughout the region. The most significant moments in our history are those that have seen us enter fully into the waste management cycle, for example the awarding of the tender for the differentiated waste collection activities in the city of Paola, and later, at the height of the waste management crisis, also in province capital Cosenza, where in just a few months we managed to resolve the several critical issues that had been © ipcm

plaguing the area for some time. Today, we are proud to say that,

From left to right: Eugenio Guarascio, the president of Ecologia Oggi, with his sister Ortenzia and son Alessio.

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N. 83 - SEPTEMBER/OCTOBER 2023 - international PAINT&COATING magazine

thanks to an effort to raise awareness among citizens to which our company has also contributed, the percentage of differentiated

FOCUS ON TECHNOLOGY

© ipcm

© ipcm

The evaporation system for bilge water treatment designed and installed by Eco-Techno.

The evaporator consists of three boilers.

waste collection in these two cities is 80% (Paola) and 72% (Cosenza), a

also include the management of waste-to-energy plants, recovery

record figure for Southern Italy and even beyond.

and recycling activities, special waste treatment operations, and

“The profound experience we have been gaining in the waste

the treatment and recovery of port waste. This all allows us to

management field has enabled us to diversify our services, which now

increasingly intensify our relationship with the local community, which

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Painting excellence for every surface Bringing your surface to perfection.

Verind offers painting solutions from manual to automatic application, high-quality and easy to integrate.

© ipcm

© ipcm

The plant extracts the waste’s entire water content to minimise its volumes down to 80% water, 10% oil and salt residue, and 10% sludge.

© ipcm

A detail of the evaporator.

© ipcm

A detail of the external heat exchanger.

Thorough laboratory checks.

our family has chosen to further strengthen through its social

illustrates: “Here, we have built a multifunctional waste storage and

commitment: my father is the President of football club Cosenza

treatment centre that has obtained the Integrated Environmental

Calcio and we own the local periodical 'Il Lametino'.”

Authorisation, aimed at verifying the environmental compatibility of

Waste management at the port of Gioia Tauro

industrial activities. It consists of as follows: • a treatment and storage centre with a capacity of over 1,500 m3 of

In the heart of the Mediterranean Sea, at the meeting point of

complex emulsions;

the East-West maritime routes and the trans-European Helsinki-

• a three-phase oil-water-sludge separation and recovery line with a

Valletta Corridor, Gioia Tauro is the largest transhipment terminal

capacity of 6 m3/h;

in Italy and one of the most important container traffic hubs

• a sterilisation centre for food waste equated to sanitary material

in the Mediterranean, with the passage of about 13 container

coming from aboard ships, using combined steam and microwave

ships per day. Ecologia Oggi technical manager Maria Amato

and reaching a treatment capacity of 150 kg/h, for the reduction of

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FOCUS ON TECHNOLOGY

the pathogen load; • a vacuum concentrator for the treatment of leachate and liquid waste in general with a production capacity of 6 m3/hour.”

“The main objective of our company,” adds Amato, “is not only to treat and dispose of waste but to recover 100% of both its solid and liquid fractions. We also manage a waste-to-energy plant for treating municipal waste, with the capacity of producing 15 MWh: considering that an average family needs 3 KWh per day, it can supply energy to as many as 15,000 households,” emphasises Antonio Labonia from Ecologia Oggi. “It works with a conventional process and it is continuously monitored by the Regional Agency for Environmental Protection of Calabria (ARPACAL) as well as by internal safety systems. The dust created during the combustion process is almost totally collected by the filtering unit and disposed of in two ways: either through an authorised landfill system or with a recovery treatment enabling it to be reused for the manufacture of different products.”

A customised evaporation process for treating water from the port and beyond Within the multifunctional plant for the Gioia Tauro port’s waste management, about two years ago, Ecologia Oggi integrated an evaporator designed and installed by Eco-Techno to treat all liquid fractions coming from both the port and its own recovery operations.

The plant as a whole has a capacity of 75,000 tonnes/year, of which

www.cmautomazione.com

50,000 are treated by the vacuum concentrator.

“The waste water to be treated carries water formed by saltwater seepage, liquids from the vessel’s necessary activities such as cooling water, fuel oils, and lubricants, from the separation of fluids in the sedimentation and settling tanks, and from discharge activities related to various purification processes, but also soot and dirt particles. The water that it is illegal to release into the open sea must be properly treated in a port, where it is discharged through special pipes and made available for disposal. Bilge water collected from ships undergo a preliminary treatment. Then, once discharged, the liquid is subjected to a three-phase treatment process through a centrifuge that separates the water from the oily and noxious substances and the sludge, so that each component can be handled individually. In particular, the sludge is disposed of, the oil is sent to CONOU (Italy’s National Consortium for Used Mineral Oils) for recovery, and the aqueous fraction reaches our Eco-Techno concentrator.”

The plant extracts the entire water content of such waste, in order to minimise its volumes down to 80% water, 10% oily and saline residue (due to the saline fraction of seawater, destined for distillation in a further Eco-Techno plant), and 10% sludge (treated in a postconcentrator before disposal). “The technology chosen for the treatment of the saline fraction,” illustrates Eco-Techno CEO Massimo

CM AUTOMAZIONE s.r.l.

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

The winning search for the right partner “We turned to Eco-Techno’s team,” indicates Amato, “after deciding to integrate bilge water treatment into our vacuum concentrator.

We were looking for the ideal plant engineering solution and its proposal convinced us because it was the only supplier to offer to carry out laboratory tests simulating the process steps useful to achieve our goal.” “We generally work in this way,” confirms Peschechera, “when we are looking for a solution to particular problems such as the one Ecologia Oggi submitted to us. We take significant samples of the product to be processed and perform several tests, sometimes with small pilot plants that simulate exactly the process we have in mind. In this case, we limited ourselves to laboratory tests because we already had experience in the waste treatment sector, although not with bilge water specifically.” The solution identified guarantees substantial energy © ipcm

From left to right: Alessio Guarascio and Maria Amato from Ecologia Oggi and Massimo Peschechera from Eco-Techno.

savings. “Another important aspect of our solution is the special material chosen for the construction of the concentrator: superduplex stainless steel is the ideal material for treating water with high salinity and chloride content levels, as in this case where it is

Peschechera, “consists of a multi-effect forced-circulation thermal

necessary to treat waste water that not only contains an organic

concentrator and a scraped thermal post-concentrator that treats

component consisting of oils and hydrocarbons but also traces of

the concentrate coming from the former. Out of the many types

seawater. If we had not used this noble material, we would have

of evaporators made by Eco-Techno, this is certainly what sets us

risked the formation of corrosion within a short time.”

apart from the rest of the market. The combination of its multiple concentration rates without the fouling and yield reduction issues

Total waste recovery target: the future lies in the circular waste economy

of conventional immersed heat exchangers (coil and especially

With a view to total waste recovery, the company also plans to

plate heat exchangers), which are related to the formation of

recover the waste water treated by the vacuum concentrator

solids, as the product passes through an external tube bundle heat

and reuse the resulting distillate in its own production processes.

exchanger and evaporation takes place while keeping the liquid in

“However, our plans for the future do not stop there,” concludes

circulation, causing a “flash” effect on its return to the evaporation

Ecologia Oggi president Eugenio Guarascio. “Since our primary

chamber.

objective is to transform any type of waste into energy or a

“In this case, the aim was to concentrate as much as possible and

reusable product, we also aim at turning it into the energy of the

at the same time limit the energy costs of the evaporation process.

future: hydrogen. If we think that all this has been achieved in

That is possible because in a multiple-effect thermal concentrator,

Southern Italy, a geographical area that is rich in resources and

the energy expenditure is almost exclusively related to the

talent but is also very problematic, the value of our mission is

heating of waste water in the first stage. The vapour produced by

truly considerable. The integrated plant system we are setting up

evaporation in the first stage is then used to heat the waste in the

represents a novelty and a model not only for countries where

second stage, which in turn activates the same mechanism in the

virtuous waste management is the order of the day, such as those

third one, whose steam is finally condensed with cold water from a

in Northern Europe, but also for those whose rapid development

dry cooler. This consists of a closed-loop water cooling system that

and urbanisation processes raise questions about intensive

makes use of the air in the environment and not of water, unlike

waste treatment. All of this, at the same time, is shaped by our

traditional cooling towers. Compared with most companies, which

indissoluble bond with our land, which has allowed us to become

focus on a specific type of system, Eco-Techno offers different

a great enterprise and whose wellbeing remains the main aim of

solutions depending on the primary supply: electric supply for heat

our entire activity: this is also why we are heavily involved in social

pump systems, mechanical vapour recompression, or thermal

and voluntary work. The history of our company is characterised

vectors such as hot water and vapour in single or multiple effect

by continuous evolution and improvement, which we carry on

versions – as in this case, where savings are obtained thanks to the

also thanks to the collaboration of trusted partners such as Eco-

possibility of heating only the first effect.”

Techno.”

effects and forced circulation makes it possible to achieve very high

46

N. 83 - SEPTEMBER/OCTOBER 2023 - international PAINT&COATING magazine

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, industrial processes and their use to the point of making them the real strength.

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

WHERE WE HAVE BEEN

48

N. 83 - SEPTEMBER/OCTOBER 2023 - international PAINT&COATING magazine

Protection upgraded

Specialità chimiche per il trattamento delle superfici Lavaggio Industriale

Pretrattamento metalli alla verniciatura

Lavaggio di precisione

Processi di conversione esenti

Sgrassanti interoperazionali

Cromo e Fosfati

Miscele di tensioattivi

Fosfatanti a bassa temperatura

Protezione temporanea

Passivanti per acciaio zincato a caldo Passivazione conduttiva su Alluminio TCP

Galvanica Funzionale

Galvanica Decorativa

Zinco e leghe di zinco

Rame, Nichel e Cromo

Passivanti e Sigillanti

Deposizione su plastica (POP)

Rivestimenti resistenti all'usura

Stagno e leghe di Stagno

Pretrattamento

Pretrattamento

SurTec Italia Sas di Externa Holding Srl Via Boito, 251 Tel.: +39 059 8579901 41019 Soliera (MO) E-Mail: info-it@surtec.com Italia Web: www.SurTec.com

SPECIAL ISSUE ON ARCHITECTURE & DESIGN

52 56

BRAND NEW FOCUS ON TECHNOLOGY

Increased Productivity, Improved Quality, Faster Cycle Times, and Significantly Lower Powder Consumption: The Advantages of the New Vertical Coating Line Installed at Extrusax

64

FOCUS ON TECHNOLOGY

70

HOW IT'S COATED

72

HIGHLIGHT OF THE MONTH

80

FOCUS ON TECHNOLOGY

88

FOCUS ON TECHNOLOGY

96

FOCUS ON TECHNOLOGY

AREES Improves the Quality of Its Products with the Introduction of a State-Of-The-Art Shot Blasting and Powder Coating Plant

Goodbye Grey, Welcome Colours

A New State-of-the-art Colour Bonding Technology Bring a Wealth of Product Enhancements at Sherwin-Williams: Higher Quality, Efficiency, and Sustainability in the Manufacturing of Metallic Powder Coatings

NIR Coatings with a 5-Second Curing Cycle Specially Formulated for Marcegaglia’s Coil Coating Line

A Hanging System that Improves Powder Coating Efficiency on Foxydry’s High-Tech Designer Clotheslines

Allcolors: a Revolutionary System with a Bell Oven for Coating Aluminium Profiles up to 8 Metres Long

104 FOCUS ON TECHNOLOGY

Operative Word: QUALITY. A Long-Standing Partnership with a Powder Coating Manufacturer Enables LADAL to Finish Its High-End Aluminium Profiles for the Architectural Sector

110 112 114

ADVANCEMENTS

UCF Researcher Creates World’s First Energy-saving Paint – Inspired by Butterflies

BRAND NEW FOCUS ON TECHNOLOGY

Mexall Upgrades Its Aluminium Profile Coating Plant with a Chrome-Free Pre-Treatment and Atomisation Cycle that Improves Performance and Reduces Water Consumption

122 HIGHLIGHT OF THE MONTH

Science-based Decarbonisation Targets and a Focus on Innovation in Powder Coatings: PPG’s Growth and Sustainability Strategy

128 BRAND NEW 130 ANALYSIS

The New Trend Towards Super-Matte Colours in the World of Design and Architecture: Stardust’s View on Research, Production, and Application Issues

international PAINT&COATING magazine - SEPTEMBER/OCTOBER 2023 - N. 83

51

© AdobeStock

BRAND-NEW

SPECIAL ISSUE ON ARCHITECTURE & DESIGN

PPG Presented Limitless, the 2024 Colour of the Year The honey beige neutral tone Limitless has been identified by the colour experts of PPG as the next trend for both architectural and industrial applications.

P

PG has recently announced its 2024 Colour of the Year:

the overarching story of how cultural undercurrents are

Limitless (PPG1091-3), a fresh warm hue that holds both

shifting toward optimism, creativity and introspection.

the power of a primary colour and the essence of a honey

“Limitless is bold enough to serve as a leading, primary

beige neutral tone, offering limitless possibilities for residential

colour, yet has the essence of a neutral to act in a

and commercial interiors and exteriors, consumer products and

supporting role. In the architectural space, we anticipate

industrial applications.

that it will rapidly become one of newest neutrals due to its

Along with this signature shade, the global experts of the company

versatility,” stated Ashley McCollum, a colour expert from

curated a colour palette of more than forty complementary hues

PPG and marketing manager of the Architectural Coatings

organised in three distinct colour palettes, or ‘volumes.’ The first

U.S. and Canada division.

features soft and grounded colours; the second includes earthy

The new colour Limitless works with both warm and cool

greens, florals and energising blues; and the third is a beautiful

tones such as shaded whites, delicate pastels, earthy

mix of playful and dramatic colours. Limitless, when combined

neutrals, softened jewel tones and bold and bright hues.

with colours from these palettes, feels very warm and soothing,

In addition, it also pairs well with popular black and brass

yet also highly curated and elegant. Together, the collection tells

metal tones and silver and bronze finishes.

© Chris Schmidt

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BRAND-NEW © Katarzyna Bialasiewicz

SPECIAL ISSUE ON ARCHITECTURE & DESIGN

“Around the globe, we are seeing a movement from cooler and deeply saturated tones to lighter and warmer shades of reds, yellows and beiges. For product designers looking to differentiate and embrace trending mellow shades, Limitless has endless applications to lend an air of modernity, leaning from polished to playful”, concluded Vanessa Peterson, the global colour styling leader of the Industrial Coatings business unit of PPG. Scan the QR Code to see the video that celebrates Limitless, the PPG's 2024 Color of the Year:

“What we found through our annual workshop was an eagerness amongst consumers to find comfort amid the chaotic world, a willingness to break free of convention, and a growing focus on creativity, well-being and fulfilment. From a

For further information: www.ppgac.com

colour perspective, these sentiments are cultivating a fondness for stabilising, calming colours with feel-good vibes,” added McCollum.

eosmarketing.it

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FINISHING SYSTEMS

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BRAND-NEW

SPECIAL ISSUE ON ARCHITECTURE & DESIGN

Axalta Partners with Xaar to Introduce a Sustainable Digital Paint Technology for the Transportation Industry The new sustainable digital paint technology Axalta NextJet™ allows two-tone vehicle manufacturers to reduce CO2 emissions by 30%.

T

he international paints and coatings manufacturer Axalta

Moreover, it eliminates masking and reduces labour, energy

has recently announced that the company has entered into

and waste while increasing productivity and efficiency rates –

a partnership with Xaar, a renowned producer of drop-on-

contributing to a 30% reduction in CO2 emissions and significant

demand inkjet technologies, in order to develop and market the

cost savings. The combined technology solution is currently

sustainable digital paint technology Axalta NextJet™.

being tested with customers and could be in production as early

“We are excited to announce our partnership with Xaar and

as 2024.

introduce Axalta NextJet™ to the market. Our latest innovation is

“Axalta was quick to recognise the unique advantages of our

powered by the leading inkjet technology of Xaar and paired with

technology for their innovation, making use of our printhead’s

our proprietary paint designed for jetting. This unique market

ability to handle fluids with viscosities way beyond what has

offering builds on our investments in digital paint research and

traditionally been possible with inkjet. Together, we do not just

development,” has stated Hadi Awada, the senior vice-president of

deliver the required productivity, but we significantly improve on

Mobility at Axalta.

it,” has declared Graham Tweedale, the Chief Operating Officer

Digital painting is an advanced application method that allows

of Xaar.

coaters to place paint more precisely. The new technology provides then design flexibility for two-tone vehicles and allows customers to create patterns, details and images in a sustainable way.

For further information: https://shorturl.at/JPV68

© Axalta

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N. 83 - SEPTEMBER/OCTOBER 2023 - international PAINT&COATING magazine

BRAND-NEW

SPECIAL ISSUE ON ARCHITECTURE & DESIGN

Stanford University Researchers Formulated Coatings Keeping Buildings Insulated The new coating can be applied on buildings and refrigerated trucks to keep them insulated, reducing energy consumption, costs and emissions.

R

esearchers from Stanford University (California, U.S.A.)

to reduce heat exchange between human living and work

have recently formulated a coating that keeps building and

spaces and their surroundings is getting more attention, and

refrigerated cargos cooler in the summer and warmer in

new materials for enhanced insulation are in demand,” stated

the winter, reducing energy usages and consequently costs and

Yi Cui, a professor of materials, energy and photon science and

greenhouse gas emissions.

engineering at SLAC National Accelerator Laboratory, who also

Space heating and cooling accounts for about 13% of global

directs the Precourt Institute for Energy and the Sustainability

energy use and 11% of greenhouse gas emissions. This new

Accelerator at the Stanford Doerr School of Sustainability.

coating reduced the energy used for heating by about 36% in

The newly formulated solution has two layers applied separately:

experiments using artificial cold environments as well as 21% in

an infrared reflective bottom layer using aluminium flakes and

artificial warm conditions.

an ultrathin, infrared transparent upper layer using inorganic

“Energy and emissions from heating are forecast to continue

nanoparticles that comes in a wide range of colours. It can be

to fall due to energy efficiency gains, but air conditioning use is

applied to exterior walls and roofs in order to keep the heat

rising, especially in developing economies in a warming world.

out by letting the infrared light passing through the colour

For both heating and air conditioning we must reduce energy

layer, reflecting off the lower layer and passing back out as light.

and emissions globally to meet our zero-emissions goals. How

Furthermore, it can be applied to interior walls to keep the heat inside, where the lower layer reflects the infrared waves that transfer energy across space and are invisible to the human eye. © UnSplash

“Both layers can be sprayed onto assorted surfaces of various shapes and materials providing an extra thermal barrier in many different situations,” has also declared Yucan Peng, the co-lead author of the study and postdoctoral scholar in Stanford’s Geballe Laboratory for Advanced Materials.

The new coatings can also be applied on trucks or train cars used for refrigerated transportation. They can be used in humid environments, since they have water-repellent layers and are resistant to high temperatures. The available colours are white, blue, red, yellow, green, orange, purple and dark grey.

“Our team continues to work on refining the paint formulations for practical applications. For example, water-based solutions would be more environmentally friendly than the organic solvents we used. That could facilitate the commercialisation of the paints,” has concluded Jian-Cheng Lai, a postdoctoral scholar and co-author of the study.

For further information: https://shorturl.at/jQXZ2

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© ipcm

The vertical coating system supplied by SAT.

FOCUS ON TECHNOLOGY

SPECIAL ISSUE ON ARCHITECTURE & DESIGN

Increased Productivity, Improved Quality, Faster Cycle Times, and Significantly Lower Powder Consumption: The Advantages of the New Vertical Coating Line Installed at Extrusax Ilaria Paolomelo ipcm®

Extrusax, a Spanish company specialising in the extrusion, anodising, machining, and coating of aluminium, has recently installed a new vertical coating system supplied by SAT (Verona, Italy) at its site in Alcantarilla (Murcia, Spain), which has enabled it to achieve several advantages including increased productivity, improved finishing quality, optimised cycle times, and reduced paint consumption.

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© ipcm

The Murcia production site covers 15,000 m2.

A

luminium is the most widely used non-ferrous metal in the world. The ductility and lightness of this material

make it extremely versatile and suitable for numerous applications, from curtain walls to photovoltaic panels, from profiles for bodywork and electric vehicles to heat sinks.

These are just a few of the application fields explored by Extrusax, a Spanish company specialising in aluminium extrusion, anodising, and coating for the architectural and industrial sectors. At its site in Alcantarilla, just a few kilometres from Murcia (Spain), this company has recently decided to replace its obsolete coating line with a new vertical system to improve its entire production and coating cycle, as well as the finishing quality of its

© ipcm

The profile cutting line.

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© Extrusax

Examples of custom-made profiles by Extrusax.

end products. For this project, Extrusax has chosen to rely on the

certification for organisation, the ISO 14000 one for environmental

technology and expertise of SAT (Surface Aluminium Technologies),

protection, and the QUALICOAT one for coating. Today, Extrusax

a leading Italian company in the design and manufacture of plants

is a major player in the aluminium sector in Europe, its core

for coating aluminium profiles.

market. Thanks to the international success gained and increased

From billets to profiles: Extrusax's production cycle

demand, in 2017 it opened a new plant in Alcantarilla (Murcia, Spain). This is where the company installed the new coating line designed and built by SAT.

Extrusax was established in Sax (Alicante, Spain) in 2008. It

Extrusax produces 180 tonnes of aluminium profiles per day, of

specialises in aluminium extrusion, anodising, machining, and

which 60 at the Murcia site. “In this plant, only 20% of products

coating with the aim of providing the market with reliable, efficient,

undergo the coating stage (in total, Extrusax coats around 30-40%

and high-quality products. It has put in place a very meticulous

of its profiles depending on the time of year); the remaining 80% is

manufacturing process that has enabled it to obtain the ISO 9001

anodised, packaged, and shipped,” explains Murcia plant manager

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© ipcm

From top left clockwise: Paint application with Gema guns.

© ipcm

Profiles exiting the curing oven.

Gema’s OptiCenter OC08 powder management unit.

Sandra García. “Our production cycle begins with the processing of aluminium billets delivered to us by a Norwegian leading supplier.

The extruded profiles are coated or anodised, then subjected to different machining processing or packed and prepared for shipment. At the Murcia site, we have 2 extrusion presses, a 1800-tonne and a 2800-tonne machine, which added to the presses at the Sax factory bring Extrusax to a total of 7 extrusion presses. The aluminium billets are heated to a temperature of 480 to 500 °C and the extruded profiles are cut to customer specifications. To meet every individual need, should a customer require a very small profile size or special cutting tolerances, we also have a separate cut-off machine.” After extrusion, depending on requirements, the profiles can be sent to the paint shop or subjected only to machining with CNC centres and to final assembly before shipment.

General characteristics of the line The vertical coating plant supplied by SAT, which replaced the previous obsolete line, was designed to meet a precise need for a modern, high-performance line with a small footprint. “SAT has managed to come up with a unique design for our plant, with a compact layout that still meets all our requirements in terms of logistical flow within the factory.” The new line allows coating

© ipcm

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© ipcm

Automatic fan-shaped unloading of parts.

aluminium profiles from 4 to 7.5 metres in length and up to

García. This curing oven is equipped with innovative solutions for

250 millimetres in width. After being hooked onto the overhead

airflow control and balancing, which together with its thoughtful

conveyor in the loading area, the profiles enter the pre-treatment

design eliminate the risk of contamination among powders in

tunnel, performing a double acid attack and nanotechnology

different colours, despite handling profiles in various tints in a

conversion cycle to achieve the quality degree required by the

continuous sequence, since the two booths work simultaneously.

QUALICOAT Seaside certification.

After automatic fan-shaped unloading, the profiles are subjected

In the system installed by Extrusax, two Cube Grande-type

to machining or directly packaged with a heat-shrinkable film

coating booths operate at the same time, one applying only white

depending on customer requirements.

(the most commonly used colour) and the second all other tints,

“One of the main advantages of this new coating line,”

with a cleaning time of 5-10 minutes per colour change. Each

comments the Murcia plant manager, “is its VISICOAT profile

booth is equipped with 20 Gema guns and a Gema OptiCenter

contour detection system. Once it detects a profile, this system

OC08 powder management unit. “Unlike the Sax factory, we

automatically matches it with the optimum coating programme,

do not have an infrared oven. Profile curing takes place inside

enabling us to optimise the spray gun parameters for each

a modern oven, in about 15-20 minutes at 190 °C depending

individual profile and significantly reduce our scrap rate due

on the characteristics of the applied powder,” indicates Sandra

to non-compliant finishes or human errors, thus ultimately

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FOCUS ON TECHNOLOGY

increasing productivity.”

offer attractive products without the slightest surface defect.

The plant also features a paint stripping machine for the

Extrusax’s focus areas include, for example, sun protection

workpiece-holding hooks, combined with a FASTRIP FP paint

systems such as pergolas and sunshades: our exclusive

stripping bath filtration unit developed by ALIT Technologies

products stand out thanks to their innovative and customised

(Verona, Italy). “We opted for an in-line paint stripping plant,

design, and the quality of the coating systems and the type

which has proved to be very cost-effective as, in addition to

of finishes applied (from metallic to textured, from glossy to

speeding up our hook stripping times, it does not require the

matte) contribute to give them an added value.”

intervention of operators.” The line has been in operation since April 2023 and works in one shift, but the company has plans to

Reasons behind this choice

increase productivity to three shifts.

The decision to install a new coating line stemmed from

The importance of finishing quality

Extrusax’s desire to equip its Murcia site with a system that would improve productivity, speed up the finishing cycles, and

Aluminium plays a crucial role in an infinite number of industrial

above all reduce colour change times. “Our previous line was

fields: Extrusax has about 80 target sectors. By treating and

outdated and did not allow us to reach tight takt times. As we

coating its aluminium surfaces properly, it enhances both

often have to process very small orders – a pergola or a dozen

their functional and aesthetic properties. “The coating phase is

bars – with different finishes, the colour change operation

therefore essential to protect the metal from any damage caused

must be quick to meet all customers’ needs. “The need for a

by atmospheric agents, including oxidation and corrosion, and

more modern line with state-of-the-art technology led us to

to guarantee greater resistance to impacts, scratches, and wear,

look at plant solutions from different companies. Our choice

improving the durability and reliability of our products,” notes

fell on SAT because we wished to collaborate with a partner

Sandra García. “At the same time, nowadays, it is also essential

that mainly specialised in the design and installation of vertical

to pay particular attention to the quality of finishes in order to

aluminium coating lines,” says García. “The cooperation with

PREMIUM POWDER COATINGS PACKED IN A NEW DESIGN • More than 400 RAL colours available in stock • Certified with Qualicoat Class 1 • Outstanding durability and corrosion resistance • Flexibility and swift delivery

www.kansai-helios.it

SPECIAL ISSUE ON ARCHITECTURE & DESIGN

© ipcm

ALIT Technologies’ FASTRIP FP for the continuous-flow paint stripping of hooks.

Quality control.

improved in terms of several aspects. First of all, we have significantly reduced powder consumption as the booths allow each profile to be covered in an optimised powder cloud that improves application, while also being equipped with an efficient powder extraction and recovery system. Moreover, the colour change operation takes only 5-10 minutes and the booth cleaning phase © ipcm

is much simpler and faster compared with our previous line. Although the plant has only been in operation

Gema and especially its customer service, always dependable

for a few months, we have already seen an increase

and punctual, also met our expectations.”

in productivity as well as our ability to provide our

“We are fully pleased with the new system supplied by Italian

customers with products characterised by higher quality

company SAT because our coatings’ quality has clearly

finishes,” concludes García.

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Control and improve your application with GemaConnect® E-App: The latest release of the GemaConnect E-App with updated features extends the control of the powder coating process providing unrivalled effectiveness.

With its intuitive interface it provides automation enhancement for simple automatic coating lines and is a proven Smart Factory tool for OptiFlex® Pro manual unit users.

Gema Europe Srl | Via Goldoni, 29 Via Carlo Goldoni 29 | 20090 Trezzano Sul Naviglio (MI) | ITALY | T. +39 02 48 400 486

gemapowdercoating.com

© AREES

AREES deals with products ranging from interior design and outdoor components to parts intended for environments in high corrosion classes, such as marine.

FOCUS ON TECHNOLOGY

SPECIAL ISSUE ON ARCHITECTURE & DESIGN

AREES Improves the Quality of Its Products with the Introduction of a State-Of-The-Art Shot Blasting and Powder Coating Plant Federico Melideo ipcm®

AREES - Area Edilfer Eurozinc Sardegna, a Group specialising in metal surface treatments, has expanded its range of services by investing in an innovative 4.0 shot blasting and powder coating plant supplied by Eurotherm (Volpiano, Turin, Italy). The system is composed of three booths, namely one for cleaning, one for shot blasting, and one for powder application, and a curing oven.

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Overview of the Eurotherm shot blasting and powder coating plant.

© Eurotherm

Inside of the cleaning booth.

© Eurotherm

A

REES is a Group consisting of two companies, EDILFER and

structural elements, and metal structures of the highest quality

EUROZINC. It operates in the province of Nuoro, in the

and surface treatments including phosphating, galvanising, and

heart of Sardinia (Italy), and it has been producing high-

coating, respectively. “We started with a wire and wove it into a

quality fencing nets and fence posts since 1979, the year EDILFER

net, a strong and secure weave to protect people’s property. We

was founded. Specifically, the two companies perform metalwork

have come a long way but always maintained the same purpose:

processes for the production of railings, gates, stairs, doors, gazebo

to protect – at the cost of defying challenging weather, which international PAINT&COATING magazine - SEPTEMBER/OCTOBER 2023 - N. 83

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SPECIAL ISSUE ON ARCHITECTURE & DESIGN

we do through a thin zinc coat. The mission to safeguard the work of others, which is also our own, is what unites the companies in our Group,” states Michela Pinna, co-owner of AREES EDILFER-EUROZINC. Over time, customers ranging from artisans to larger companies began to demand that its products meet additional requirements: resistance to abrasion and corrosion caused by the local weather and marine environment, as well as high aesthetic appearance. “This is why we founded EUROZINC, the second company in our Group, devoted to metal surface treatments. We established it in the early 2000s to operate in the hot-dip galvanising market and later expanded its offer with electrolytic galvanising, phosphating, and electropolishing services,” indicates Pinna. Growing demand then called for a further © Eurotherm

upgrade of the services offered by EUROZINC, which decided to embark on an investment path to complete its range of

The three water recovery tanks with no discharge to the sewerage system.

surface treatment technologies.

One of the first projects was the installation of a water-based coating system in 2017, as up to that point the only painting operations had been sporadic and performed with solventbased products. Later, and more precisely as of this year, the company also added a powder coating service with the adoption of a state-of-the-art plant.

The Industry 4.0-oriented powder coating plant Equipped with two inlet and outlet storage areas for loading and unloading and an intermediate storage area, the manual powder coating line supplied by Eurotherm consists of a cleaning booth with a liquid recovery and reuse unit, a shot © Eurotherm

blasting booth with a local shot recovery device, a powder application booth, and a curing oven. They are all linked

Inside the shot blasting booth, soundproofed to reduce the workplace noise level.

together by a motorised conveyor complemented by a lift station and connected through Industry 4.0 solutions.

The manual cleaning booth takes care of part pre-treatment.

As metal components can require pre-treatment prior to coating, it was decided to install this machine performing different cleaning cycles such as degreasing and rinsing even at high temperatures, with a “0 reject” water recovery system, i.e. no discharge to the sewer. Through three tanks, this system ensures that clean water is always available and can be reused in subsequent cycles, limiting water wastage.

The new plant also integrates a shot blasting booth equipped with a local shot recovery unit consisting of an auger with scraping blades, which allows the operator to recover the abrasive for reuse. This reduces waste and guarantees a © Eurotherm

The powder coating booth.

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well-cleaned booth with full-capacity, completely safe vacuum cleaners.

FOCUS ON TECHNOLOGY

EQUIPMENT FOR

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

© AREES

Powder application on parts with different shapes and sizes.

The coating booth, finally, is the ideal environment for

© AREES

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

painting workpieces. It has a manual unit with a traditional Zeus Electrostatic Venturi system and a suction wall for air extraction and filtration, preventing the dispersion of powder.

The last element of the new plant is the curing oven, designed to operate at temperatures between 180 and 220 °C. The motorised overhead conveyor can handle several load bars at the same time and it is equipped with a lift station that facilitates the operators in the loading and unloading of

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

workpieces without the aid of other equipment, improving ergonomics and safety.

AREES’ most recent investment was also motivated by its willingness to take the factory to the next level of modernisation and automation. “We decided to invest in an Industry 4.0-oriented, interconnected plant to keep up with digital evolution, in order to automate and better control our business processes in terms of both quality and service,” states AREES production manager Marco Lai. In fact, the

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

company has embarked on a digitalisation project that does not only concern the new plant but the entire production department. Its aim is to integrate new manufacturing technologies to improve working conditions, raise productivity, and further increase quality. In addition, the new

Find out more about ZEUS

plant adopts IT tools that allow the machines composing it to provide the operators with real-time data on the status of the various jobs.

www.zeus-el.it

SPECIAL ISSUE ON ARCHITECTURE & DESIGN

© Eurotherm

The coating line was designed according to the parameters of Industry 4.0.

Advantages

treating very small batches.

Such technologies undoubtedly bring numerous benefits.

Lastly, Eurotherm designed the system with an eye to

The first one is certainly the flexibility of the new system,

some increasingly crucial technological aspects, such as

which improves efficiency and quality because it can adapt its

the insulation of the oven to minimise heat dispersion,

coating cycle to treat products ranging from interior design

the soundproofing of the shot blasting booth to reduce

and outdoor components to parts intended for environments

the workplace noise level, and the handling and loading-

in high corrosion classes, such as marine. Two other relevant

unloading system conceived to allow the material to be easily

benefits are related to the factory’s production capacity

moved by the operators. “We are pleased to have chosen

and layout. Thanks to the integration of four stations and a

Eurotherm as a partner. Our new plant has improved both

conveyor, the new plant can coat more parts than the existing

the efficiency and capacity of our company, which can now

liquid system, handling larger jobs while occupying less

carry out the full range of surface treatments our customers

space. It can also powder-coat aluminium frames, thanks to

require. With a wide and comprehensive offer, we can

the possibility of implementing a multi-metal pre-treatment

manage our entire production cycle, up to the end products,

process. This is particularly useful for re-coating parts or

within a single factory,” concludes Lai.

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VELVET

SUPER MATT APPEARANCE SUPER SOFT TEXTURE

MEET US

8-9 NOVEMBER 2023 BOOTH 2

w w w. s t p o w d e r c o a t i n g s . c o m

?

HOW IT’S COATED

Goodbye Grey, Welcome Colours Last June FIAT announced the decision to stop producing cars with a grey livery, starting with the new Fiat 600e: the historic brand will coat its vehicles exclusively with colours inspired by the Italian sea, sun, land and sky.

S

tarting last June, FIAT stops producing grey cars. The

“We broke the rules: we decided to stop the production

decision was made to enhance the importance of

of FIAT grey cars. This is challenging and disruptive and

colours in life, embodying the Italian way of living and

it is aimed to further reinforcing FIAT’s leadership as the

reaffirming the brand’s New Dolce Vita value.

brand of joy, colours, and optimism. Italy is the country of

Italy is indeed related to bright colours such as the sea of

colours and, starting from today, FIAT’s cars too,” declared

Italy, the sun of Italy, the earth of Italy and the sky of Italy;

Olivier François, FIAT Chief Executive Officer and Global

landscapes that provide FIAT with a lot of inspiration for its

Chief Marketing Officer at Stellantis. “This choice further

cars. The strategy is implemented to add a distinctive feature

communicates to people the New Dolce Vita values and the

to FIAT’s cars in the automotive market, as 2023 is the year of

Italian DNA embodied by the Brand. FIAT wants to inspire

a remarkable change for the brand.

people to live with optimism and positivity​and this will also

© FIAT

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be one of the missions of the new Fiat 600e,

Dipinto di Blu, Blu Italia, Blu Venezia,

the electric for families and friends, which was

Verde Rugiada, Verde Foresta, Rose Gold

presented on 4th July”.

and Nero Cinema - all with an evocative name

In the new dedicated video, thanks to which

that recalls the beautiful landscapes and the

customers can discover FIAT brand-new

Italian Dolce Vita.

colourful world, Olivier François aboard the new Fiat 600e takes a deep dive into colour, under the claim “Italy. The land of colours. FIAT. The brand of colours”.

The current FIAT range - Nuova 500, 500 Hybrid, 500X, Panda and Tipo - is available in different colour shades, including Bianco Gelato, Arancio Sicilia, Arancio Paprika, Rosso Passione, Blu

© FIAT

© FIAT

Scan the QR Code to see the video in which Olivier François announces the decision of the Italian brand:

©Sherwin-Williams

Operators working on the new Sherwin-Williams bonding system.

HIGHLIGHT OF THE MONTH

SPECIAL ISSUE ON ARCHITECTURE & DESIGN

A New State-of-the-art Colour Bonding Technology Brings a Wealth of Product Enhancements at Sherwin-Williams: Higher Quality, Efficiency, and Sustainability in the Manufacturing of Metallic Powder Coatings Alessia Venturi ipcm®

Sherwin-Williams is proud to have invested in its Minerbio (Italy) production site with a new bonded metallic powder coatings technology. With this state-of-the-art bonding equipment, Sherwin-Williams is now able to provide its customers with improved processes, quality, and output. This new equipment gives powder coatings a better bonding quality, as well as batch-to-batch consistency. ipcm® had the occasion to interview on this topic Flavio Marchi - Executive Vice-President and General Manager GI EMEAI, Federico Marchi - Senior Director, Channel-to-Market and General Finishes EMEA, Leandro Aquilante - Sales Manager Italy, and Nada Karaivanova - Marketing Communication Manager GI EMEAI. The experts gave ipcm® an inside look at how and why they selected this new metallic powder coatings technology.

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HIGHLIGHT OF THE MONTH

© ipcm

Flavio Marchi.

The interviewees from the left clockwise Federico Marchi, Leandro Aquilante, Flavio Marchi, Alessia Venturi, Nada Karaivanova.

W

© ipcm

hat is the significance of the Minerbio plant for Sherwin-Williams Europe?

transfer Inver’s liquid paint production from the city of Bologna

Flavio Marchi: Located close to our European

manufacturing centre for industrial paints. The first powder

to a larger industrial centre and it soon developed into a key

headquarters, it is Sherwin-Williams’ largest production plant in

production lines were started in the second half of the 1990s, when

the continent and almost 100% of its operations are devoted to

Inver, which initially distributed powders from another company,

the production of paints for the general industry. It is the only site

acquired a manufacturing licence and started producing powder

where we can efficiently manufacture powder and liquid coatings

products with proprietary formulations. Since then, the Minerbio

but also resins for our internal needs. Therefore, it puts us in a

factory has been growing unabated.

unique and exclusive position within the paint market because

of our European business and puts us in a unique position to

As Sherwin-Williams’ largest plant in Europe, Minerbio was the subject of one of the company’s most recent and largest investments, the acquisition of a new bonding system for the production of metallic powder coatings. Can you explain what this is all about?

serve customers in several countries with different technologies

Flavio Marchi: This new, enhanced technology enables us to

very efficiently. We also have three other powder production

increase our throughput by bonding more metallic pigment, which

plants in this geographical area — in Thouars (France), Liverpool

leads to higher special effect-paint quality and faster production. At

(UK), and Dębica (Poland) — but Minerbio is the largest one. The

Sherwin-Williams, we have made investments at all our production

other two liquid paint production sites are located in Germany,

sites, either to improve safety or, above all, to enhance our

in Mannheim and Dresden, but again Minerbio is the largest

processes. According to our approach, our employees, those who

one. Minerbio is also Sherwin-Williams’ largest R&D resource in

make things happen every day, are at the top of the corporate

Europe.

pyramid, immediately followed by our customers and then by what

Federico Marchi: The Minerbio plant was founded in 1990 to

supports them, namely our production processes.

here we can produce both coating technologies, vertically integrate resin production, and serve the other Sherwin-Williams sites in various European countries, including Italy of course, but also practically every country where we are active in the continent, from France to Finland. Minerbio is a significant part

international PAINT&COATING magazine - SEPTEMBER/OCTOBER 2023 - N. 83

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© ipcm

© ipcm

© ipcm

From top left clockwise: The building that houses the new Sherwin-Williams bonding line, together with the accessory equipment needed for its operation, was created as an extension of the existing hall in 2022 View from above of the bonding system.

Bottom view of the bonding system.

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Sherwin-Williams sells solutions: not only products, but also advice, service, technical support, and much more. These three elements — employees, customers, and processes — are the main pillars of our business. Then come innovation, technology, and quality. The aim of our investment in the most modern bonding technology available on the market

HIGHLIGHT OF THE MONTH

was to further improve our ability to support our customers in the architectural segment, who are the main purchasers of metallic powder coatings. Previously, we only had one

Nordson Powder Coating System with

Color-on-Demand

bonding machine located in Liverpool, with good technology and production capabilities for a good quality degree.

However, we had to make the leap and increase our metallic powder manufacturing capacity because the demand for these products is huge and constantly growing, especially for exclusive, customised colours. Therefore, we conducted a market research study and decided that the new bonding machine had to be installed here in Minerbio because of both its significance and the enormous wealth of knowledge and expertise in the production of metallised powder coatings that it encompasses. Here in Minerbio, we have been producing metallic powder coatings using bonding technology since 2000.

We have in-depth knowledge of pigment formulation, final results, resins, and anything else that affects a paint’s special effect. We thus invested in state-of-the-art equipment to obtain the best possible production process and achieve two goals: very high productivity and uncompromising quality — because sometimes increasing production means having to sacrifice quality. With this new equipment, however, we can produce more and better, even adding a higher metal content to metallic powders, while still exerting full control over their final quality level.

The new bonding system guarantees excellent performance, high production quality, and high metallic pigment concentration and, at the same time, it is more sustainable

Maximum Flexibility: Any color, Any time

thanks to an integrated recovery system. Our long-standing

Nordson's Color-on-Demand® powder coating system

customers who purchased metallic powders manufactured

provides ultra-fast, contamination-free color change. It

with this new bonding plant were very satisfied with their

enables efficient production management and minimizes

quality level, which is currently exclusive to Sherwin-Williams.

Federico Marchi: I would like to add an element to the qualityoriented perspective outlined by Flavio. This plant also ensures state-of-the-art recyclability of metallic powder coatings, since

work-in-process by dynamically adapting to production requirements.

it produces colours that are absolutely constant from start

The system can accommodate up to 28 colors at a time for

to finish, all the way to our customers’ application plants. It

more color changes per shift, higher throughput and

enables us to achieve a level of quality and batch-to-batch consistency comparable to that of solid colours, which entails a leap forward in terms of quality control. It controls 10 times more production parameters than any previous technology in use. Therefore, the amount of waste is also reduced to zero.

To enable our readers to put this investment into context, can you explain why bonding is so important for the production of metallic powder coatings? Another technique, called dry blending, is also available.

Federico Marchi: Exactly. The dry blending technique consists

just-in-time manufacturing to eliminate inventory and improve production efficiency.

Our experienced experts are available worldwide to tackle application projects with you.

ics.eu@nordson.com www.nordson.com/hdlv

SPECIAL ISSUE ON ARCHITECTURE & DESIGN

for many years now, but our new machine achieves a much higher quality degree with a much more specific level of automatic parameter control at all process steps. With a metaphor, we could say that the new Sherwin-Williams bonding machine installed in Minerbio has much more firepower than any other technology in use today.

Is the aim of this investment to further strengthen your presence in the world of metal architecture?

Leandro Aquilante: Yes, absolutely. This machine is aimed at boosting our presence in the architecture and design sector, but also in any other segment for which beauty, aesthetics, and special effects are very important. In today’s market, increasingly numerous and diverse industry segments © ipcm

The main advantage of this machine is its innovative operating software package: after starting the operation, the machine runs fully automatically.

actually require special-effect powders. Our new bonding line also meets another requirement of these market sectors: consistency and repeatability among batches and between different parts within the same batch. It is simply the best the market has to offer for the production of metallic powders and it is a truly innovative plant. We started this project in 2019 and today we have a fine-tuned, perfectly calibrated

in the mechanical mixing of two different materials in powder

process to start high-volume production.

form: paint in a solid colour and a small percentage of metallic

Nada Karaivanova: Launched on 25 September, our new

pigment, which gives it the required special effect and colour.

Vision 2030 collection of architectural powder coatings

However, when the powder mixtures reach the customers’

features completely new colours conceived by our Design

application plants, these seem to be designed to separate

House in Minneapolis (USA), Sherwin-Williams’ hub for

the two mixed components rather than keep them together:

colour and texture development, supported by a laboratory

as a result, only a part of the metallic pigment is transferred

equipped with state-of-the-art tools. The Design House

together with the base paint, whereas the rest is dispersed into

supported us in the creation of the new colours, most of

the environment and makes the overspray paint not recyclable

which were bonded with our new machine.

effectively. In addition, the metallic pigment tends to surface after

The collection provides the modern style of Syntha Pulvin in

curing, resulting in a colour change of the cross-linked coating.

48 colours in four inspirational colour palettes. The colour

Thus, the performance of dry-blend metallised powders depends

palettes — Generation Past, Quantum City, Restore & Rewild,

largely on the customers’ application skills and technologies, but

and Hybrid Community — are backed by our more than 155

also on the type of substrate on which they are applied.

years of experience and are based on our in-depth knowledge

In contrast, bonding consists in the physical addition of

of architectural colour trends. The collections are inspired by

the metallic pigment, which is literally bonded to the main

nostalgia, the effects of technology on large cities, nature, and

component, namely the powder coating, through a process at

a sense of community. The 48 colours are designed to evoke

a high temperature but below the melting point of the powder

emotion, define global cultures, and galvanise the imagination.

itself. This does not cause any chemical variation in the base

All Syntha Pulvin powder coatings fully comply with the criteria

powder but allows the metallic pigment (aluminium flake or mica)

and standards set by the Quality Associations GSB: Florida 3

to be stably bonded with the powder particles regardless of their

and Qualicoat: Class 2.

chemical nature (epoxy, polyester, hybrid, and acrylic). Thanks exactly the same as the overspray product that ends up in the

Have further investments been planned for the Minerbio plant?

cyclone for recovery. There is no separation between the two

Flavio Marchi: We are expanding our laboratory to increase

components and this guarantees consistency in quality.

its operational capacity by 10-15% and optimise the resources

Bonding has been a well-known process in the powder industry

devoted to research and development, which remain crucial

to bonding, the metallic powder applied to the workpieces is

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HIGHLIGHT OF THE MONTH

The reactor of the bonding system on the intermediate floor.

©Sherwin-Williams

The reactor of the bonding system on the intermediate floor.

© ipcm

Detail of the loading area.

in this region. Minerbio is becoming

time, meets our need to limit transport

the centre of the Sherwin-Williams

and logistics with a view to greater

universe in Europe for R&D in the

sustainability. Indeed, if we look at the

industrial coating field. Outside Italy, we

Life-Cycle Assessment (LCA) of products,

are investing in Germany to increase

transport accounts for a large part of

production capacity both through direct

their carbon footprint.

acquisitions and by expanding our

Sherwin-Williams is going to further grow

production facilities. At the Dresden

with the aim of bringing added value to its

plant, in particular, we are investing in

customers, also in terms of sustainability.

producing paints locally for the military

There is more behind our offer than just

sector. We already manufacture them

the supply of paint: there are people,

in Minerbio, but the expansion of

there are experience and expertise, there

the Dresden site will allow us to limit

are services. We will continue to invest in

imports from the US by localising the

people, in increasing our service offer, in

production of most of our range for

production processes, and in safety.

military applications here in Europe.

There is no end to the quality game. It is

This responds to a specific request

a journey in which one must invest with a

for local supplies from the European

view to continuous improvement.

Defence Ministries and, at the same international PAINT&COATING magazine - SEPTEMBER/OCTOBER 2023 - N. 83

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SPECIAL ISSUE ON ARCHITECTURE & DESIGN

THE NEW BONDING SYSTEM: PROJECT DEVELOPMENT AND PROCESS CHARACTERISTICS “The building that houses the new SherwinWilliams bonding line, together with the accessory equipment needed for its operation, was created as an extension of the existing hall,” says Paolo Modica, Operations-Production Engineer. “Work began in late 2021 and was completed in 2022, when we started production. The months between installation and commissioning were necessary to fine-tune the process on a laboratory scale and develop the formulations through small-scale R&D tests. After this validation phase in the laboratory, we performed industrialisation tests on a pilot plant identical to the new bonding system. This guaranteed an exact match between the product developed in the laboratory and the one achievable in production.”

“The main advantage of this machine is its innovative operating software package,” adds Modica while showing us the line. “It guarantees a stable and robust process that is free from human error. After selecting the product code and production batch, the operator loads the formulation recipe and is presented with an overview of process parameters in real time. After starting the operation, the machine runs fully automatically. All process parameters are also recorded and archived so that malfunctions can be traced in case any quality issues arise in a batch. This system ensures full process control both in real time and post-operation and, above all, it guarantees absolute quality and colour consistency among different batches processed with the same parameters. An on-board screen identical to the PC’s one in the control room displays the different process

© ipcm

Chris Vaughan, Plant Manager in Minerbio.

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parameters, the production stage being performed at any time, and the programme’s progress.

“The preparation of the raw material is also fully automated: the software package transmits the selected recipe directly to the weighing system, which weighs the exact quantity of materials required for the production of the batch, i.e. the base powder and the metallic pigments, without any possibility of error. Indeed, by scanning the powder’s label, the system recognises the recipe to be produced and automatically calculates the quantity of raw materials required, displaying the relevant parameters on the weighing station’s computer. Human error is minimised in this stage as well because the system can identify any error in terms of material quantity and type and block the selection. Production control takes place in the control room, where the operator is simply required to monitor the process’s progress and parameters. The cycle continues with the mixing of the two components at a controlled temperature for the physical bond between powder and metal to take place. The obtained product is then cooled down to room temperature to enable the operator to take a sample for quality control and, if the result is positive, add the additive necessary for paint application and unload.”

“This bonding machine is very efficient in terms of operational safety. It is inerted with nitrogen and all the oxygen in it is removed to avoid reactions with the powder, which is combustible,” indicates Leandro Aquilante.

“This system is automatic, too: if the amount of nitrogen rises above a given value, which is much lower than the explosive limit, the plant stops. An automatic loop unit controls the amount of oxygen in the system and there are two oxygen detection sensors, one operational and the other ready as a backup in case of failure.

“This investment is going to bring a huge benefit to our customers,” comments Chris Vaughan, Plant Manager in Minerbio. “It ensures full control and high quality. For the first time, we can reproduce products week after week, month after month, and year after year with perfect consistency. For Sherwin-Williams, it is imperative to be a leader in this field. My approach is to work better, not more. Therefore, in the production processes of all our paint technologies, I am introducing lean production principles such as the “5 S's”, by involving all employees and fostering communication from the bottom up. There is a long way to go, but my goal is to make Minerbio the best plant in the Sherwin-Williams Group.”

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© Marcegaglia Group

With 6.5 million tonnes of finished product and having been active in the steel processing sector for over sixty years, Marcegaglia is the leading Italian industrial Group in the national and international steel market.

FOCUS ON TECHNOLOGY

SPECIAL ISSUE ON ARCHITECTURE & DESIGN

NIR Coatings with a 5-Second Curing Cycle Specially Formulated for Marcegaglia’s Coil Coating Line Monica Fumagalli ipcm®

Marcegaglia’s production hub in Ravenna, the largest plant of this Italian steel giant, is equipped with four hot galvanising lines of which one is a combined galvanising-coating system, a continuous-flow pre-painting line, and an intermittent-flow line with digital printing technology. The research and development of solutions to reduce the environmental impact of its steel processing and coating processes as well as energy consumption is the order of the day here. In this article, engineer Antonio Bonoli, the head of Marcegaglia Ravenna’s coil coating plants and the President of ECCA Italy, explains how the company’s close collaboration has enabled chemical supplier Condoroil Chemical to also become a major player in the supply of paint products, including NIR coatings capable of curing in about 5 seconds.

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FOCUS ON TECHNOLOGY

© Marcegaglia Group

© Marcegaglia Group

The Ravenna factory is a strategic logistics and intermodal hub for all industrial and commercial activities of Marcegaglia’s production chain.

“D

With over 540,000 m2 of floor area, the Ravenna plant is Marcegaglia Group’s most important production hub.

ue to the peculiarities of coil coating processes, the

equipped with the most modern systems and the most advanced

coating division of Marcegaglia Group stands out as a

production technologies for chemical pickling, cold rolling, static

company within a company. We deal with a

annealing, galvanising, and coating of steel coils, as well as a service

high-tech transformation process, based on skills that are closer

centre for levelling and cutting carbon steel coils.”

to the chemical than to the metallurgical field. Such expertise,

Steel coils are transformed into finished products through the

which we have built up over time, enables us to cooperate with

various processing stages carried out by the factory’s different

the suppliers of the chemicals we use for our surface treatments

lines. “Steel is pickled with a hydrochloric acid treatment to remove

in an active manner, working with them to co-engineer the

any oxides from its surface, trimmed at the edges, and subjected

products that are best suited to our coils,” states Antonio Bonoli.

to a skin-passing process to achieve excellent flatness properties.

“Marcegaglia entered the pre-painted steel sector in 2001 as part

After pickling, the coils can be cold rolled to the desired thickness,

of an industrial expansion that involved the entire flat-rolled coil

with a reduction of up to 80%, and sent to the static annealing and

production chain, from pickling to rolling and on to galvanising

final skin-passing cycle, or subjected to a hot-dip galvanising stage

and coating treatments. At the Ravenna plant, pre-painted steel

for the application of an inorganic zinc alloy coating.

production has reached 450,000 tonnes per year, equal to more

“A part of our galvanised coils reach the coating plant for the

than 8% of the total European market. With 10 million kg of

production of pre-painted coils, ready to be sold to customers

paint consumed per year, it is the production site that uses the

or intended for our Service Centre for further processing into

most paint products in Europe. Our collaboration with Condoroil

flattened sheets or coils. The start-up of a new combined

Chemical (Casale Litta, Varese, Italy), geared towards continuous

galvanising-coating line has guaranteed a further increase in our

improvement, enables us to achieve increasingly ambitious goals

capacity and flexibility in terms of the production mix of coated

in terms of process efficiency and finished product performance

steels, which were initially mainly intended for the construction and

thanks to research and development in the area of chemical

flashing industry but which are now also used in numerous other

treatments and coatings.”

sectors such as the household appliance, furniture components,

Ravenna: Marcegaglia’s largest metallurgical hub

and automotive ones. The pre-painted coil is a winning product from all points of view, thanks to its quality and sustainability

“The world’s leading independent steel processor, Marcegaglia

characteristics but also to the fact that it is an easily customisable

Group has built its largest metallurgical plant and its most

and cost-effective product compared with competing materials.”

important logistics and intermodal hub for all the industrial and commercial activities of its production chain in Ravenna,” specifies

Infrared as a sustainable choice

Bonoli. “This factory covers an area of more than 540,000 m ,

When Marcegaglia decided to invest in a new production plant

250,000 of which are covered, and employs 885 people. It is

in 2010, it opted for infrared technology. “This choice was a

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© ipcm

© ipcm

Above: the galvanising-coating line applies NIR paint products capable of curing in 5 seconds.

gamble for us. The topic of using NIR (Near InfraRed) paint in © Condoroil

the coil coating industry was discussed for the first time at an ECCA meeting, presented by an innovative manufacturer that had borrowed this solution and technology from the aerospace industry. The advantages described immediately convinced us: the high-energy density lamps with a power output of 3.5 kW each significantly reduce curing times and the adjustment speed solves the critical issue of thermal transients in process variations, making it possible to combine a galvanising and a coating process in series in one industrial plant, at very high process speeds. The extremely short reaction time due to such a highly concentrated energy is one of the most advantageous but at the same time problematic aspects, as it calls for a significant revision of all resin, solvent, and catalyst formulations. Until a few years ago, the curing time of coil coatings was between 20 and

© ipcm

40 seconds, whereas this solution has reduced it to 5 seconds.

From above:

The enormous progress achieved in the last few years has been

The recently installed combined galvanising-coating line.

the result of teamwork among plant users, process technicians,

The NIR oven in the Condoroil's lab.

and supplier companies’ researchers, in a journey that for us

The energy used by the galvanising-coating line accounts for 30% of the entire industrial cost.

began with a few traditional partners and has continued with the

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constant and growing contribution of Condoroil Chemical.”

EPISTOLIO EPISTOLIO

FOCUS ON TECHNOLOGY

towards the future

SOLUZIONI ROBOTIZZATE DI ROBOTIC PAINTING SOLUTIONS VERNICIATURA

© ipcm

The pre-painting line and the galvanising-coating line together process about 600,000 tonnes/year of steel.

Ad hoc paint formulation “The main challenge in the search for this solution,” notes Condoroil laboratory manager Sara Ponti, “lay in NIR coatings’ cross-linking speed, which in an IR oven is 5 seconds, compared with 40 in a conventional hot-air oven. Such a quick curing time calls for the right parameters to prevent paint from hardening too much and creating defects, such as burn marks, that may compromise the products’ functional and aesthetic characteristics as well as subsequent processing. During the formulation phase, our laboratory paid great attention to the choice of raw materials, in particular the resin, the solvent mix, and the pigments responsible for heat absorption and subsequent curing. We were able to achieve the required results thanks to the use of a laboratory NIR oven and the close collaboration of the Marcegaglia team, which contributed its specific know-how to provide us with realistic feedback that helped us solve every problem. This has also further consolidated our partnership: in addition to the paint used on

Epistolio Srl.

the NIR line, Condoroil also supplies coatings for the company’s

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

conventional line, including metallic and textured products with special effects.” Besides that, for more than ten years, Condoroil Chemical has also been providing the Marcegaglia Ravenna plant with numerous other products such as pretreatment formulations, passivating agents for galvanised coils, pickling and rinse inhibitors, degreasing products, and water

Publierre_Milano

conditioning products.

SPECIAL ISSUE ON ARCHITECTURE & DESIGN

© ipcm

© ipcm

The right curing parameters are crucial to avoid defects that could compromise the characteristics of the coating and subsequent processing.

The balance between high productivity and energy resource consumption

the material during the discontinuous-speed phases between

“The continuous-flow coating process,” indicates Bonoli

the whole process is a very significant part of the industrial cost,

“consists of a preliminary surface preparation phase with

almost 30%: nowadays, this entails new challenges concerning

chemical cleaning and passivation treatments; the application

efficiency, savings, and new formulations for less energy-

of a primer, which plays a fundamental role in improving

intensive products.”

the treatment of one coil and the next. The energy required for

adhesion and chemical resistance, and usually of a primer the adhesion of polyurethane foams and glues; and the

The quality laboratory’s support through a pilot line

application of a top coat on one or both sides of the coil. Each

“Our laboratory is characterised by the extreme accuracy

application step is carried out with liquid paint products, using

of controls,” states Bonoli. “In addition to the traditional

two- or three-roller coaters. The polymerisation phase then

instrumentation, which includes spectrophotometers,

takes place in an oven at pre-set temperatures, typically 232-

glossmeters, Erichsen deep drawing machines, and MEK test

245 °C, necessary for solvent evaporation and polymer cross-

devices for checking paint polymerisation, it is equipped with a

linking. This is followed by a cooling zone and a coil rewinding

pilot line that enables us to test samples of the paint products

station. The line’s process section operates with a continuous

we receive from our providers before the shipment of an entire

flow at a constant speed and it is placed between two vertical

supply. Here, we apply the coating on a pre-treated substrate

tower buffers in which the position of the trolley allows storing

identical to the one reaching our coating department and we

or a back coat on the reverse side to protect it or to improve

cross-link it in an oven with the same parameters that are going to be used on the line. The coated steel sheet is then subjected to the same tests planned for the finished product after coating, to check properties such as colour, gloss, adhesion, flexibility, hardness, and solvent resistance. This method enables us to verify products and validate process parameters before the industrial production phase, eliminating or minimising the inconvenience, disruption risk, and cost of any non-conformity.

The pilot line is also of support in cases where we detect a critical issue during the preparatory stages of production, as we can immediately take a sample of paint and apply it in our laboratory, even under different environmental conditions, thus identifying

© ipcm

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Quality controls are carried out on 100% of the main coils.

FOCUS ON TECHNOLOGY

painted coils. “100% of these main coils, from which we obtain the finished coils in the size required by our customers, are subjected to strict quality controls.”

Continuous research Even after achieving its goal with the formulation of optimal NIR coatings, the Marcegaglia team’s research activity will not stop. “At present, we are focused on the fact that many commonly used raw materials for paint formulation are undergoing technological upgrades by the chemical industry chain, with a view to improving product sustainability and eliminating the most critical substances.

As was successfully done years ago for hexavalent chromium, today © ipcm

A view of the outside area of the plant.

researchers are innovating the basic formulations while maintaining their same performance quality degrees, which enable us to guarantee our 25-micron coils for 15 years and 50-micron ones for up to 30 years. Another goal is the development of coatings

the source of the defect and solve the problem.”

that can be cured at lower temperatures without reducing the

At the end of each working day, a few samples are selected

throughput of our lines.

on the line and production records are collected to carry out

“In our research, we rely on trusted partners such as Condoroil

statistical checks and destructive tests. At the same time, at the

Chemical, to which Marcegaglia is increasingly turning. This is

end of the line, quality controls are performed on the main pre-

evidenced by the fact that their supplied products’ volume at our

MADE IN ITALY

IMPIANTI

we design, build and install plants for the surface treatment of metals pre-treatment | anodizing | wet paint application | powder coating plastic coating | EDP (electrophoresis) | enamelling systems

visaimpianti.it

SPECIAL ISSUE ON ARCHITECTURE & DESIGN

plant is growing steadily: it started with the first 1,000 kg in December 2014, went up to 14,000 kg the following year, and exceeded 1,200 tonnes in 2023 (forecast of 20 September). Our company adopts a philosophy of plurality in its relationships with suppliers, with no exclusive agreements, involving all the best players in each field. However, helpfulness, professionalism, and customer support make all the difference. Condoroil’s commitment contributed to making it a trusted partner for us and we have been rewarding it in terms of volume of orders. In our research and development activities, when we want to make sure that we will achieve a satisfactory result in a short time, as well as in the application phase, when we are looking for the most effective support in solving the most complex problems, we know we can rely on Condoroil. After all, we are Marcegaglia’s coating division, 'always at the forefront of © ipcm

experimentation and innovation'.”

A few control instruments in the Marcegaglia laboratory.

THE WINNING DNA OF MARCEGAGLIA Marcegaglia is Italy’s leading industrial Group in the national and international steel sector, which has been processing steel for over sixty years. It is characterised by constant growth and high-quality products and processes, contributing significant added value to the market while maintaining a strong focus on sustainability.

The Company’s unique production and business model is a true expression of Italian family entrepreneurship, by successfully combining its own operational flexibility with strong market presence typical of multinationals.

Established in 1959 by Steno Marcegaglia in the town of Gazoldo degli Ippoliti (Mantua), today it is a Group fully run by his children Antonio and Emma Marcegaglia. In over sixty years, this entrepreneurial adventure has seen a small local business become one of the top Italian companies, which was successfully able to promote its “Made in Italy” business model globally but without losing sight of its deep-rooted origins.

Independence, dynamism, agility, responsiveness, resilience, and sustainability are the key elements of Marcegaglia’s corporate culture: factors that have helped make the company the main point of reference for steel processing both in Italy and abroad, present throughout the steel value chain, both horizontally and vertically, thanks to its unique strategic positioning.

The Group is the world’s leading independent steel processor with a product range that covers everything from carbon to stainless steel, from long to flat products, from commodity to specialty. In January 2023, the Company acquired an electric furnace for special steel products in Sheffield, UK: this being the first primary production asset inthe Group’s history. Marcegaglia has invested with a view to shortening and stabilising supply chains and developing an offer of increasingly sustainable and competitive products.

Marcegaglia manufactures products sector-wide: from distribution to mechanical engineering, industrial plant engineering, building and construction, and the automotive industry, without

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forgetting specialisations for the food, agriculture, chemical and petrochemical, hydromechanics, hydraulics, furniture sectors, and many more.

Ready to seize every opportunity for growth whilst paying constant attention to customers needs, Marcegaglia Group has created a network of 37 production plants that guarantee the very best skills, quality, service, and know-how, along with a highly efficient logistics and distribution network.

The strength of its supply network combined with flexible and diversified solutions allow Marcegaglia to better address market volatility, always satisfying the needs of its customers.

All Group activities strive for excellence, constantly seeking new and improved quality standards and making structural innovation.

This is a mindset that is applied to every aspect of corporate life. A high degree of planning and openness to change make Marcegaglia a ground-breaking company, which is always at the forefront of experimentation and innovation.

The Group’s IT Engineering and R&D Divisions are strongly engaged in multiple activities focused on designing and implementing digitisation and integrated automation solutions. Developing highperformance and low-carbon production through the adoption of the best technologies available and optimising the steel production chain and processes. With particular attention to plant productivity, worker safety, and energy efficiency thanks to the use of renewable sources.

Marcegaglia: facts and figures 6.5 million tonnes of finished product 9 billion Euros turnover 7 thousand employees 37 plants on 4 continents 15 thousand customers.

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©Foxydry

The Foxydry Pro remote-controlled, ceiling-mounted clothesline.

FOCUS ON TECHNOLOGY

SPECIAL ISSUE ON ARCHITECTURE & DESIGN

A Hanging System that Improves Powder Coating Efficiency on Foxydry’s High-Tech Designer Clotheslines Gabriele Lazzari ipcm®

As with many other everyday objects, clotheslines are often underestimated in terms of both functionality and aesthetics. Foxydry has decided to revolutionise this market by offering high-tech aluminium solutions that are both convenient and stylish. To insource its finishing process, it relied on the expertise of Rostirolla, which developed a specific hook hanging system to increase the number of parts loaded into the company’s new powder coating plant.

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FOCUS ON TECHNOLOGY

©Foxydry

A wall-mounted clothesline of Foxydry.

T

©ipcm

The load bar with the parts in use and its 3D drawing.

he skilful combination of the potential

devoted to laundry and often find

offered by an international online

themselves placing essential tools

showcase and an original idea is often

such as their clotheslines in unsuitable

the basis for the development of a winning

places. That is why Foxydry has decided

business, as it provides high visibility and

to redefine this product’s concept by

allows leveraging the strengths of one’s

designing, manufacturing, and marketing

products by communicating them directly to

wall- and ceiling-mounted clotheslines

customers.

online. Its solutions are geared towards

This has also been the case with Foxydry,

both functionality and design with the

an Italian digital native business based in

aim of eliminating the annoying clutter

Sernaglia della Battaglia (Treviso), known

caused by traditional floor-standing

for its space-saving aluminium clotheslines

models and optimising the space

and home laundry accessories. In fact, many

available in the house, creating more

households do not own a room specifically

room for living and making people with

©ipcm

international PAINT&COATING magazine - SEPTEMBER/OCTOBER 2023 - N. 83

89

SPECIAL ISSUE ON ARCHITECTURE & DESIGN

©ipcm

GNW hook bars stored in baskets after chemical paint stripping.

disabilities more independent.

Surface finishing is an essential aspect of such products, as it provides high resistance properties while enhancing aesthetics. That is why Foxydry wanted to insource its coating operations for better controlling its entire production flow and gaining higher flexibility. So, it installed an automatic powder application system and, at the same time, collaborated with Rostirolla Srl (Morgano, Treviso), a manufacturer of hanging systems, hooks, load bars, and masking systems for industrial powder, liquid, and cataphoresis coating processes since 1990.

This supplier played an essential role in the project, not only because it provided flexible, efficient, and durable tools to ©ipcm

Foxydry components on Rostirolla’s P25 series pillars.

optimise the line’s hanging density and productivity but also by supporting Foxydry during the study and design phases, helping it identify the best solutions to take advantage of the new plant’s full potential.

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FOCUS ON TECHNOLOGY

©ipcm

Load bars at the entrance to the plastic pre-treatment tunnel.

Foxydry: the clever combination of an innovative product and a winning distribution model The Foxydry brand was created in 2015 based on the entrepreneurial idea of its owner Luca Antoniazzi to sell hightech clotheslines online. This spin-off project has grown within a few years, going through all the typical steps of a modern startup. “The Foxydry brand has spread worldwide thanks to two factors. The first one is our product itself: a remote-controlled, space-saving clothesline that fits into a niche in the laundry market with a solution that solves the problems caused by the clutter of conventional clotheslines. The second one lies in the distribution model we have chosen, which enables us to offer this original product directly to end consumers through online sales. This strategic choice allowed us to immediately gather feedback, understand what people liked, and work on our

SPECIAL ISSUE ON ARCHITECTURE & DESIGN

© Foxydry

The Foxydry Air remote-controlled ceiling-mounted clothesline.

initial idea to improve and develop it further,” says Sara Bernardi, co-founder together with Antoniazzi. “The initial start-up thus developed from a micro-enterprise into a small artisanal business that manages to meet the needs of local, European, and North American customers thanks to its eighteen employees, equally divided between the production plant and the administrativecommercial office.”

High-tech solutions that combine functionality with aesthetics

©ipcm

Gema spray guns in the Saldoplast booth.

Foxydry’s flagship product is a space-saving, high-tech ceiling- or wall-mounted clothesline, which can be either manual or remotecontrolled – with the advantage of managing all functions quickly

Pro, the latest version introduced to the market in January 2023, also

and easily, lowering the grille by 180 centimetres with one click and

features a ventilation system that produces warm air with low energy

lifting it without shoulder and back effort. It is a practical solution

consumption to speed up the natural drying process of laundry while

that eliminates the clutter of traditional floor clotheslines and the

respecting even the most delicate and valuable fabrics.

risk of bumping into or tripping over them, thus transforming the domestic space devoted to laundry management into a comfortable

Focus on growth

experience of freedom. Its modern, minimalist design is perfectly

Considering that each Foxydry clothesline is made up of at least 20

suited to environments furnished with care and attention to detail,

different components and that the company can build and ship its

while its aluminium and stainless steel structure ensures robustness

products worldwide within a maximum of 48 hours, its distribution

and resistance, allowing up to 35 kilograms of laundry to be hung.

model calls for a fully integrated manufacturing process that is highly

All models are equipped with an integrated LED lamp that emits

efficient, fast, and repeatable to ensure that all the required parts

a warm, homogeneous, high-intensity light to illuminate darker

can be produced in the shortest possible time. Manufacturing is

spaces, fans that promote the circulation of air inside the room and

done completely in-house. The company acquires the necessary

direct it towards the clothes, and tubes that can be extended up

aluminium profiles and carries out all the required machining and

to 240 cm for hanging sheets, tablecloths, and blankets. Foxydry

cutting operations, followed by surface finishing, the assembly of

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FOCUS ON TECHNOLOGY

wear and weathering resistance. The plant is also equipped with a manual pre-finishing station with a Smart Inline Technology gun to improve paint penetration into the workpieces’ edges. Finally, the powder coating department is completed by a Fastrip series machine supplied by ALIT Technologies, which chemically paint strips hooks and frames with a continuous flow, so that they can be immediately reused on the line.

A combination of standard and custom-made hooks to optimise production When designing the system, Rostirolla initially suggested using its P25 range of pillars. This system consists of a vertical column (pillar) with brackets designed to accommodate horizontal hook bars that can be of various types depending on customer requests. In the ©ipcm

Coated components entering and exiting the curing oven.

case of Foxydry, bars+hooks from the GNW product family were selected because they make the load bar even more flexible and are therefore ideal for a beginner coater requiring equipment that is suitable for the widest possible range of workpieces. The hook-

parts with electrical components, and finally packaging and shipping

holding bars are made of 1.5 mm thick punched sheet metal that is

to end customers.

bent for higher strength, with a hole for the hooks every 20 mm. The

“Our DNA is made up of values such as commitment and a focus on growth and improvement through cutting-edge technology. In fact, we have chosen to carry out all our processes in-house, from design to finishing, to constantly monitor every phase and identify any room for improvement,” explains Antoniazzi. “One of the most recent investments in this area is the new powder coating plant. Installed in summer 2022, it has already enabled us to increase the efficiency of our production flow.”

Competence in Shot Blast Technology

The importance of powder coating In the market in which Foxydry operates, aesthetics are of paramount importance. Coating therefore plays an essential role and must meet several quality and performance parameters, as clotheslines can also be exposed to weathering or particularly humid environments. Previously, the company purchased pre-anodised grey bars, which however were prone to damage during cutting, drilling, and milling, thus increasing the scrap rate. Now, however, Foxydry can apply multiple colours and finishes to its clotheslines (such as white or black) and even coats parts for the furniture, The coating plant built by Saldoplast (Zoppola, Pordenone, Italy) includes a loading and unloading area and a one-rail overhead conveyor taking the load bars inside a spray pre-treatment tunnel made of polypropylene, carrying out a 6-stage cycle developed

by Alufinish Italia (degreasing, two rinses with mains water, one rinse with demineralised water, nanotechnology conversion, and

As a full-range supplier, we design and manufacture shot blast machines including filter and transport technology. ➜ New shot blast machines ➜ Second hand machines ➜ Service and spare parts ➜ Reparation & maintenance ➜ Inspection & consulting ➜ Performance improvement AGTOS | GmbH | 48282 EMSDETTEN | GERMANY info@agtos.de | www.agtos.com

final rinse with demineralised water). Next, the components enter the Saldoplast coating booth, where 4 Gema guns mounted on

391-01/23-4c-GB

motorbike, and medical industries on a contract basis.

automatic reciprocators apply polyester powder paint for greater international PAINT&COATING magazine - SEPTEMBER/OCTOBER 2023 - N. 83

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SPECIAL ISSUE ON ARCHITECTURE & DESIGN

©ipcm

Energy savings in the plastic pre-treatment tunnel In addition to the optimisation of its hanging and coating operations, Foxydry also paid special attention to the environmental impact of the plant supplied by Saldoplast. That is why this includes a 21-metre-long pre-treatment tunnel made of plastics (polypropylene) for a considerable reduction in energy consumption and maintenance work.

“In a tank in ferrous material, scales could be formed that absorb chemicals. Our experience in the electroplating industry has therefore led us to opt for a structure in polypropylene, as this is a material with high chemical compatibility, greater strength, and higher heat capacity properties, making it insulated and suitable for use with different chemicals. In fact, we are planning to replace the iron in a clothesline component with stainless steel, thus converting the alkaline degreasing stage into an

ALIT Technologies’ Fastrip machine for paint stripping hooks.

acid degreasing one. Moreover, the whole tunnel features a honeycomb structure with an air chamber that prevents heat loss,” adds coating department manager Giovanni Puppetti.

hooks are made of C70 spring steel with a diameter of 1.5 and 2

“This also offers maintenance-related advantages, as it is

mm and they can be easily inserted into the hanging system directly

much easier to clean and integrate with new spray bars or

by the end user, at a rate of 400-450 hooks/hour.

manifolds. Finally, as the tunnel’s structure is prefabricated and

“Often, with coating plants, there is a tendency to place too much

pre-assembled, the assembly operations in our factory took

emphasis on optimising loading, assuming that the higher the

only one week. Together with Saldoplast, we have estimated

number of parts arranged on each bar, the greater the plant’s

that this plastic pre-treatment system is going to reduce our

optimisation. This is not always true: for example, if a firm coated

consumption by 35%.”

one hundred different components, it would need one hundred different load bars, a lot of time to switch among types, and a lot of

Constant dialogue as a strategy for the future

storage space for unused bars. That is why, for this company, we

For a company like Foxydry, whose aim is to produce diverse

sought the right compromise between capacity saturation and the

components of high structural and aesthetic quality that make

flexibility required by a lean and efficient workflow. The P25 pillars

the clothesline not only a functional and practical object but

and GNW bars fully meet this production philosophy. However,

also a piece of furniture and design, having the right tools to

following the commissioning of the plant and the rapid increase

make production smoother and more flexible is an absolute

in the volumes processed in this factory, the need arose to also

must. Indeed, optimising its hanging operation has proved to be

coat components whose finishing characteristics called for specific

strategic for improving and speeding up its workflow.

equipment. Therefore, for those workpieces that had shown critical

“The choice of the right hanging system was the result of a study

issues, we designed special hook bars that would meet Foxydry’s

carried out together with Rostirolla to enable us to hang as

new quality requirements. I therefore asked the customer for the

many parts as possible while respecting the cycle times of our

drawings of these new parts and our technicians found a solution

coating line. Rostirolla’s technical staff performed a meticulous

that would optimise the performance of our pillars, thus enabling

3D computer simulation, immediately understanding our needs

the company to take full advantage of its powder coating plant’s

and demonstrating a high level of professionalism in offering us

potential. Thanks to the combination of these elements, Foxydry

a quick solution. We were already satisfied with this collaboration

can now adjust its hooks’ spacing in width and height. Furthermore,

even before they suggested some improvements for hanging

the harmonic steel in which these are made allows supporting

new parts more easily and achieving maximum flexibility

heavy workpieces even with a small diameter (e.g. Ø2). Finally, the

even with the chain in motion. Adding bars to the P25 pillars,

flexibility of our P25 system ensures that obtaining the required

moreover, has further optimised the positioning of components

hanging structure is so simple and straightforward that it can be

on the frames and increased the amount of hung workpieces.

done quickly, directly on the chain,” states Simone Rostirolla, owner

Rostirolla’s expertise has truly been a great asset to our growth

of Rostirolla Srl together with his brother Pierluigi.

strategy,” concludes Luca Antoniazzi.

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© 2023 The Sherwin-Williams Company

© Allcolors

The new horizontal powder coating plant for Allcolors’ profiles, designed and installed by Visa Impianti.

FOCUS ON TECHNOLOGY

SPECIAL ISSUE ON ARCHITECTURE & DESIGN

Allcolors: a Revolutionary System with a Bell Oven for Coating Aluminium Profiles up to 8 Metres Long Ilaria Paolomelo ipcm®

Allcolors is a powder coating contractor serving the international market. To increase its production capacity and meet the diverse needs of its customers, it has recently installed a new horizontal plant for coating aluminium profiles at its site in Târgu Mureș (Romania). The plant designed and installed by Visa Impianti (Triuggio, Monza Brianza, Italy) is unique in that it is among the first to boast a bell oven for curing profiles up to 8 metres long.

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© Allcolors

The loading station.

P

assion for finishing, attention to quality, and constant

furniture, and automotive. Since 1999, when it installed its first

commitment to meeting the needs of its customers are the

coating line for aluminium profiles, it has notched up a series of

three pillars contributing to the success of Allcolors, a powder

successes. Thanks to the growing number of requests, it opened

coating contractor that has been operating on the European

a new plant in Bucharest in 2001 and new production facilities in

market for over 25 years. Founded in 1997 in Târgu Mureș

Timișoara in 2004 and Târgu Mureș in 2005. It is precisely at the

(Romania) and originally named SC SINTELECTRO SRL, Allcolors has

site located within the Târgu Mureș Industrial Park that Allcolors

quickly established itself at the international level in a wide range of

decided to install a new, unique horizontal powder coating plant for

industries: first design and architecture, then household appliances,

aluminium profiles. It relied on Italian plant engineering company

agricultural machinery, bicycle and motorbike components, street

Visa Impianti (Triuggio. Monza Brianza, Italy), with whom it has been international PAINT&COATING magazine - SEPTEMBER/OCTOBER 2023 - N. 83

97

SPECIAL ISSUE ON ARCHITECTURE & DESIGN

© Allcolors

Profiles entering the pre-treatment tanks.

enjoying a successful partnership for several years now.

Focus on finishing quality

coating but also various decoration and customisation technologies, which guarantee a very high level of quality in compliance with international standards (including Qualicoat

For a contract coater that has made quality its main strength,

Seaside and IATF - ISO 9001:2015) and environmental protection

carefully selecting technologies and partners is key to meeting

regulations,” states Allcolors owner Laszlo Nyaradi.

all market requirements and, above all, providing high-quality finishes in terms of both aesthetics and functionality. Indeed,

7 coating lines

whereas the architectural sector used to pay more attention to the

With over 25 years of experience, Allcolors has managed to

functional properties of coatings, such as durability and UV and

consolidate its leading position in the industry of electrostatic

weather resistance, nowadays the aesthetic quality of finishes, the

contract coating nationally and internationally, working with over

colours chosen, and the type of paint product used are playing

1,000 customers from a wide range of industries. “Initially, our

an increasingly important role. Therefore, it is crucial to be able

core business was the coating of aluminium profiles. Since 2005,

to supply products without the slightest aesthetic and functional

we have been gradually expanding and reaching other markets.

defect. “To meet the expectations of our customers, we have

Today, profiles account for one third of our turnover, whereas

installed state-of-the-art systems for pre-treatment and electrostatic

components for other sectors account for the rest.” In order to

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FOCUS ON TECHNOLOGY

PASSION FOR MASKING SOLUTIONS www.global-mask.com

WHEELS

© Allcolors

The plant is equipped with a power&free conveyor provided by Futura Convogliatori Aerei.

increase its production capacity and meet the

Features of the new Visa Impianti coating system

evolving needs of its customers, over the years

The new powder coating plant supplied by Visa

Allcolors has made numerous investments to

Impianti can handle components measuring up

equip its Timișoara and Târgu Mureș plants with

to 8 metres in length, 1.5 m in width, and 0.4 m in

the most modern and high-performance coating

height. The system includes a manual loading and

technologies. Currently, the company owns as

unloading station and a power&free conveyor

follows:

supplied by Futura Convogliatori Aerei (Robecco

• 2 automatic pre-treatment and powder coating

Pavese, Pavia, Italy). After pre-treatment, the

lines for aluminium profiles and bars up to 8 x 1.5

workpieces are transported inside the automatic

x 0.2 metres;

coating booth provided by Wagner and located in

• 3 automatic tunnel-type pre-treatment and

an air-conditioned and pressurised clean room.

coating lines for steel, cast iron, and aluminium

After the automatic application phase, the profiles

industrial parts up to 4 x 2 x 0.80 metres;

dwell in a bell oven for about 25 minutes. “The bell

• 2 automatic sublimation lines.

oven makes this plant unique because, usually,

“Our latest investment dates back to 2020,

the curing of large bars and profiles takes place

when we approached Visa Impianti to design a

in conventional tunnel ovens. As it has no inlet

new coating plant for the Târgu Mureș site. The

air curtains, this prevents part contamination – a

resulting horizontal line for aluminium profiles

coating defect that occurs when uncured powder

and bars has enabled us not only to increase

lifts off one profile and settles on another – thus

productivity and gain more control over the entire

minimising the company’s scrap rate,” indicates

coating cycle but also to achieve significant energy

Paolo Massari, the owner of Visa Impianti.

savings,” explains Nyaradi.

Inside the bell oven, the parts gradually rise to

CUSTOM

STANDARD

SPECIAL ISSUE ON ARCHITECTURE & DESIGN

© Allcolors

© Allcolors

The cyclone.

companies that turn to us, we also offer various customisation services, including two-tone profile coating, sublimation to imitate the grain of wood, marble, granite, and other patterns on metal surfaces, and the insertion of barriers and thermal bridges for insulation.”

The fully automated immersion pre-treatment cycle

© Allcolors

Profiles inside the bell curing oven.

In 2020, Visa Impianti also designed and installed a new immersion pre-treatment plant for Allcolors. The components are placed on the load bars and moved through the individual tanks

a height of 6 metres, where they remain for about 25 minutes.

by the automatic overhead crane to undergo a pre-treatment

Afterwards, they are taken back to the floor level and conveyed to

cycle consisting of the following phases:

the storage buffer for cooling, before being manually unloaded by

• alkaline degreasing

the operators. “At the end of the coating cycle, if the components

• 2 rinses

meet all quality requirements, they are transported to an automatic

• acid attack

packaging line, located next to the coating system, and finally

• 1 rinse

shipped to customers,” illustrates Allcolors’ owner. “With the aim

• 1 rinse with demineralised water

of providing an all-round service and meeting all the needs of the

• chromate conversion coating

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GLOBAL SOLUTIONS FOR WATER TREATMENT

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

© Allcolors

Profiles entering the coating booth.

• 1 rinse • 1 rinse with demineralised water.

This is followed by a dripping phase and a drying one in a pit oven. Once cooled, the components are then unloaded and manually transferred to the coating line. “All the parameters of the pre-treatment cycle (times, chemicals dosage, demineralised water production) can be set via the PLC and

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

constantly monitored. This has enabled us to gain more control over our pre-treatment process. With the previous plant, we were used to carrying out all operations manually: the overhead crane was not automatic but managed by an operator, as was each stage’s cycle time. With the new line featuring a PLC, we have been able to automate the entire process, minimising the possibility of human error,” notes Laszlo Nyaradi.

“Finally, the plant is equipped with a DUPLEX demineralised

srl

water system that treats and recirculates polluted water with a zero-liquid discharge process. With this unit, water is also available during the regeneration process,” adds Massari.

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

SPECIAL ISSUE ON ARCHITECTURE & DESIGN

© Allcolors

The Wagner powder management unit.

A completely revolutionised coating cycle

equipped with an air-curtain curing oven, which however

The design of the pre-treatment plant and the coating system

displaced the excess powder and polluted the components’

was a significant challenge, as Allcolors required a modern, high-

surfaces. With a bell-shaped layout and without air curtains,

performance line with a small footprint. “Visa Impianti was able to

the new oven solved this problem, which often led to significant

offer us an advanced, high-performance solution with a compact

quality defects, and reduced paint wastage, costs, and cycle times.

layout that met all our needs. The new, fully automatic plant has

The percentage of rejected products due to quality defects is now

enabled us to revolutionise our coating cycle. With the previous

around 2% and therefore significantly lower than in the past.”

line, we used to manage all individual processes manually, from the

“Allcolors also pays special attention to environmental

movement of the overhead crane to the selection of cycle times for

sustainability. We are currently finalising the installation of a

the pre-treatment stages, up to the application of paint. Now, we

series of photovoltaic panels. We plan to monitor the amount of

have greater control over our entire process and finishing quality

energy we consume and, together with Visa, we are considering

degree, minimising the percentage of human error,” confirms Laszlo

harnessing some of that energy within a few years to generate

Nyaradi.

the heat needed to warm up the water in the pre-treatment cycle

“The bell oven was also a novelty because the previous plant was

or the drying oven,” concludes the owner of Allcolors.

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© Adobe stock

The façade of the Museum of Contemporary Art of Barcelona with profiles coated by LADAL.

FOCUS ON TECHNOLOGY

SPECIAL ISSUE ON ARCHITECTURE & DESIGN

Operative Word: QUALITY. A Long-Standing Partnership with a Powder Coating Manufacturer Enables LADAL to Finish Its High-End Aluminium Profiles for the Architectural Sector Ilaria Paolomelo ipcm®

In architecture, colours and finishes play as important a role as the coating quality degree. Precisely the culture of quality has led LADAL, a company specialising in the coating of aluminium profiles and sheets and considered one of the pioneers of the Spanish aluminium powder coating market, to collaborate with AkzoNobel for almost forty years.

F

or several decades, powder coatings have been used

characteristics but also excellent aesthetics, only applied liquid

exclusively in industrial sectors where high functionality,

paints.

effective weather resistance, and good corrosion protection

It was not until the second half of the 1970s that the first powder

were required. Little attention was paid to aesthetics. Sectors such

coatings combining functionality and aesthetics, also thanks to an

as architecture and design, which not only required functional

ever-increasing range of colours and finishes, and guaranteeing

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© ipcm

© ipcm

The immersion pre-treatment phase.

LADAL’s headquarters in Lleida, Catalonia, Spain.

excellent results even in the metal architecture sector were launched

reliable, and long-lasting finishes is at the heart of all our activities. As

on the market. Major transitions like this, however, require time,

proof of this, we were the first in the Spanish market to obtain GSB

the willingness to accept change, and of course innovation-oriented

International and Qualicoat certifications and today we are one of

companies and resources ready to carry out technical studies and

the main European benchmarks of excellence for aluminium powder

tests to check the quality and reliability of the new products on

coating.”

different substrates. Germany, Switzerland, and Austria were the first coatings in design and architectural projects, in the years 1977-1979.

The importance of pre-treatment on high-quality aluminium profiles

In Spain, on the contrary, the transition from liquids to powders

LADAL has been specialising exclusively in the powder coating of

was slower than in other countries: at the end of the 1970s, the

aluminium profiles, sheets, and mouldings and investing in the best

companies that had started applying powder coatings on aluminium

technologies and products on the market to maintain the high quality

profiles could be counted on one hand. Among them was LADAL

level that has distinguished it for over forty years. “The quality and

(Lleida, Spain), which for more than forty years has distinguished

durability of a coating depend largely on the pre-treatment stage.

itself in the market for the excellent quality of its aluminium profile

Generally, paint defects are visible at a glance and can be rectified

coatings and its attentive customer service. Its success also stems

in a short time. However, on a window or curtain wall, if the pre-

from its solid, long-standing technical and commercial collaboration

treatment phase has not been carried out optimally, the defects are

with high-profile partners such as AkzoNobel Coatings S.L.U. (Vallirana,

not visible immediately, but only after about five or six years. This

Barcelona, Spain), capable of meeting any requirement in terms of

undoubtedly leads to greater inconvenience and costs. That is why we

finishes and colours and offering timely assistance and technical

only use products that comply with Qualicoat and GSB International

advice geared towards improving the overall quality level of coating

standards,” explains Farré.

processes.

“For years, there has been a debate on which is the best pre-

geographic areas to witness significant growth in the use of powder

A pioneer in the Spanish aluminium coating market

treatment technology between acid and alkaline degreasing. Although both have advantages and disadvantages, however, the synergy

The history of LADAL began in 1977, when powder application on

between the two processes does result in a flawless pre-treatment

architectural and design components was still an unexplored process

process: this is the reason why we subject our aluminium components

in the Iberian Peninsula and the market was not familiar yet with

to both operations.” LADAL’s sprinkling pre-treatment process with

these products’ potential, but also with their related regulations

Chemetall chemicals consists of the following stages:

and quality certifications. “The drive for innovation and the desire

• Alkaline degreasing

for improvement of our company’s founders and employees were

• Rinsing

the main factors that led LADAL to invest in training, skills, and the

• Rinsing

best technologies available on the market at the time,” states José

• Acid pickling

Farré, coating consultant at LADAL. “The goal to achieve qualitative

• Rinsing

excellence and provide customers with attractive, sophisticated,

• Rinsing with demineralised water

international PAINT&COATING magazine - SEPTEMBER/OCTOBER 2023 - N. 83

105

SPECIAL ISSUE ON ARCHITECTURE & DESIGN

© ipcm

Profiles entering the horizontal line’s Gema booth.

© ipcm

Some profiles in the vertical coating line.

• Aluminium profiles up to 7000 mm; • Slabs and mouldings up to 6500 x 2000 mm; • Mouldings up to 600 mm in length; • Curved and complex-shaped profiles; • Accessories. © ipcm

The manual application phase.

The horizontal system performs up to 40 colour changes per day.

The Trasmetal vertical line, on the other hand, features two booths equipped with the latest technology, enabling LADAL to speed up the required colour changes, up to 20 per day. Process control

• Chromate conversion / Nanotechnology conversion

and monitoring ensure complete traceability from the material’s

• Rinsing

receipt to its delivery.

• Rinsing with demineralised water.

“We only use polyester powder coatings and apply them in one

The coating department

coat with thicknesses between 60 and 80 microns. We do not carry out any machining operation in our factory but, to provide our

Within its 6,000 m²-wide facility, LADAL has a large paint shop

customers with an increasingly complete service, we have recently

equipped with a vertical coating line supplied by Trasmetal (Milan,

started to complete the coated profiles with rubber seals, hinges,

Italy) and a horizontal coating line. “We use the horizontal system

or other small accessories upon request,” adds Farré.

to handle small batches, but also very large or complex-shaped attention and precision degree that can only be guaranteed with a

The wood-effect coating process as an alternative to sublimation

plant of this type, where the operator has more control and visibility

The wood-effect coating process aims to faithfully reproduce the

over the workpieces,” notes Farré. Installed to provide LADAL with

elegant nuances and grains of wood on aluminium profiles and

greater flexibility to coat any part regardless of its shape and size, this

provide interior designers and architects with the widest possible

horizontal line is equipped with a Gema quick-colour change booth.

range of special effects and finishes. “By combining the most

Specifically, LADAL coats the following types of parts:

modern paint technologies and products, we are also able to

profiles that cannot be treated on the vertical line as they require an

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© ipcm

After application, the profiles enter the curing oven.

© ipcm

The vertical line supplied by Trasmetal.

perform a wood-effect coating process, which unlike conventional

states Nanet Tamayo-Durango from the specification sales marketing

sublimation does not require the application of a sublimation film,”

department of AkzoNobel.

explains Farré.

“In the Spanish market, the transition from high-gloss to matte colours

The wood-effect coating process begins with the pre-treatment of the aluminium profiles, with dimensions between 6000 mm and 6700 mm, in compliance with the Qualicoat Seaside Class AA standard, which requires an etching degree of 2 g/m². The first coat of polyester powder is applied on the profile and pre-cured in an oven. A second layer of powder coating (again polyester-based) is then applied by deposition and without contact just 1 mm above the surface of the aluminium, using a special cylinder. Finally, both layers are cured. “This process was developed according to LADAL’s quality approach: many years ago, we examined the existing processes that were used to give aluminium a wood-effect finish, i.e. sublimation and powder-on-powder coating, and our numerous tests demonstrated that the latter provided greater UV resistance. This led us to implement the wood-effect coating technology, which not only imitates and enhances the wood grain, but also ensures high coating durability and weathering resistance,” indicates José Farré.

The evolution and trends of the Spanish market The architectural market has evolved and there is now an infinite number of tints and finishes available, including metallic, rough, matte, satin-finished, and so on. As a result, paint manufacturers have progressively launched a multitude of colour, finish, and effect collections to give designers and architects greater freedom of choice in their projects. “The architectural sector is much more demanding than it was in the past. When LADAL started its activity, the trend in the Spanish market was towards white and a dozen bright colours with a gloss value of 75-80. Today in Spain, the trend seems to have reversed as the most popular finishes are matte and extra-matte textured finishes, with an average gloss value of 15,” international PAINT&COATING magazine - SEPTEMBER/OCTOBER 2023 - N. 83

107

SPECIAL ISSUE ON ARCHITECTURE & DESIGN

Futura collection provides architects, engineers, and designers with a source of inspiration for their projects through increasingly highperformance and sustainable finishes,” says Vicente Herrero Asensio, sales manager for Catalonia at AkzoNobel.

In addition to AkzoNobel’s standard products, the Netherlandsbased multinational also supports LADAL through the development of customised paints. “In particular, AkzoNobel developed a matte white coating for us that we have already been using successfully for years. White is one of the colours with the most varied shades and tones and, therefore, there can be significant differences between © ipcm

From left to right: Ilaria Paolomelo from ipcm®, José Farré from LADAL, and Nanet Tamayo-Durango from AkzoNobel.

the whites supplied by different paint manufacturers. To avoid colour-matching issues and have greater control over our painted products’ quality, we prefer to always use the same type of white that AkzoNobel has specially designed for us,” notes Olga Eito, coating and

took some time, but today it seems to be the winning choice for both

project manager at LADAL.

applicators and end users: matte finishes have greater mechanical

“Our partnership with AkzoNobel has been going on for over forty

resistance and fewer quality problems than glossier and shinier

years, even before this was its name, and we are very pleased to be

ones,” confirms Farré. “Another trend we are observing in the metal

working with it. We have a very close supplier-customer relationship

architecture market is the increasing demand for super-durable

with its team, which is not only limited to the supply of products

coatings, which are specially formulated to flawlessly withstand the

but also includes advice on all new products launched by the

elements and wear and tear of time and thus guarantee the high

company and reliable and timely customer service. Finally, since

level of quality that distinguishes LADAL. When we coat a profile, for

all of AkzoNobel’s architectural products are Qualicoat and GSB

example, we do not know exactly where it will be located: perhaps along

International approved, they perfectly meet our requirements and

the coast, or in areas where it rains a lot? Therefore, to maintain the

those of the companies that rely on us, with whom we have a ‘quality

quality level that characterises our company, it is important to apply

commitment‘.”

more advanced coatings that offer greater guarantees than standardquality finishes.”

Future projects

“Architects, designers, and engineers who specify the ideal type of

“Without ever losing sight of quality, LADAL intends to continue

finishes for each project should especially understand this. In fact, that

investing in the near future to increase the sustainability of its

is why AkzoNobel is conducting an information campaign to promote

processes and provide its customers with an ever higher level of

the use of super-durable coatings in the architecture and design fields,

service. We are fully aware that the market rewards those who

particularly with our Interpon D2525 range,” indicates Tamayo-Durango.

focus on customer satisfaction, high process quality, but also

A long-standing, successful partnership with AkzoNobel

environmental sustainability. To this end, we are already developing a new pre-treatment cycle on our vertical coating line that entails replacing the chrome conversion phase with the use of a high-

Interpon, AkzoNobel’s powder coatings division, supplies LADAL with

performance, environmentally friendly nanotechnology product.

a wide range of powders with multiple finishes and special features.

Similarly, we are replacing all our packages, which until recently were

These include the RTS (Ready-To-Ship) range, which comprises

made of cardboard, with reusable iron containers,” illustrates Farré.

about 1700 powder products with a wide variety of high-quality

“There are many components in a window or façade: the finish is

colours, textures, and special effects, such as the Futura 2022-2025

only a small part of it. Looking back, I realise how technologically

collection. “The service life of a building or product is determined by

advanced each one of them is: not only finishes but also, for instance,

the durability and performance degree that its powder coating can

thermal insulation and double glazing systems to increase energy

provide. The Futura collection has been created to set trends in the

savings. Fortunately, surface defects due to errors made during the

world of architecture and design while guaranteeing super-durable

pre-treatment or coating phases are now a thing of the past. On

quality and ensuring the highest levels of gloss retention, colour

our part, as promoters of the use of powder coatings on aluminium

stability, and UV resistance to limit deterioration, in compliance with

profiles, we have always had the vision to offer high-quality products

international standards including Qualicoat Class 2 and GSB Master.

and an accurate and timely service. We will keep on doing so in

In addition, launched every four years based on in-depth market

future, continuing to rely on the best partners on the market, such as

studies and analyses of trends in the global architectural sector, the

AkzoNobel,” concludes Farré.

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www.infragas.com

INFRARED RADIANT GAS SYSTEMS FOR THERMAL TREATMENTS

© UCF

The UCF-developed plasmonic paint uses nanoscale structural arrangement of colourless materials — aluminium and aluminium oxide — instead of pigments to create colours. Here the plasmonic paint is applied to the wings of metal butterflies, the insect that inspired the research.

ADVANCEMENTS

SPECIAL ISSUE ON ARCHITECTURE & DESIGN

UCF Researcher Creates World’s First Energy-saving Paint – Inspired by Butterflies Katrina Cabansay, UCF - University of Central Florida Office of Research – Orlando (FL), United States

katrina.cabansay@ucf.edu

Instead of pigment-based coloured paint, which requires artificially synthesized molecules, a UCF researcher has developed an alternative way to produce coloured paint that is more natural, environmentally friendly and light weight.

T

he UCF-developed plasmonic paint uses nanoscale structural

primary colour-generating mechanism in several extremely vivid species

arrangement of colourless materials — aluminium and aluminium

where geometrical arrangement of typically two colourless materials

oxide — instead of pigments to create colours. Here the

produces all colours. On the other hand, with manmade pigment, new

plasmonic paint is applied to the wings of metal butterflies, the insect

molecules are needed for every colour present.”

that inspired the research.

Based on such bio-inspirations, Chanda’s research group innovated

University of Central Florida researcher Debashis Chanda, a professor

a plasmonic paint, which utilizes nanoscale structural arrangement of

in UCF’s NanoScience Technology Center, has drawn inspiration from

colourless materials — aluminium and aluminium oxide — instead of

butterflies to create the first environmentally friendly, large-scale

pigments to create colours.

and multicolour alternative to pigment-based colorants, which can

While pigment colorants control light absorption based on the electronic

contribute to energy-saving efforts and help reduce global warming.

property of the pigment material and hence every colour needs a

Debashis Chanda, a professor in UCF’s NanoScience Technology Center,

new molecule, structural colorants control the way light is reflected,

drew inspiration from butterflies to create the innovative new paint.

scattered or absorbed based purely on the geometrical arrangement of

“The range of colours and hues in the natural world are astonishing —

nanostructures.

from colourful flowers, birds and butterflies to underwater creatures

Such structural colours are environmentally friendly as they only use

like fish and cephalopods,” Chanda says. “Structural colour serves as the

metals and oxides, unlike present pigment-based colours that use

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ADVANCEMENTS

artificially synthesized molecules.

plasmonic paint could cover a Boeing 747, which normally requires

The researchers have combined their structural colour flakes with

more than 1,000 (453.5 kg) pounds of conventional paint, he says.

a commercial binder to form long-lasting paints of all colours.

Chanda says his interest in structural color stems from the vibrancy of

“Normal colour fades because pigment loses its ability to

butterflies.

absorb photons,” Chanda says. “Here, we’re not limited by that

“As a kid, I always wanted to build a butterfly,” he says. “Color draws my

phenomenon. Once we paint something with structural colour, it

interest.”

should stay for centuries.”

Additionally, because plasmonic paint reflects the entire infrared

Future Research

spectrum, less heat is absorbed by the paint, resulting in the

Chanda says the next steps of the project include further exploration of

underneath surface staying 25 to 30 degrees Fahrenheit cooler

the paint’s energy-saving aspects to improve its viability as commercial

(-3,8 to -4,4 °C) than it would if it were covered with standard

paint.

commercial paint, the researcher says.

“The conventional pigment paint is made in big facilities where they can

“Over 10% of total electricity in the U.S. goes toward air

make hundreds of gallons of paint,” he says. “At this moment, unless we

conditioner usage,” Chanda says. “The temperature difference

go through the scale-up process, it is still expensive to produce at an

plasmonic paint promises would lead to significant energy

academic lab.”

savings. Using less electricity for cooling would also cut down

“We need to bring something different like, non-toxicity, cooling effect,

carbon dioxide emissions, lessening global warming.”

ultralight weight, to the table that other conventional paints can’t.”

Plasmonic paint is also extremely lightweight, the researcher says.

Chanda says.

This is due to the paint’s large area-to-thickness ratio, with full coloration achieved at a paint thickness of only 150 nanometers,

The complete development was published in Science Advances

making it the lightest paint in the world, Chanda says.

as a featured article. You can find it at the following link:

The paint is so lightweight that only about 3 pound (1.3 kg) of

https://www.science.org/doi/10.1126/sciadv.adf7207

Ricambi

Convogliatori

Via P.I. Radrizzani 108, 21040 Uboldo (Va) Italia +39 02 96780581

BRAND-NEW

SPECIAL ISSUE ON ARCHITECTURE & DESIGN

Interpon’s New Flat Matt Steps into the Light AkzoNobel has launched its Interpon D2525 Flat Matt in Thailand.

F

or designers and manufacturers in Thailand, creating

Şirvan Canıtez, Commercial Director South Asia at AkzoNobel

surfaces with ultra matt finishes that bring a glint of

Powder Coatings, says matt finishes are an architect’s dream:

brilliance and luminescence to their architectural creations

“All shades within the new range provide an astonishing

just got easier following the launch of Interpon D2525 Flat Matt

non-reflective surface never seen before with an Interpon

from AkzoNobel, a global leader in innovative, sustainable, and

powder coating. Thanks to the metallic travel, light is capable

durable powder coatings.

of dancing across the surface while keeping its ultra matt

The new coating delivers a finer mica effect that enables an

appearance.”

ultra matt surface to change appearance depending on the way

AkzoNobel has a proven track record of innovating to

light reflects on it, giving architects a finish that not only looks

meet the architectural sector’s ambitions with on-trend

amazing, but also offers stunning levels of superdurability.

colours and finishes and Interpon D2525 Flat Matt is no exception: “We always stay true to our mission of creating the best products on the market from both a durability and sustainability perspective to support the design of Green

© AkzoNobel

Buildings,” Şirvan adds.

Thanks to its commitment to innovation, AkzoNobel is redefining how powder coatings contribute to the aesthetics of a building with new finishes and textures that enable architects to create truly amazing designs that stand the test of time. Interpon D2525 Flat Matt comes with a 25-year warranty (when applied by an approved Interpon D applicator) and conforms to the AAMA2604 industrial standard.

With no volatile organic compounds (VOCs), Interpon powder coatings are more sustainable than coating alternatives. Customers are also making the switch because they generate significantly less waste compared to other solutions and any overspray can be easily recovered and reused. Interpon powder coatings offer the architectural sector a means of creating lasting legacies with less impact on our environment.

For further information: https://architectural.interpon.com/th/products/

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with Fluidized tank

Inocart HF & NDT with Pressure tank

FOCUS ON TECHNOLOGY

Mexall Upgrades Its Aluminium Profile Coating Plant with a Chrome-Free Pre-Treatment and Atomisation Cycle that Improves Performance and Reduces Water Consumption Gabriele Lazzari ipcm®

Mexall Progress is a leading designer of thermal break aluminium, aluminium-wood and woodaluminium window frames with maximum performance, comfort, and safety, characterised by a focus on its personnel and the natural resources of its local community. It has 5 coating plants for aluminium profiles and has recently updated its pre-treatment line thanks to the atomisation of the chrome-free passivating agent SurTec 643 through the RainTec technology installed by SurTec Italia, improving the cycle and reducing water consumption by 40%.

“A

n industrial group with more than thirty years’ experience enriched by a drive for innovation and constant research in the technological field, with

creativity as its most distinguishing feature, always attentive to the world around it and ready to take on new challenges.” This was the description of Mexall Progress S.r.l. offered to ipcm® on the occasion of its first report on this company in 2016. Nine years on, it has now forty years’ experience, but its other features have © ipcm

Coated aluminium profiles.

remained the same – actually, they have been enhanced: the range of profiles has been expanded, the available colours have increased, and the search for innovative environmentally friendly technologies has taken centre stage.

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FOCUS ON TECHNOLOGY

© ipcm

The vertical coating system in the Scafati plant.

© ipcm

Elisa and Francesco Prete, the first and second generation of the family at the helm of Mexall Progress.

Its most recent investment has involved the pre-treatment

considerably reduce water consumption while at the same

tunnel, where upgrading work has been carried out through

time increasing the application consistency of the passivating

collaboration with SurTec Italia, already the supplier of the

product SurTec 643, compliant with Qualicoat and GSB

chemicals used in this cycle. In particular, this has introduced its

standards. This solution has allowed replacing the previous

RainTec atomization technology in the final passivation phase to

products, containing hexavalent chromium, with an equally international PAINT&COATING magazine - SEPTEMBER/OCTOBER 2023 - N. 83

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SPECIAL ISSUE ON ARCHITECTURE & DESIGN

© ipcm

© ipcm

efficient alternative that is also safe for humans and the environment.

Mexall: a constantly growing company The company was founded in 1980 as Meridall, a business devoted to the resale of aluminium profiles acquired from local manufacturers and surface-treated through agreements with a few coating contractors. In 1990, in order to speed

From top left clockwise: - The entrance to the spray pre-treatment tunnel.

- The RainTec technology’s management unit. © ipcm

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- The outside of the tunnel.

FOCUS ON TECHNOLOGY

From left to right: Ulderico Capozzi, Elisa Prete, and Patrizia Angeli from SurTec Italia.

up its sales processes and expand its offer, it installed its first polyester powder coating plant. Nine years later, the Prete family at its helm officially founded Mexall Progress S.r.l.

In the following years, expansion continued in step with the growing demands of the market, also met with the installation of two coating and three effect finishing plants.

“Trends in the world of window and door frames have changed dramatically in the 21st century, as houses but also buildings in general have become smaller and the need to make the most of natural light has increased, even with fewer and smaller windows than in the past. Therefore, more space must be given to the glass component at the expense of the © ipcm

aluminium profile section, of course without

ONE SINGLE GROUP FOR ALUMINUM FINISHING DIVISION ANODISING AND POWDER COATING DIVISION WASTEWATER TREATMENT PLANTS CHEMICALS SPECIALTIES

www.cieeng.com info@cieeng.com

SPECIAL ISSUE ON ARCHITECTURE & DESIGN

© ipcm

© ipcm

Coating with Gema technologies.

sacrificing aesthetics and perfomances. Our production has

armoured doors and grilles, as well as sublimation machines.

been adapted to these requirements, also in line with studies

The Scafati plant purchases raw aluminium bars, which are

on psychophysical well-being. We currently offer 22 different

extruded with Mexall’s proprietary dies, and subjects them to

frame series and we can produce profiles in 430 different

machining and thermal cutting operations to obtain profiles in

shapes within a short time, for windows that recover on average

the required shapes. The profiles are then coated with polyester

more than 13% of light by mirroring and have a low thermal

powder products. Out of these, some batches are sent to the

transmittance value, so that houses can be kept thermally

Tito Scalo site, where they undergo wood-effect sublimation

insulated in both winter and summer,” says Francesco Prete,

finishing, or to Tekla Srl, a door and window producer also run by

the founder of Mexall Progress.

the Prete family, carrying out the final assembly operations of the

Process diversification as the key to success

aluminium and aluminium/wood frames with accessories such as gaskets and glazing beads, before installing them.

Mexall Progress currently has two production sites: one in

“We have always had an artisan but at the same time pioneering

Scafati (Salerno, Italy) for the coating of aluminium profiles and

soul, as demonstrated by the manual operations we used to

one in Tito Scalo (Potenza, Italy) for the processing of aluminium

perform to imitate the texture of wood with brushes and pads

and steel sheets, with a powder coating plant devoted to

before the industrial sublimation process was developed.

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FOCUS ON TECHNOLOGY

© ipcm

The display of RainTec control unit.

Throughout our forty-year history, at the same time, we have been investing in industrialisation to meet the market’s ever-increasing quality demands quickly and expand our offer with new and innovative finishes and effects, always while paying special attention to the sustainability of our operations. The Prete family is very attached to its local community and the natural resources of the beautiful Campania region, such as the Sarno river, which requires care and attention from us all,” notes Elisa Prete, R&D manager at Mexall Progress. “Our renewed collaboration with SurTec Italia bears witness to these values: we were already using its products for the pre-treatment of aluminium profiles and were pleased with their efficiency, so when it presented us with a chromeFind out more...

www.freilacke.com

SPECIAL ISSUE ON ARCHITECTURE & DESIGN

free alternative that could also increase the quality of our products

measure developed by SurTec has significantly reduced the

and the enviroment, we immediately decided to adopt it.”

line’s maintenance requirements,” says Elisa Prete.

Pre-treatment with SurTec 643 and RainTec technology

Water consumption reduced by 40% without stopping production

In the Scafati plant, Mexall has one vertical and one horizontal

Thanks to the technologies developed by SurTec and

coating plant, both connected to a pre-treatment tunnel

skilfully adapted to Mexall’s production requirements, the

performing an alkaline degreasing operation and an acid one

company’s aluminium profiles – coated with a process

to remove all contaminants and residues left by the previous

awaiting Qualicoat certification – now reach an acetic salt

machining operations. The last stage of the pre-treatment cycle

spray resistance of 1,000 hours. In addition to the quality and

is passivation with RainTec technology, which atomises the

safety-related benefits of a chrome-free product, the upgrade

chrome-free no-rinse product SurTec 643 to completely cover

of its pre-treatment cycle has substantially reduced Mexall’s

the profile, thus improving paint adhesion and preventing filiform

environmental impact. “Previously, the passivating product

corrosion. “SurTec 643 is a chrome-free passivating solution

was sprayed and not finely atomised. The RainTec technology,

composed of an inorganic (zirconium) and an organic base that

on the other hand, allows it to be deposited uniformly over

has been optimised to align the weight of the layer. The RainTec

the entire length of each profile, avoiding the risk that a

technology has been selected to improve deposition consistency

variation in exposure to the product compromises the coating

over the entire length of the profile,” explains SurTec Italia sales

of the underside of the parts. At the same time, it has also

manager Patrizia Angeli.

reduced water consumption by 40%, since there is no longer

Since no final rinsing is required, the load bars are then led to the

a need for a final rinsing stage and since the amount of liquid

drying oven at 80° C. Afterwards, the profiles proceed to the vertical

atomised together with the pre-treatment product is lower.

booths (performing up to 7 colour changes per shift) or they are

Our energy consumption has also been reduced, as we have

unhooked and loaded in the horizontal system (performing over

been able to switch off the pumps of the passivation tank

30 colour changes). Finally, after paint polymerisation, they are

and the subsequent rinsing one, which we have completely

unloaded to continue their production cycle.

removed,” notes Elisa Prete. “Moreover, the pure SurTec 643

A tailor-made chrome-free process

product can be applied with RainTec directly onto the profiles without prior mixing in the tank, so it is no longer necessary to

The combination of RainTec and SurTec 643 was therefore

constantly monitor process parameters. Finally, in addition to

specifically designed to obtain a process that could best atomise

the environmental and health improvements, the chromium-

a fresh, high-performance solution on aluminium profiles with a

free process has made it unnecessary to draw up a list of

length over 7 metres and eliminate the use of products containing

operators exposed to carginogens. As a result, our workflow,

chromium, which in addition to being a health hazard for operators,

internal communication, and production logistics have also

used to require time-consuming and costly purification and

significantly improved.”

disposal steps. This process has also been further customised

“We installed this new system in only one weekend in May

based on the characteristics of Mexall Progress’ coating line, with

2023, without stopping the plant. It remained operational

an automatic cleaning system integrated with the pre-set idle times

until the end of the evening shift on Friday and SurTec’s

for colour change and maintenance operations.

technicians installed the new system and performed the

“The organic component of the pre-treatment product releases

bypass of the hydraulic circuits on Saturday. We tested it

physical residues that must be removed; at the same time, the

on Sunday and by the start of Monday’s first shift, the plant

company needed to optimise its process times. Therefore, together

was ready. The system has only been operational for three

with the plant engineering firm, we devised a system capable of

months, but the benefits are already evident: we have not

carrying out the cleaning of nozzles with demineralised water and

experienced any issues and there is no trace of chromium in

the subsequent drying stage in complete autonomy whenever the

our processes. We now hope to continue to take advantage

plant stops or when the barcode reader located in the loading area

of SurTec Italia’s expertise to further improve our processes

does not detect any more incoming parts to be coated,” indicates

and achieve the zero liquid discharge goal, so that we can

Angeli.

be trailblazers towards a complete ecological transition

“The RainTec system has been built using materials that do not

in our local community,” Francesco Prete concludes with

corrode and have a high degree of chemical resistance. This

satisfaction.

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© PPG

Powders are a strategic line of business for PPG, which has set a target to increase its sales share of sustainable products and solutions to 50% by 2030.

HIGHLIGHT OF THE MONTH

SPECIAL ISSUE ON ARCHITECTURE & DESIGN

Science-based Decarbonisation Targets and a Focus on Innovation in Powder Coatings: PPG’s Growth and Sustainability Strategy From an interview with Justin Epler, WW general manager of Industrial Coatings, EMEA, and Anne Banuls, PPG powder coatings business manager, EMEA, Industrial Coatings

Sustainability has been a key component of PPG’s strategy for more than a decade now and with its new decarbonisation and greenhouse gas emissions reduction targets set for 2030, the American multinational company is now raising the bar in the paint and coatings industry. Powder coatings play a key role in this framework, as demonstrated by the range of innovative products and the investment volume in this field that PPG has been implementing over the past three years.

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© PPG

© PPG

durability of the products and technological solutions provided are also important sustainability factors.

We talked about these issues and much more with Justin Epler, PPG general manager of Industrial Coatings, EMEA, and Anne Banuls, PPG powder coatings business manager, EMEA, Industrial Coatings. We asked them to provide an overview of the technologies and market trends of PPG’s Industrial Coatings division, especially focusing on the role that powder coatings play in the growth strategy of this American multinational in light of

Justin Epler.

global market trends as well as of the company’s sustainability

Anne Banuls.

policy.

S

need. “Sustainable development is development that meets

WE PROTECT AND BEAUTIFY THE WORLD®: a purpose, a promise

ustainability is not a trend but rather a specific, pressing the needs of the present without compromising the ability of

As one of the largest and most recognised paint manufacturers

future generations to meet their own needs” in terms of “economic,

in the world, PPG offers high-performance solutions that provide

social, and environmental dimensions,” as stated in the correct

durability, beauty, and long-term colour stability to products

definition of “sustainability” by the Brundtland Commission at the

spanning a wide range of industries. Founded in 1883 as

1987 UN Conference. Acting sustainably, therefore, does not only

Pittsburgh Plate Glass by Captain John B. Ford and John Pitcairn

mean reducing the environmental impact of one’s activities but also

in Pittsburgh (Pennsylvania, USA), PPG is now a global supplier of

implementing social, economic, and governance policies to ensure the

paints, coatings, optical products, and speciality chemicals. With

achievement of this objective.

more than 52,000 employees worldwide, operations in over

To reach one’s corporate sustainability goals, in particular, it is

70 countries, and $17.7 billion in sales by 2022, it is a giant in the

essential to work with partners that share the same values and

global industry of paint and surface treatment speciality chemicals.

objectives and guarantee mutual support, knowledge exchange, and

For 140 years, this American multinational company has been

the implementation of common solutions. More and more today,

earning the trust of a multitude of customers within a wide

suppliers are assessed in the light of their sustainability policies and

variety of sectors.

their environmental and climate neutrality goals. At the same time,

Sustainability has been a critical component of its strategy

however, sustainability cannot just be a mere marketing lever: it must

for a long time now. In its 2022 ESG Report, there are countless

permeate all areas of a company, become a shared value among all

examples of PPG products that are tangibly contributing to a

levels of the organisation. Downstream of this, the high quality and

more sustainable future, for example by extending the service life of bridges, buildings, and infrastructure; reducing energy consumption and greenhouse gas emissions through the elimination of curing phases required by automotive coatings and sealants; enabling near-infinite recyclability of aluminium food and beverage packaging; and even improving the fuel efficiency of aeroplanes and cargo ships. Now, as part of its mission to “protect and beautify the world”, PPG has set itself some new, ambitious environmental, social, and governance targets to be achieved by 2030.

Can you give us an overview of PPG, especially the Industrial Coatings division and its main markets?

JE: “The best way to outline PPG’s activities is to start with our mission, “We protect and beautify the world®,” because it truly © PPG

Ultra durable powders for metal architecture are one of the core focuses of PPG in the architectural coatings segment.

encapsulates everything we do. Two market segments drive our business: Performance Coatings, including products for aerospace, architecture, auto refinish, and protective and marine applications, and Industrial Coatings, with products for automotive OEMs, international PAINT&COATING magazine - SEPTEMBER/OCTOBER 2023 - N. 83

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general industrial, packaging, coatings and special materials, and

is Asset Protection and all things corrosion management. PPG

traffic solutions. The group Anne and I are here to represent today

boasts great expertise in this area and it has invested heavily

is Industrial Coatings. Under the “Industrial” umbrella, PPG identifies

in research into one-coat powder coatings with excellent edge

segments such as energy, building and construction, consumer

protection properties. The third pillar is UV Resistance, with the

products, vehicles in general, machinery, and equipment. One of

emergence of ultra durable powders. This is a new technology,

PPG’s major endeavours in the Industrial sector is to bring value

but we are seeing progress year by year. The fourth and final

through four integrated product ranges that differentiate us from

pillar is Functionality. Research here is increasingly focusing on

the competition, namely pretreatment, electrocoat, liquid paint, and

attributing new functions to powder coatings, to be exploited in

powder coatings, the latter technology having become central to

emerging industrial segments such as electric vehicles, where

PPG’s future worldwide.

powders are used to coat batteries due to their dielectric and

Powder coatings are key to PPG’s expansion and sustainability

thermally conductive properties”.

strategy. The sustainability of powder coatings is reflected in the growth of the technology throughout the global manufacturing industry”.

According to PPG, what are the most important trends driving the spread of powders?

In light of this scenario, what is the role of powders within PPG’s growth strategy, especially in Europe?

AB: “Powders are a strategic line of business for PPG, which has set a target to increase its sales share of sustainable products

AB: “A key factor driving the rapid adoption of powders worldwide is

and solutions to 50% by 2030, especially in Europe. Powder

the strong interest in sustainability and sustainable development at

coatings fall squarely within this quota for all the mentioned

all levels of the market, from producers to end consumers. Powders

reasons. Since 2019, PPG has been focusing on growing its

are undeniably a strategic tool for this purpose, thanks to the

powder production capacity both through acquisitions and by

extremely low content of Volatile Organic Compounds (VOCs),

expanding its existing manufacturing and service capabilities

a utilisation rate of nearly 100%, and the possibility of being

worldwide. We recently made two acquisitions in Europe, one in

recovered and recycled.

Germany two years ago (manufacturer Wörwag) and one in Italy

For PPG, today’s market dynamics rest on four pillars: one of

last year (the powder business of Arsonsisi)”.

them is Sustainability. This is why one of our main lines of

JE: “In May this year, our CEO, Tim Knavish, spoke of “purposeful,

powder-related research concerns lowering curing temperatures

profitable growth” that PPG will achieve in three ways: with

from the traditional 160-180 °C to 130-160 °C to decisively limit

its existing technology portfolio, by maintaining leadership in

energy consumption; at the same time, we are investing in the use

research, innovation, and leverage of its global operational

of bio-based raw materials and recycled materials. The second pillar

expertise, and through investment in powder coatings. PPG’s

In the EV segment powders are used to coat batteries due to their dielectric and thermally conductive properties. © PPG

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HIGHLIGHT OF THE MONTH

© PPG

The use of primers from the Envirocron Primeron range in multi-coat systems is the key to extending the life of products and preserving their structural integrity.

© PPG

PPG Envirocron Extreme Protection Edge provides excellent edge protection characteristics together with good chemical resistance and excellent outdoor durability properties.

strategy is to think globally, implement regionally, and serve locally.

powder-focused R&D facilities worldwide. In Europe, we have four

Over the past three years, we have invested $150 million globally in

production plants in three countries: one plant is in Poland, two are

production capacity and powder expertise. PPG now has 21 powder

in Germany, and one is in Italy. Out of these factories, three have the

production plants, with production capacity also for resins, and

same production capacity whereas one is devoted solely to acrylic

AS FLEXIBLE AS YOU ARE READY FOR ANY APPLICATION. PEA-X1 & PER-X1

New generation of automatic guns

wagner-group.com

• Highest coating results with maximum application efficiency • Variants for coating systems & robot-based manufacturing environments • Modular design with a wide range of accessories Ready for you: Get more information on https://go.wagner-group.com/pea-x1

SPECIAL ISSUE ON ARCHITECTURE & DESIGN

2030 ESG Commitments

While sustainability has been a critical component of PPG’s strategy for over a decade, we’re continuously looking to the future. As part of our promise to deliver on our purpose — WE PROTECT AND BEAUTIFY THE WORLD® — we’ve set new, ambitious 2030 environmental, social and governance (ESG) goals that will guide our continued efforts. We’ve established a stronger focus on decarbonization, including emissions reduction targets that have been validated by the Science Based Targets initiative (SBTi).

structural integrity. For one-coat applications, on the other hand, PPG Envirocron Extreme Protection Edge provides excellent edge protection characteristics together with good chemical resistance and excellent outdoor durability properties.

Among the most innovative products, PPG

15%

50%

reduction in water intensity at priority sites

reduction in Scope 1 and 2 GHG emissions

30%

reduction in Scope 3 GHG emissions

25%

reduction in waste intensity

Envirocron EnergX™ Ultra is a low-temperature

100%

cure powder that combines ultra durable

process waste reuse, recycle or recovery

outdoor performance with an efficient and

validated science-based targets

sustainable production process, especially for companies coating large-sized parts such as those operating in the agricultural

50%

$5MM

sales from sustainably advantaged products

in additional COLORFUL COMMUNITIES® project funding, incorporating an element of sustainability

100% key supplier assessments

100%

of employees go home safely each day

5%

and construction machinery sector, because it allows a 20 °C reduction in curing

annual reduction in spill and release rate

temperatures with a 20% energy saving and a 15% reduction in CO2 emissions. Finally, the

To learn more about PPG’s environmental, social and governance progress, please visit:

PPG Envirocron HTE (High-Transfer Efficiency)

ppg.com/sustainability

powder has excellent adhesion and resistance

The PPG Logo, We protect and beautify the world and Colorful Communites are registered trademarks of PPG Industries Ohio, Inc. ©2023 PPG Industries, Inc. All rights reserved.

© PPG

PPG’s 2030 ESG Commitments.

properties and is ideal for complex, difficult-topaint surfaces. Available in durable and ultra durable versions, this innovative coating helps increase productivity while reducing material

technology, which we believe in strongly”.

What are the advantages of acrylic technology over polyester technology?

AB: “All raw materials used to produce powders are solid, VOC-free

usage, energy consumption, and maintenance costs with a firstpass transfer efficiency of 85%. I would also like to mention the PPG Envirocron LUM retroreflective powders, launched in 2022, and the rich product line conceived for e-mobility”.

powders can create an orange peel on the surface. The acrylic

To conclude this interview, let us go back to the subject of sustainability: what is PPG’s vision and commitment to it?

technology provides many aesthetic advantages, including very

JE: “PPG’s vision is to value all stakeholders and strive to be the

high film distension and UV resistance, which are strategic in some

first-choice partner for our customers, with whom we work closely

markets such as that of alloy wheels, trims and bikes, without

to understand their evolving needs in terms of coatings and

sacrificing outdoor performance. This is the reason why it is mainly

surface treatments. Having worked at PPG for over fifteen years, I

implemented for topcoats”.

am personally excited to see the direction the company is taking

products that are mixed, extruded, ground, and finally applied by spraying. Sometimes the application of epoxy, hybrid, or polyester

What are the main product innovations in the powder sector?

towards sustainability. We have a dedicated sustainability team, both globally and regionally. We partner with our customers to help them achieve their sustainability goals. Finally, sustainability

AB: “One and two-coat corrosion protection powder coatings

is the core around which all PPG innovation gravitates: we ensure

are increasingly in vogue. Protective primers are the first line of

that new products contribute to further sustainability in the world.

defence to safeguard metal surfaces against corrosion, the most

At the organisational level, PPG continues to evolve thanks to

difficult challenge in the metal coating industry. Therefore, PPG has

the feedback we get from all stakeholders: customers, investors,

launched a complete portfolio of protective powder primers, the

and regulators. Our 2022 ESG Report shows a strong focus on

PPG ENVIROCRON Primeron range, designed to provide metal

decarbonisation by 2030 and a push towards science-based

substrates such as steel, galvanised steel, metallised steel, and

greenhouse gas emission reduction goals: a 50% reduction in

aluminium with high corrosion resistance properties. The use of

Scope 1 and 2 emissions and a 30% reduction in Scope

primers from the Envirocron Primeron range in multi-coat systems

3 emissions. PPG is the first U.S. coatings manufacturer to have

is the key to extending the life of products and preserving their

validated science-based targets”.

®

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N. 83 - SEPTEMBER/OCTOBER 2023 - international PAINT&COATING magazine

eosmarketing.it

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

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

With Chemtec technologies you can replace zinc&iron phosphate:

PRONORTEC multi-metal surface treatment

TORAN 3® multi-metal pre-treatment process

WASTE WATER TREATMENT SYSTEMS

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BRAND-NEW

GET TECHNICAL 2023: Multi-tech Solutions for Surface Finishing Process by the sppot Ecosystem

T

he sppot is a unique one-stop platform, giving state of the

GET TECHNICAL 2023

art surface finishing solutions to the bicycle and sporting

This Autumn will be all about practical solutions and improving

goods industry. The sppot is a partnership of well-known,

surface finishing processes marking the grand finale to this year’s

globally presented companies: TIGER Coatings, Berlac AG, WAGNER,

BIG3 events of the sppot: GET TECHNICAL, edition 2023, the two-

Posterama, Eurotherm Spa, Lesta and Duthoo Care and Repair

day, free-of-charge, live event dedicated to technical expertise and

Systems. The ecosystem was established 7 years ago to support

innovations in the bicycle and sporting goods industry. Guests of

bicycle and sporting goods producers in Europe to get the best

the event will join an interactive and versatile conference followed

technical quality and know-how in the surface finishing process. Our

by real-time demonstrations of a surface finishing process of

approach is knowledge sharing and extensive expertise.

frames and other bicycle components. Also, they will have the

No matter if it is a question on the production line issue or inquiry of

opportunity to participate in insightful discussions and build new

setting up a new painting facility, the sppot is a one-stop for quality

valuable connections with other industry members in order to have

services and products manufactured in Europe and aims high to

a deeper understanding of the latest surface finishing technologies.

help customers find trendy color and effect combinations for their The team starts with the customer on the “bare frame” and finish

Conference where industry speaks out of experience

with a well-designed high-end surface. What meets the eye of the

Noticeable representatives from the bike industry will share their

customer is an evolutionary process involving several technologies

hard-earned insights about sustainability and energy efficiency

and design elements.

gained through years of experience. Experts from the production

GET TECHNICAL is part of the sppot’s BIG3 annual events along with

line will be there as well to discuss how to prevent troubleshooting

Color Trend Days and Eurobike, where we are regularly present.

within the production process.

frames and accessories.

© TIGER Coatings

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© TIGER Coatings

N. 83 - SEPTEMBER/OCTOBER 2023 - international PAINT&COATING magazine

SPECIAL ISSUE ON ARCHITECTURE & DESIGN

Unveiling the surface finishing process in real-time The combination of various products from different global suppliers makes surface finishing a hard and complex process.

Get more from water

At the sppot we bundled our know-how and the guests of the event will be able to witness it through real-time demonstration of surface finishing of a bike frame and some of the most common troubleshooting within the whole process. The host of the event, Eurotherm Spa is setting up a brand-new demonstration area with powder and liquid coating booths, equipped with Lesta’s robots, WAGNER’s spray guns and manual application systems needed for surface finishing of a bike frame. Posterama will have a decaling workshop. Duthoo will have live demonstration of scratch repairments with WAGNER’s application system. Along with the process, visitors will have the opportunity to check the latest colors and shades of TIGER’s powder coatings portfolio and Berlac’s liquid coatings.

Despite the explanation of the whole finishing process in details, the event will provide room for individual troubleshooting and

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

one-to-one meetings with specialists from the sppot’s ecosystem.

Batch type systems

GET TECHNICAL 2023 will take place at Eurotherm’s facilities in

Flotation units

Turin, Italy. Both days of the event will cover the same topics

Chemicals and spare parts for water treatment

and will follow the same program of conference and technical demonstrations. Visitors are free to choose between two options depending on their language preferences: 21st of November – program in English;

Technical service, support and maintenance of wastewater treatment plants

22nd of November – program in Italian.

Programme 10.00 – 12.30: Conference 12.30 – 14.00: Lunch 14.00 – 17.30: Technical demonstrations & workshops • Powder coating process with robot and manual application systems • Decaling workshop • Liquid coating process with a robot • Repair/touch-up demonstration

Registration website

For further

to GET TECHNICAL:

information:

Beware of imitations, buy the original!

info@waterenergy.it

www.waterenergy.it

© Stardust

ANALYSIS

SPECIAL ISSUE ON ARCHITECTURE & DESIGN

The New Trend Towards Ultra-Matte Colours in the World of Design and Architecture: Stardust’s View on Research, Production, and Application Issues From an interview with Guido Pozzoli, CEO of Stardust Powder Coatings, L’Aquila (Italy)

Matte finishes have been overtaking glossy and semi-gloss ones in consumer preferences for some years now – in architecture as well as in many other industrial sectors, from automotive to furniture, from make-up to photography. The world of coatings is now going further, towards a far-off frontier that looked impossible to reach only five years ago: that of ultra-matte finishes, with gloss values of less than 5. A difficult frontier for powder coatings at that, as it poses objective difficulties in terms of both production and application and demands an evolved industrial culture for successful use, at least as evolved as this type of product is. We discussed this with Guido Pozzoli from Stardust, which has just launched an ultra-matte black epoxy paint for design applications.

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ANALYSIS

“I

was born in 1972 and, through my family’s history in the aluminium powder coating sector, I have witnessed first-hand the development of colours and

finishes from the late 1970s to the present day,” says Guido Pozzoli. “I have seen how in the world of architecture, for example, the few colours used initially have gradually grown in the number of shades and effects. Whereas in the early 1980s some fifteen RALs were in fashion, basically

Efficient and reliable solutions for surface coating since 1988.

all glossy, in the early 1990s the number of RAL tints increased and there was a shift from glossy to semi-gloss finishes and on to the first matte ones. In the early 2000s, the first NCS colours made their appearance, all of them matte. From the 2000s until today, there has been a fast race to request paint suppliers to develop new finishes, progressively reducing the gloss of innovative colours.

Today, this race has reached – not without technical problems – the 5, 3, and even 2 gloss frontier.”

Ultra-matte paint products: a challenge for R&D technicians and applicators “Going from 90 to 85 gloss is child’s play,” adds Pozzoli,

electrostatic systems for liquid painting

“also considering that ±5 is the tolerance range within which matteness can vary during the curing phase. Such a small difference goes unnoticed at the visual level.

Conversely, switching from 10 to 5 gloss means halving

electrostatic systems and spraying booths for powder coating

this value and, going even further, transitioning from 3 to 2 gloss means reducing it by 30%. Lowering the gloss degree so much involves impressive efforts in terms of R&D because it is not only about achieving an aesthetically

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

beautiful finish, but rather about doing so while meeting all the chemical, mechanical, and ageing resistance requirements that have already been achieved with traditional products.”

The life cycle of colour trends in different industrial segments “The world of design and architecture, which can be

IR and UV drying systems

robot and reciprocators

considered a pioneer in researching new materials and finishes, always pushes laboratories and R&D technicians to develop innovative and even daring solutions,” notes Pozzoli. “On the other hand, whereas in the world of fashion colours change once a season, in the world of design they do so every five years, in the automotive world every three to five years, and in the world of architecture even more slowly: colours and finishes change every ten years, because the average service life of products is also finishes that are developed today must be guaranteed to

eosmarketing.it

taken into consideration. This means that the colours and

CM SPRAY s.r.l. www.cmspray.it

last for at least the next ten years to continue to be trendy. international PAINT&COATING magazine - SEPTEMBER/OCTOBER 2023 - N. 83

131

stability and relative ease of application. On the other hand, when exploring unfamiliar frontiers such as that of ultramatte paints (i.e. below 5 gloss), we find ourselves operating in the world of niche products and specialties. As such, these cannot be treated like commodities: these special coatings call for distinctive measures in terms of storage, handling, feeding, and application parameter adjustment. They are more delicate products, which do not allow for the slightest application or handling error, offering great advantages but also critical aspects that can be coped with only if users learn to treat them with due care. For instance, if 2 or 3-gloss paints require a curing temperature of 190 °C for 15 minutes, this is imperative and does not allow for variations. They also demand controlled storage conditions, as they are highly reactive and cannot be stored near ovens, for example; Stardust itself adopt significant measures to prevent their pre-curing and transports them in cold storage units, at least in summer. In other words, they are evolved products for evolved customers. Paint manufacturers like Stardust can offer innovative ideas and solutions, but their success is determined by the application phase, i.e. the joining link with the consumers. That is why the coaters must be able to understand, handle, and apply these innovative products under the right conditions.”

M87: Stardust’s new ultra-matte product “Our laboratories have developed a series of ultra-matte © Stardust

powder coatings with distinct characteristics that make them ideal for use in the architecture and design sectors. The first products included have gloss values of around 3 and fully

In the last few years, I have witnessed an acceleration of this

meet Qualicoat Class 1 and 2 requirements (ULTRAMATT-R

process, a painstaking search for innovation, as tints and finishes

and ULTRAMATT-HR). The second ones (ULTRAMATT2)

have become a key distinguishing factor for innovative architects

have achieved the extreme value of 2 gloss and have film

and designers. Social media contribute to this trend because

distension properties comparable to that of liquid paints, as

they keep on showing and offering novelties at an impressive

well as excellent chemical and scratch resistance.

speed.

Ultramatt2 belongs to the new generation of epoxy powders

“Stardust invests significant resources in the research and

which guarantees excellent mechanical properties and

development of new products that can meet the needs of the

high chemical resistance. The film shows notable aesthetic

most demanding customers – and it is capable of doing so very

properties, particularly a “silky” effect with the highest levelling

quickly, also thanks to its ability to grasp downstream needs

and a brilliance of 2 gloss at 60°. This kind of coating is

and translate them into requirements to suppliers. Stardust’s

specifically designed for indoor application and provides

entire operational structure has adapted to its speed in taking

metal parts with a premium appearance with the lowest

up suggestions from raw material suppliers and translate them

possible gloss currently available.

into the development of interesting innovations to present to its

The film shows excellent mechanical performances with

customers.”

impact resistance (EN ISO 6272-1) of 2.5 Nm, bending (EN

Ultra-matte: evolved products for evolved customers “95-gloss glossy to 10-gloss hyper-matte products enjoy a certain

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ISO 1519) of 5 mm, adhesion Gt-0 (EN ISO 2409:1994) and good scratch and abrasion properties. Chemical resistance to MEK Test (ASTM D4752) and cold liquids (EN 12720:2013) are also very good, as a matter of fact, the surface can be easily

ANALYSIS

© Stardust

cleaned without any marks or fingerprints. The

“With such low gloss levels, application

film can be developed in any kind of colour,

problems can increase tenfold. I would like

customised or within a colour chart. The product

authoritative magazines such as ipcm® to

is VOC free and does not have any hazard

emphasise these aspects, in the hope that

warning for safety” states Pozzoli.

readers will be made aware of the application

“The ULTRAMATT2 family also includes a black

and handling issues posed by these products,

colour conceived for design applications, which

which are not just “nice to see and touch”. In

we have named M87 after the largest black hole

addition to targeted training, it is necessary to

in the universe: it is the central black hole of the

make coaters more aware of the importance

giant elliptical galaxy Virgo A, the largest galaxy

to read all the technical sheets and

in the “near” universe, located 56 million light-

operational instructions for the application

years from us, in the Virgo Cluster,” says Pozzoli.

of our specialties. In fact, Stardust’s mission

“The peculiarity of a black hole is that it absorbs

remains to offer to its customers maximum

the entire spectrum of radiation: in the same

safety and ease in the application of any

way, the lower the gloss value, the more visible

colour, including the most innovative and

radiation is absorbed and not reflected by the

complex ones” ends Pozzoli.

coated object. M87 is part of our new collection of ultra-matte products, which are available in countless colour variations”.

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© AdobeStock

© AdobeStock

ADVANCEMENTS

Tintelligence™ is Ready to Transform the Paint Tinting Industry Nidhi Shetty Fast & Fluid Management, A Unit of IDEX Corporation

nshetty@idexcorp.com

After a successful global announcement at the European Coatings Show 2023, Fast & Fluid Management is set to go live with Tintelligence™ — unified tinting solutions. Fast & Fluid Management is a unit of IDEX Corporation and has been leading the way in innovation, reliability, and service for decades.

With regional offices and a network of certified channel partners across the globe, the company offers a complete range of paint dispensers, mixers, shakers, and software suitable for a wide range of applications. The products are developed by keeping regional market trends in mind. Fast & Fluid Management’s state-of-the-art machines come with robust, clean-cut, and award-winning design to ensure the best user experience.

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ADVANCEMENTS

“Y

ears of passion and hard work have been dedicated by our team to bring Tintelligence to life, and we are thrilled to announce this exciting milestone as we go-

live. Our team is excited to embark on this new journey, providing unparalleled support to our first set of customers to help them unleash the true potential of Tintelligence. And this is just the beginning – we welcome everyone to experience Tintelligence as we prepare to make it available to even more customers from 2024. We look forward to sharing more about what is to come, including new products, features, and more”, said Ana Garcia, President Global Dispensing, IDEX Corporation.

Driven by a mission: propel the paint tinting business Point-of-sale tinting processes are complex and involve multiple stakeholders driving results simultaneously. There is a unique need and opportunity to enable stakeholders of the tinting business to enhance operational and commercial performance.

Tintelligence empowers customers to elevate their tinting business performance by bringing state-of-the-art tinting

C

equipment and advanced digital applications into one unified

M

solution, enterprise-wide.

Y

This new solution allows customers to:

CM

• drive their business performance to new heights with smart

MY

technology and actionable insights • enhance their in-store experience with a connected and intuitive tinting solution • maximize fleet uptime and lower costs with remote monitoring

CY

CMY

K

and analytics • Improve accuracy and sustainability with a simple and future-proof tinting solution.

Born with a vision: one experience, enterprise-wide Tintelligence empowers key stakeholders across the tinting value chain with a unified experience.

• Business managers can fuel business growth with real-time visibility into commercial data. Gain actionable insights from data to recognize trends and strategize corrective actions. With every insight available in a single dashboard, respond to market trends quickly, optimize marketing promotions and campaigns, and enhance inventory and supply chain efficiencies to meet market demands.

• Fleet managers can maximize fleet uptime and reduce costs with remote fleet monitoring, smart alerts and remote machine inspection. Single dashboard view can monitor critical KPIs for equipment health, colorant condition, machine-related behaviour of the store operators, and take required actions. This solution rolls out new software or database updates for all or a few

Wherever paint matters!

analytics. Provides real-time visibility and actionable insights into

ADVANCED DIGITAL APP SUITE TO ACCELERATE BUSINESS GROWTH

the operational and commercial data for faster and smarter decisions.

• TI Data HUB - Advanced solution for smarter dispense database management Cloud-based comprehensive dispense database management application that allows you to create, manage, publish and track dispense databases remotely in real-time. No one needs to visit each store to install or update the dispense database to formula books – eliminating the high costs and time involved with physical in-store visits.

T I

S E R V I CE

• TI Service - On-time assistance to maximize uptime All-in-one service management mobile app to configure, enrol, T I

DATA

T I

H U B

I N SI G H T

monitor, diagnose, maintain and repair the equipment. Whenever issues occur, they will be diagnosed swiftly and resolved promptly – resulting in less business disruption and lesser cost of service.

• TI Dispense – Intuitive dispensing for faster order

T I

A SSI S T

T I

D I SPE N SE

fulfilment Formula book application for faster and intuitive dispensing available in mobile and desktop application format. Packed with smart functionalities like quick formula searches, custom orders, order queuing, housekeeping reminders and more, ensuring hassle-free order fulfilment.

© Fast and Fluid Management

• TI Assist – Smarter assessment for seamless operations equipment in minutes.

Part of the TI Dispense mobile application, TI Assist gives critical

• Service engineers can ensure swift and effective maintenance

equipment assessment to ensure seamless store operations.

with an all-in-one service management app. With remote,

Provides a clear view of dispenser timeline and service contact

real-time access to machine status, service log and timeline of

details enabling on-time maintenance.

events, a service engineer can diagnose an equipment faster and

Tintelligence drives real business value for you – improved

accurately – resulting in less business disruption and lesser cost

performance, lower costs, enhanced customer experience, and

of service.

more sustainability.

• Store associates can elevate in-store experiences with quick, hassle-free and error-free order fulfilment. With on-time

A bright future ahead

reminders of housekeeping operations, store associates can

As the Tintelligence Apps prepare to go live, Fast and Fluid

improve machine performance and life.

Management is inviting businesses to embrace the future of

Accelerate business growth with Tintelligence Apps

tinting operations. Experience firsthand how this revolutionary solution breaks barriers, enhances efficiency, and catapults tinting processes to unmatched levels of excellence.

The advanced suite of applications seamlessly integrates with the equipment, enabling smarter colour management and faster data-driven business decisions. They enhance profitability, increase efficiency, lower TCO, and enable online ordering: • TI Insight – Real-time data for smarter decisions Cloud-based application for fleet management and business

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Scan the QR Code to discover more about the Tintelligence™ solution:

© HangOn

ANALYSIS

The New Financial-Economic Era: Post-Globalisation Adriano Antonelli Tecno Supply - Ibix Srl, Lugo (Ravenna) – Italy

adriano.antonelli@tecnosupply.com

W

e lived in the era of globalisation. Underlying this economic

components and process products with significant added value,

and financial concept is the free movement of goods and

whereas the southern part could finally start its industrial and

the maximum openness of markets, which enabled each country

economic-financial development.

(or macro-area) to specialise in what it could produce best,

More production led to more employment and, in fact, between

purchasing goods and services that were not within its reach

the 1980s and 2000s, there was an increase in employment

efficiently. This resulted in the relocation of low-added value

of around 800 million people. “Turbo-production” linked with

production and, for developing countries, in a great opportunity

“turbo-finance”, therefore, resulted in a long period of high

to grow stably. It also forced companies to find new forms of

employment rates and the illusion of lasting global stability.

organisation to be globally competitive. It was possible to find

However, some emerging issues were not taken into account,

any product at the best price and in a short time. Warehouses

such as the fact that “turbo-finance” was causing disruptions in

were downsized and some productions that were no longer

the banking circuits or that the soft power of certain countries

considered interesting were relocated. We thus witnessed a so-

was causing friction at the international level. On the other

called “win-win” process: the northern part of the world could buy

hand, we had the great advantage of living in a period that can

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ANALYSIS

© HangOn

Ibix, distributor of HangOn products, investigated which segments of a coating line are most energy-intensive and what actions can be taken to reduce their impact and footprint.

be described as “deflationary”: just think of the price of some

components for goods production. Globalisation has transitioned

products that would not have been sustainable if production

from a worldwide scope to the district and local levels.

had been carried out entirely in Europe or in Western countries in general.

The contraction of markets

Ecological issues and the WLB index Last but not least, different ecological factors should be considered. We have realised that resources are not infinite.

Since 2008-2009, however, several issues have been

Extreme climate events, supply shortages, and the issues

undermining the economic and financial system: in

related to rare earths have drawn attention to how we use

chronological order, recession, Covid, climate change, and even

and manage raw materials. We have started considering new

the war in Ukraine. Particularly during the pandemic, problems

production processes, new but more expensive energy sources,

emerged with company closures and the lack of components

and a new sustainable mobility model. This has clearly affected

that had been taken for granted and readily available for a long

and will continue to affect the manufacturing fabric and its

time. It was precisely at this time that markets such as China

reorganisation. Another aspect not to be underestimated in

started to become increasingly closed, causing restrictions,

this process is the change related to human capital. When

limiting trade, and diminishing opportunities for growth and

comparing how work was and is conceived by Baby Boomers and

for the specialisation of industrial districts where technological

the Millennials, it is important at least to mention the new WLB

innovation and improvement could take place. Attempts have

(Work-Life Balance) index. All this concretely affects production

been made to solve this problem by shortening value chains.

processes, habits, purchasing choices, and in general the

Long supply chains with departments located in every corner of

organisation of society, which is experiencing major frictions

the world have shrunk, bringing back “home”, or at least close

at the global level that generate both financial and production

to the company’s headquarters, the production of essential

tensions in the markets. international PAINT&COATING magazine - SEPTEMBER/OCTOBER 2023 - N. 83

139

© HangOn

In the HQL bar, you can hook 1 mm or 1.5 mm on both side (or just one) to increase hanging density.

Effects on the industrial coating sector On these pages, we would like to analyse how this affects the industrial coating market. We asked our customers, through a survey focussing on the value of sustainability, the reduction of energy costs, and the use of raw materials. We also investigated which segments of a coating line are most energy-intensive and what actions can be taken to reduce their impact and footprint. These values are not only hypothetical but are now actual standards required to work with large groups and multinationals, and they cannot be underestimated for all the reasons described above. Numerous products and production © HangOn

lines are now being reshored to Europe, and many of these include coating operations. Times, quality standards, and costs are changing.

The HQL bar is also suitable for hanging the pieces in its two holes.

All this requires an organisational and production analysis.

How to reduce coating times and costs Some solutions that can facilitate hanging operations and therefore

The Flexi Frame system

reduce coating times and costs include frames and systems such as

Another new product launched this year is the Flexi Frame (flexible

bars produced automatically to reduce both absolute and relative

frame) system. It is a frame that can be completely disassembled

costs, so much so that the price of each hanging point can now be

and stored on shelves, consisting of a T-shaped bar housing two

equalised to that of a single hook. The advantage is having stable

workpiece holders. HQL, HCL BHL, H11B, and HQS bars can be

frames, which increases hanging density and reduces cycle times,

accommodated. The system is designed to be stocked and then

especially compared with hook-by-hook hanging.

used in case of urgent need.

It guarantees the following advantages:

The HQW system

- saving storage space and reducing storage problems;

An example of this is the new HQW system, a 2 mm diameter tree-

- lower transport costs, including one-off ones;

shaped frame with fixed hanging points. The range is wide, so that

- easy handling;

every customer can choose its ideal pitch. To have a compact frame,

- flexible and compact design;

also in terms of packaging, hanging must be done with separate

- self-locking;

hooks. This frame is designed to be used when a sudden need arises

- customisable as required;

and to avoid hanging hook after hook. The cost is less than one Euro

- reduced cost.

to eliminate any regeneration-related issue.

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ANALYSIS

© HangOn

The HQC bar accommodates hooks with a diameter of 1.5 mm, but only on one side.

BE WASTEWATER FREE © HangOn

The advantages of using the HQC bar include increased efficiency, in terms of both speed and hanging density.

The HQL bar HQL bars are produced fully automatically: this reduces costs and eliminates the need for regeneration. Hooks with a diameter of 1 mm can be inserted into the bar on both sides, in order to hang the workpieces symmetrically. For example, the HQL 800x33 bars accommodate 46 hooks over a length of 800 mm. The bars can be inserted into the universal HCF system. This makes the system modular and enables bars to be inserted according to the length of workpieces. Moreover, the HQL G6 caps guarantee perfect electrostatics.

1.5 mm-hook bars, also made of spring steel, are now also available for small, heavy parts. Different configurations are available in the range, including the triple-bend one, as it provides more secure anchoring in the case of light workpieces that could be lifted into the air during pre-treatment. HQL bars for single-sided hanging are also available, in case it is necessary to hang parts only on one side and

ZLD SINCE 1984 www.eco-techno.it sales@eco-techno.it

The new metal adapter also allows inserting H11B bars.

thus avoid any shading effects and other issues.

Examples of magnets.

mm in diameter to be inserted, thus achieving horizontal flexibility.

The advantages of using this bar are numerous: - time saving: it is possible to achieve a speed that is 30 times higher

The H11B bar

than with single hooks;

These are punched bars inside which hooks are lodged. This

- the hooks leave only a slight mark on the coated parts;

ensures clean and protected contact points as well as the flexibility

- spring steel hooks;

to change the hanging hooks whenever necessary. Standard or

- possibility to configure the bars with special hooks;

twin hooks can be used with the same bar, fitting between the two

- smart packaging to reduce transport costs.

punches and remaining fixed. As far as twin hooks are concerned, any configuration can be chosen for even greater flexibility. These

The HQC bar

bars are highly durable (it has been assessed how much they can

A more robust version of the HQL bar is the HQC one. It

support depending on their length). Even more robust H2B, H25B,

accommodates hooks with a diameter of 1.5 mm, but only on one

and H3B versions are also available. These bars can accommodate

side. It has a coupling that allows hooks to be inserted into a central

hooks up to 10 mm. Hooks can be welded at their ends to obtain

10 mm-diameter one. The R 58 bar holder allows the bar to be stable

a T-shaped frame. This guarantees part stability, while the system’s

and easily removed, also thanks to the BH G 20 caps. The resulting

modularity allows hooks to be inserted where needed without losing

frame is economical and flexible, as it is possible to avoid filling all the

conductivity.

levels. The hooks have a pitch of 50, 75, or 100 mm. This type of bar was also designed to avoid using individual hooks, which dramatically

The HCL bar

reduces the operators’ hanging time. Indeed, the availability of a

HCL bars have housings for the insertion of springs or hooks made

ready-to-use frame eliminates the need to handle single hooks. In

from round rods or sheet metal. Their ends are protected with

addition, it allows for easy offline pre-hanging. Another advantage

silicone caps that allow easy removal and ensure conductivity. They

is that it can be used for multiple hanging configurations. This bar’s

can have single or double housings to increase hanging density.

production technology makes it possible for it to have a similar cost

They are therefore extremely flexible, eliminating the need to build

to that of an individual hook. Therefore, there is no extra cost for the

a different frame for every part to be coated. Special accessories

purchase of frames compared to standard hooks. Finally, to make

can be created, depending on the workpieces. Two springs can be

this frame even more versatile, a new metal adapter was launched

accommodated inside the hook holder with a 4-end outlet. These

that also allows H11B bars to be inserted. In this way, using the same

bars can also be used for cataphoresis processes, thanks to a cap

central hook, a bar can be accommodated allowing hooks up to 4

system that allows their ends to be protected and prevents the

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ANALYSIS

Increase your productivity WITH SELF-LEARNING ROBOT FOR FINISHING

HQS frames have metal slats for hanging any element from individual parts to profiles.

cataphoresis product from climbing up.

The flexibility of the HCF universal frames allows using bar holders with interchangeable bars, and in some cases, bars with accessories that can be inserted depending on the workpiece to be hung. This leads to a significant reduction in the number of frames required for the different workpieces processed, in the space needed for storage,

SELF-LEARNING ROBOT 1 OPERATOR REQUIRED EUROPEAN ASSISTANCE

and in the possible handling problems. The universal frames can also be used for cataphoresis operations: the structure remains the same, but the bars and accessories are changed to guarantee maximum conductivity. Already-welded bars with universal hooks are available in the range, allowing for minimal contact. For greater flexibility, we

info@Lesta.it

www.Lesta.it

The new tool developed by HangOn to calculate the cost of coating lines.

also offer hook holders where universal accessories and, at the top,

In addition to its automatically produced and standardised range,

protective caps can be inserted.

HangOn can build customised frames, hooks, and systems according

Another interesting application is the use of magnets. In cases

to customer requirements. In addition, the implementation of

where no metallic paint is used and where it is acceptable to have

trolleys offers the possibility of managing one’s treatment processes

an unpainted area on one of the two faces of the metal workpiece,

even better. Indeed, trolleys have become essential to reduce

magnets can be employed for hanging. This makes the operation

process times and increase density. In-line hanging may not be

quicker and easier, especially when there are no holes. The range

efficient in terms of density, when it is not possible to adequately

includes different magnets depending on the weight to be supported.

fill the m3 available within the line handling time. Trolleys allow for

The magnets are always covered by silicone masking systems to

pre-hanging and handling within the plant. Some HangOn trolleys

prevent them from getting dirty.

are designed to be modular and flexible and to be combined depending on the type of frame used. If switching among frames

The HQS frame

with different coupling devices or different sizes, trolleys adapt to

HQS frames have metal slats for hanging any element from individual

the various requirements to perform two functions: that of allowing

parts to profiles. The central 4 or 5-mm hook guarantees an overall

pre-hanging and bringing all the frames on the coating line and that

resistance of the frame up to 100 kg. These frames have been recently

of storing unused frames in an orderly manner. Special trolleys can

launched on the market with various types of hooks, thanks to which

be designed according to the various requirements posed by the

each customer can find the best configuration for its specific use.

components’ characteristics.

The tree can be up to 2,400 mm in length, whereas the slats are

Managers can and should have the strength to change their

1.0 mm thick and 18 mm high. It is possible to create different slat

company’s inefficiencies and get out of the comfort zone in which

configurations, e.g. sheared (i.e. on one side only), zigzag-shaped,

the most common phrase is: “We have always done it this way”. A

or bent from 0 to 180°. This type of frame was also designed to

tool that can be useful for moving from ideas to figures is the new

avoid using individual hooks. It is manufactured automatically,

CCC calculation system on HangOn’s website1. It allows comparing

which guarantees a low cost, equal to that of single hooks. The new

two hanging systems: relevant data such as the cost of powder, the

configurations made available allow the users to find the appropriate

number of people employed on the line, machine cost and times,

hook shape for every workpiece to be hung. Another new feature

etc. can also be entered. Hanging costs can also be shown and

launched on the market is the adapter that allows HQS frames to

compared.

be extended using standard or currently available frames. The HQS frames can be used for hanging small parts, but also workpieces with varying weights, including profiles.

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1 https://ccc.hangon.com/

PRETREATMENT & WATER TREATMENT

OUR SKILLS INNOVATION PERFORMANCE NANO TECHNOLOGY R&D ESG TECHNICAL ASSISTANCE

a Dollmar Group Company

© AdobeStock

MECCRIOS is specialising in engineering and manufacturing cryogenic technologies for different industries, from industrial to food and research sectors.

HIGHLIGHT OF THE MONTH

Research, Innovation, and Circular Economy in Paint Stripping: MECCRIOS Group’s Vision on its 32nd Anniversary From an interview with Attilio Bernasconi, director of MECCRIOS Group, Caltignaga (Novara, Italy)

Can paint stripping be a sustainable process? Can it contribute to the circular economy? Above all, what are the most advanced innovations and research studies in a field dominated by four technologies – thermal, chemical, mechanical, and cryogenic? Attilio Bernasconi from MECCRIOS, who has made cryogenic and dry ice technology the backbone of his career in the industry since 1991, gave us the answers to these questions.

“T

he contract paint stripping market was a thriving one

the constant R&D activity that has distinguished it over the

that unfortunately no longer exists today.” Welcoming us

last thirty-two years. While also paying special attention to

with these words is Attilio Bernasconi, the founder and

the development of environmentally friendly solutions, the

director of MECCRIOS Group together with his wife Margherita

MECCRIOS Group provides state-of-the-art machinery that

and son Andrea. “It is concentrating around large industrial groups

makes use of the many advantages of cryogenic technology,

taking over smaller businesses, and only a few independent paint

both in the industry and food sectors.

stripping centres remain with the strength and ability to pursue

“MEC works with two gases: carbon dioxide in its various forms

research and innovation.”

and liquid nitrogen in its forms for industrial applications. The

Active since 1991 in the field of cryogenic paint stripping and

Group is divided into four sectors: the first relates to services

cryogenic separation for the restoration of equipment and the

such as industrial paint stripping using various technologies

recovery of workpieces, MECCRIOS’ solutions are the result of

(cryogenic, thermal, and mechanical), sub-zero heat treatment,

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HIGHLIGHT OF THE MONTH

© ipcm

On the left, the cluster shot blasting machine and, on the right, the pyrolytic paint stripping oven.

© ipcm

Some machines producing dry ice.

pellets to cylinders, from tiles to blocks. We are also investigating

Today, sustainability dominates every conversation in the industry: is cryogenic and dry ice technology sustainable?

new forms, such as carbonic snow bags for supermarkets, to

“Liquid nitrogen used for cryogenics certainly is, since 78% of the

encourage their use in other areas by virtue of the fact that

atmosphere in which we live and breathe is composed of nitrogen.

it does not melt but rather sublimate, thus not producing

On the other hand, I cannot take such a clear-cut position on

any liquid. The third sector is the design and construction of

CO2: its sustainability degree is still under discussion. Apart from

cryogenic shrink fitting, and shot blasting,” says Bernasconi.

“The second sector is dry ice production in all its forms, from

machines that produce dry ice or use it for technical cleaning

the fact that if carbon dioxide did not exist, there would be no

operations, including precision cleaning. In this regard, we are

life on Earth, the main issue, at least in Europe, is that it cannot

designing a new system that uses 3-mm dry ice pellets, which

be produced but only recovered from other sources; in Italy,

can be reduced to 0.5 mm so that their size can be adjusted

there are basically three sources: fertiliser production and biogas

depending on whether a more delicate precision cleaning or

and biomethane production, of which CO2 is a by-product, and

a more aggressive and coarse process is required. Finally, our

recovery from underground. On the other hand, dry ice is the solid

fourth target sector is the food industry, for which we produce

form of carbon dioxide and this capacity to give another life to a

liquid nitrogen and liquid carbon dioxide freezing cabinets and

product that is already recovered in itself makes it very sustainable,

regenerate and recertify existing ones. The most interesting

in my opinion; not to mention that after dry ice is used, it

aspect of my work is facing new challenges and offering innovative solutions to meet increasingly daring demands.”

sublimates, turning back into CO2 and re-entering environmental

air. Nothing is lost, nothing is created, everything is transformed”.

IT IS THE PROCESS THAT BECOMES YOUR SOLUTION. Whether you are coating e.g. automotive or aerospace elements, metal or plastic parts, we can provide the solution for the entire finishing process.

venjakob.com

© ipcm

Dry ice which has been just produced.

What are the sectors in which cryogenic paint stripping is most widely used?

“All sectors, because any company performing coating also

© ipcm

© ipcm

The criogenic paint stripping system.

liquefaction systems. For CO2 separation, I chose the “hard” way,

i.e. the most sustainable and least dangerous way: I avoided using amines, which are toxic but are also the best way to capture CO2,

needs to perform paint stripping. Of course, there is no such

and opted for magnesium oxide (MgO), which acts like a “sponge”.

thing as universal technology: anyone wanting to open a paint

When the gas flows through magnesium oxide, this retains carbon

stripping centre must carry out all available processes. Then,

dioxide and lets everything else pass: when it is saturated, if

with experience, one can make choices and specialise in some

heated it automatically releases the recovered CO2. There are

technologies rather than others. MECCRIOS, for example, abandoned chemical paint stripping over twenty years ago”.

What innovations are you developing in the cryogenic or dry ice paint stripping fields?

“In today’s industry, there is only one material that poses serious paint stripping problems: carbon fibre, and in general

also systems other than amines, such as zeolites, but these create problems with the moisture contained in all combustion products (because there are hydrogen and oxygen), so their use would require the installation of dryers and complicate the operation. We presented this technology for NRP funding and we are waiting to receive the allocated funds”.

all engineered composite materials. MECCRIOS is developing a

What is the potential of this innovation?

system for this purpose. Whereas plastics can be stripped either

“This CO2 recovery system is potentially suitable for any industrial

by cryoblasting with dry ice or with certain chemicals, depending

chimney, provided that a flue gas analysis is performed to verify its

on the nature of the material to be removed, composites entail

compatibility with magnesium oxide. I chose to use this substance

additional challenges that we are trying to address and solve. We

because it absorbs at 300 to 400 °C and de-absorbs above

have done a lot of testing but we will focus on this in 2024 because

500 °C. By law, flue gases leaving a chimney must have a

we are carrying out another important project this year”.

temperature of at least 850 °C: the system we are developing

What is it?

takes advantage of such heat and uses it for CO2 absorption and de-absorption. In other words, this is free energy. If we consider

“In cooperation with the Politecnico di Torino and a Norwegian

that the price of carbon dioxide has more than doubled since the

institute, we are developing a method for recovering CO2 from

pandemic to date, this CO2 recovery technology can have a huge

are two combustion processes occurring, that of pyroscission

recovered to create liquid CO2 that can be used to produce dry ice,

pyrolysis oven chimneys. CO2 abounds in them because there

burners and that of afterburners. We estimate that we could recover 500 to 1000 kg/day based on an 8-hour shift. With this

economic impact: CO2 is produced at the industrial chimney, it is

which in turn will sublimate and turn back into the same CO2 from which it originated.”

method, carbon dioxide is captured, separated from the other aeriform fluids in the chimney, compressed, liquefied, and stored in suitable tanks. MECCRIOS can produce both compression and

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Now that is the circular economy!

The only European producer of customized electrodialysis cataphoresis / anaphoresis cells with tubular extruded membranes. models available: AUF65 DIALYSIS CELL d. 65 mm AUFL80 DIALYSIS CELL d. 80 mm AUFL80 PLUS DIALYSIS CELL d. 80 mm - news 2022!

ENERGY SAVING | QUALITY PROCESS | IMPROVED LIFETIME | REDUCED MAINTENANCE

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ASK JOE POWDER

The “Ask an Expert” Column Kevin Biller

kbiller@chemquest.com

Dear Joe, I have some brake calipers that I powder coated, and I would like to add lettering then then add a clear powder coat and put in the oven and bake it. I would like to know of any material (vinyl, decal, or anything) that can withstand 200 °C to be powder coated over.

Thanks, Ismael Garcia Baja California Dear Ismael, This is a tricky proposition. First of all, PVC (vinyl) decals will not take 200 °C. So they're out. There is a number of materials used to make decals, and the table below provides type and heat resistance.

Decal Materials and Heat Resistance

Polymer Type

Synonyms Heat Resistance (⁰C)

applied at relatively thick films to give a high gloss with excellent

Polycarbonate

PolyCarb

distinctness of image. Please ensure that the coating is fully cured

Polyester Polyvinyl Chloride Polyethylene Terephthalate

66 120

PVC, vinyl

150

PET

180

Polyimide

500+

to make certain that it provides full durability performance.

Please let me know if you need anything more.

Best regards, Joe Dear Joe Powder,

For your application, I would consider PET or polymide as the decal

I carry out jobbing, currently doing batch oven curing.

polymer. PET may be borderline for heat resistance; however, you

I understand that UV powder coating materials are

should be able to use a clear powder coating that can cure around

different, but what will be the temperature required for

175 °C and avoid exceeding its heat resistance threshold.

the first stage of melt? After this, can the parts be touched

Otherwise, you will have to use a polyimide-based decal, which easily

before transferring to the UV curing? Are UV powders

outperforms all other decal materials for heat resistance. Polyimide

more expensive than normal epoxy powders? How about

tapes are regularly used as masking for powder coated articles, so I

the energy costs?

can attest to their resistance to typical powder curing temperatures.

Can you give some insights about UV cured powder

Preparing the surface for the decal and choosing a powder

coatings. How is this process carried out?

coating are also important considerations for the success of your

Augustine Philip

project. The surface should be wiped clean with a good solvent. I

Malaysia

recommend either denatured alcohol or acetone. Both are readily available at your house paint store or DIY.

Dear Augustine,

I would recommend a low-temperature-cure polyester powder

I would need to know much more about what substrates you

coating as your clearcoat. Epoxies discolor with heat, and

are considering coating and then I can accurately answer the

polyurethanes have a tendency to outgas at thick films. Polyesters

question.

capable of low temperature (i.e., around 160 °C) are very commonly

Indeed the powder must be melted, and it cures best at an

available. These products have good heat resistance and can be

elevated temperature. The melt phase can be accomplished by

150

N. 83 - SEPTEMBER/OCTOBER 2023 - international PAINT&COATING magazine

Engineering specialized in the supply of systems for surface treatment, painting and coating © Kevin Biller

A brake calliper powder coated and the lettering to be added.

E-COAT SYSTEMS any source of heat—convection, infrared, or a combination of both. This can take anywhere from a few seconds to a minute

LIQUID PAINTING SYSTEMS

or two depending upon the source and the intensity of heat.

The melt temperature depends upon the formulation and can range from about 100 °C up to 125 °C. The parts can be

POWDER COATING SYSTEMS

touched, but the coating should not be touched.

UV powders are generally more expensive than epoxies,

SELF-LEARNING ROBOTS FOR AUTOMATED PAINTING

but not outrageously so. Energy costs are quite low, though the process is more complex. Heating a substrate to 110 °C instead of 180-200 °C obviously saves energy costs. The UV process requires high energy, but it is very compact, saving floor space and capital equipment expenditure.

UV cure is “line of sight," meaning the UV energy must penetrate the coating. Shadows and unexposed spots do not cure. The UV curing typically takes seconds, very few seconds.

Too long and the coating will burn. In addition, it is important that the coating is warm and relatively fluid when exposed to the UV energy. This allows for better molecular mobility and more complete cure.

Any substrate that can be powder coated can most probably be coated and cured with a UV powder. The key is to melt the powder without damaging the substrate. Metals substrates are relatively easy to finish with UV powders. More difficult are plastics, especially those possessing low HDTs (heat distortion temperatures).

Best regards, Joe Powder

SYSTEMS FOR THE TREATMENT OF VOCs EMISSIONS

ROAD TO 2050

EcoQPower Takes Paint Shop Energy Efficiency to a New Level EcoQPower uses energy flows in a completely new way to make automotive paint shop operations as energy efficient as possible. Dürr’s innovative system allows plant operators to move away from gas, a fossil fuel, towards climate-neutral production through electrification. EcoQPower offsets the additional electrification costs by reducing paint shops’ total energy consumption – in an initial customer project by up to 19 percent.

H

igh energy prices, uncertainty about gas supplies,

and cooling requirements. By intelligently networking

and climate targets, which require carbon-neutral

all components, their efficiency increases substantially,

production, pose significant challenges for paint shop

and almost no energy is left unused. “EcoQPower is a

operators. Dürr is meeting these challenges with EcoQPower,

milestone in energy efficiency. Even in climatically ideal

a new solution for optimizing paint shop energy consumption

locations for paint shop operation, we are achieving

independently of production conditions. EcoQPower is based

energy savings in the double-digit percentage range. This

on a comprehensive analysis of paint shops’ individual heating

is equivalent to the amount of energy needed to paint

© Dürr Systems AG

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N. 83 - SEPTEMBER/OCTOBER 2023 - international PAINT&COATING magazine

Filtrazione per impianti di verniciatura 13,000 to 20,000 cars,” says Dietmar Wieland, Senior Manager of R&D at Dürr.

Spotlight on the energy supply of the entire paint shop Many individual adjustments have been made on the path to the sustainable paint shop, from products and layouts to digitalization, to keep increasing the energy efficiency of paint booths, ovens, and ventilation concepts, among other things. Instead of continuing to optimize individual elements, EcoQPower looks at the paint shop collectively, including the plant operator’s energy input. To get the most from all available energy sources, the energy flows for the supply of all the paint shop’s process steps are networked.

Rotoli, pannelli e celle in fibra di vetro Celle filtranti per alte temperature Rotoli e pannelli in fibra sintetica Accumulatore vernice “Columbus” Filtri “Andreae” Cartucce filtranti Filtri assoluti Applicazioni speciali

filtering for finishing lines

Rolls, panels and cells of glass fiber Filtering cells for high temperatures Rolls and panels of synthetic fiber Paint accumulator “Columbus” “Andreae” filters Filtering cartridges Absolute filters Special application

Intelligent network for energy flows Getting the networking right is the decisive factor and requires a high level of expertise. It is comparable to the human nervous system, via which the body absorbs information and controls a wide range of mechanisms. Figuratively speaking, the networks in the paint shop form the “nervous system,” which redirects the heating and cooling flows from one process area to another. What does this mean? Instead of supplying each process area – for example, paint booth, oven, or pretreatment zone – with energy individually, often wasting energy in the process, each process area only receives the exact amount of energy it needs.

Identifying and using sources of waste heat When electrifying processes, the temperature level at which heat needs to be provided is relevant for heat pump integration. Until now, there was one level for all processes which was geared, for example, towards the intermediate oven temperature of 80°C. However, the high-temperature water for heating is also used to operate ventilation systems which heat the room air to around just 21°C. This is exactly where EcoQPower comes in. Each process receives not only the right amount of energy but also the required temperature level, making it possible to exploit waste heat sources that previously went unused. For this, Dürr developed software that determines heating and cooling requirements in the form of a source/sink profile. This profile also considers the climatic site conditions and general framework data, such as production capacities, vehicle types, and available energy sources which EcoQPower makes the most of all available energy sources and also enables the complete electrification of the paint shop.

Via Vincenzo Monti 173 20099 Sesto San Giovanni (MI) - ITALY Tel.(+39).02.24.89.583/02.26.224.313 Fax(+39).02.26.21.065 e-mail: info@defil.it www.defil.it

ROAD TO 2050

© Dürr Systems AG

EcoQPower networks all cooling and heating flows across all process steps so that all process areas are supplied with exactly what they need.

can be incorporated, such as geothermal or solar thermal

and distributed yet again to the components via intelligent

energy. Since each process has different requirements, for

networking. “EcoQPower improves each new plant’s energy

example, for the temperature level of heat and cold, Dürr clusters

efficiency, mostly in combination with specific energy-saving

the various levels to combine them economically. Recognizing

products, such as our electric oven EcoInCure and the

which waste heat sources can be used for what makes it possible

electric exhaust air purification system Oxi.X RV. We are

to take advantage of synergies from the processes and to select

using these in our first project with EcoQPower in a new,

and exactly size the right hardware components for the intended

fully electrified paint shop for a German car manufacturer.

purpose, whether heat pumps, hot and cold water tanks, or a

In doing so, we are minimizing energy consumption so

cooling tower.

significantly that it offsets most of the additional costs

Keeping operating costs under control

of switching to this more expensive energy source of electricity,” explains Dietmar Wieland. When a paint shop is

EcoQPower also takes a different approach to energy supply,

electrified following the EcoQPower concept, its high energy

which until now was centrally organized for car plants. For optimal

efficiency not only helps to become independent from gas

energy solutions, the cold and heat is generated decentrally

and keep operating costs under control but also to operate

within the paint shop using electricity, recovered there again,

entirely carbon neutrally using green electricity.

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N. 83 - SEPTEMBER/OCTOBER 2023 - international PAINT&COATING magazine

We convey the future since 1959

Future-proof and reliable overhead

and floor MONORAIL and P+F CONVEYOR systems that can be perfectly integrated into your production processes.

We take care of all your requirements and create a tailor-made and cost-optimized concept for you.

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STANDARD & LEGISLATION - UCIF Informs

Do System Certifications Still Bring Value for Companies in the Mechanical Engineering Sector?

Manuela Casali, UCIF – Italian Surface Treatment Equipment Manufacturers’ Association, Milan, Italy

I

info@ucif.net

n the complex and delicate choice of a trusted industrial

degree, through an objective, standardised, transparent, and

or commercial partner, we all tend to select a supplier with

international technical reference framework.

a proven track record of expertise, professionalism, and

On the other hand, companies are now required to comply

reliability. However, how can we recognise these elements and on

with a significant number of both voluntary and mandatory

the basis of which parameters can we be sure of their effective

standards, which require an organisational and management

implementation within a company, be it large or small? Leaving

capacity that sometimes is not easy to reach. Despite

aside reputational information, which is still considered important

numerous efforts to make compliance easier to achieve, these

today despite being difficult to verify, one of the tangible

can call for complex preparation and availability of resources

indicators we can turn to is system certifications, i.e. certificates

and people.

that are issued by independent organisations to attest to the

The choice of having a management system in place should

achievement of certain standards in a specific field of activity.

be felt as a necessity to streamline and better understand

According to data published on the website of Accredia (the

how one’s company is organised with regard to the pursuit

Italian accreditation body), certifications in Italy are growing

of certain objectives. Certified companies demonstrate

steadily, with an increasing number of management system

a systematic, reflective approach to work, based on the

accreditations. Leading this ranking is the 9001 standard, the

use and sharing of information and communication. For

quality management system certification, followed by other

instance, one of the latest additions to the legislation in effect

increasingly specific certifications that are more tied to particular

was the integration between the General Data Protection

historical moments. Whereas it is almost “obvious” to have

Regulation (GDPR) and the ISO 27001 certification scheme, an

and maintain the ISO 9001:2015 certification, which offers

international standard that lists the requirements for setting

a guarantee to customers and demonstrates a company’s

up and managing information security management systems

commitment to continue to improve its processes and comply

(ISMS). Companies that are ISO 27001 certified are certainly at

with regulations, nowadays it is just as essential to focus on a new

a greater advantage from a procedural and systemic point of

way of doing business, one that ensures continuity of operations,

view in adopting certain provisions of the GDPR. Incidentally,

guarantees data protection, and safely promotes the creation of

it should be remembered that ISO certifications are voluntary,

increasingly innovative services while maintaining a high quality

whereas the European General Data Protection Regulation is a mandatory standard.

It is also important to emphasise that a project that leads a company to obtain a certification should be an effort aimed at creating an added value and not an end in itself. Without this prerequisite, certification becomes a mere cost, which certainly enhances the organisation’s image on the market but generates neither value nor reputation.

© AdobeStock

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16 Blechexpo th

STANDARD & LEGISLATION - UCIF Informs

International trade fair for sheet metal working

9th Schweisstec

D 07. – 10. November 2023 a Stuttgart

The trade fair duo showcases modern, future-oriented sheet metal working, presents complete process sequences and, thanks to the exhibitors in 9 exhibition halls broken down into 5 thematic areas, impressively demonstrates the industry’s performance capabilities.

It attracts highest levels of interest and is accompanied by a world-class supplementary programme.

Sheet metal, pipe and profile processing Stamping technology Cutting, joining and fastening technology Pressing, forming and shaping technology Steel, metal service and surface technology

H EXHIBITOR FORUM 5 Blechexpo

STEEL CONVENT 2023 + Challenges on the steel market

Innvations Award Ceremony A On Opening Fair Day # #bestAWARD bestA

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A Green Steel, shaping the industry of tomorrow

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of charge ticket:

Ticket code: 32M9X-FUGME

@ www.blechexpo-messe.com @ www.schweisstec-messe.com ü ?ägB Organizer: SP. E. SCHALL GmbH & Co. KG

T +49(0)7025 9206-0

blechexpo@schall-messen.de

schweisstec@schall-messen.de international PAINT&COATING magazine - SEPTEMBER/OCTOBER 2023 - N. 83

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MEETING THE INDUSTRY

Covered by ipcm®

FABTECH 2023 Concludes with High Marks and Remarkable Success The pinnacle event for metal forming, fabricating, welding and finishing has successfully wrapped up its four-day run, achieving significant milestones for attendance, exhibitors and show floor size.

F

ABTECH 2023, the pinnacle event for metal forming,

edge technology, engage in education sessions, establish

fabricating, welding and finishing, successfully wrapped up

new business relationships and foster invaluable networking

its four-day run at Chicago’s McCormick Place on September

connections.

14th, achieving significant milestones for attendance, exhibitors

“We extend our sincere gratitude to the attendees,

and show floor size. From 11th to 14th September, the trade fair

exhibitors, speakers, members and everyone who joined

welcomed 40,505 attendees from across the globe – a 26% year-

us for FABTECH 2023 in Chicago. This year’s event was

over-year gain in attendance compared to the previous event

an exceptional gathering, offering the industry a one-

held in Atlanta and a 40% increase compared to the 2021 event

stop-shop for solutions with an expansive show floor that

in Chicago. Representing 80 countries and all 50 states, industry

truly showcased the future of manufacturing. FABTECH

professionals converged at McCormick Place to explore cutting-

remains well positioned to continue its leadership role in delivering access to leading-edge trends, technologies and innovations that are driving manufacturing forward,” has stated Tracy Garcia, CEM, FABTECH Group Director at SME. FABTECH 2023’s show floor, spanning an impressive 825,325 square feet across three exhibit halls, featured an extensive showcase of over 1,500 world-class suppliers. Among these were 235 new exhibitors unveiling more than 575 new products, exemplifying the industry’s unwavering commitment to innovation, efficiency and sustainability. The energy at FABTECH 2023 was palpable, with attendees experiencing a whirlwind of activity on the bustling exhibit floor.

The eight technology pavilions, spread across three halls, explored critical sectors such as 3D/Additive Manufacturing, Forming and Fabricating, Finishing, METALFORM, Tube/Pipe, Robotics and Industrial Automation, Welding and Welding Automation.

Prominent industry leaders, alongside a diverse range of exhibitors, once

© ipcm

again converged at the event, drawing The ipcm booth at Fabtech 2023.

158

N. 83 - SEPTEMBER/OCTOBER 2023 - international PAINT&COATING magazine

significant attention.

– Mike Pellecchia, Regional Sales Manager, MC Machinery Systems, Inc, a subsidiary of Mitsubishi Corporation Special events at FABTECH 2023 included inspiring keynote presentations and FABx Tech Talks, addressing the latest industry trends and challenges. Attendees gained valuable insights into topics ranging from advanced technology and manufacturing processes to business leadership and risk management. The 12th September morning keynote featured former pro golfer and PGA announcer David Feherty who entertained audiences with his sharp wit and colourful personality sharing great life stories and behind-the-scenes moments from life on the PGA Tour.

Additional special events featured daily Leadership Exchange Panels, offering discussions on advanced manufacturing, © FABTECH

robotics, workforce development and capital funding sources. The Women of FABTECH breakfast celebrated the

Attendees and exhibitors alike

we’ve attended in over a decade. The

achievements of women in manufacturing

shared their overwhelmingly positive

high level of attendee traffic and the

and the State of the Industry session

experiences at FABTECH 2023,

overwhelmingly positive reception of our

offered a comprehensive analysis of the

emphasizing the event’s vibrant and

new products by customers have left us

manufacturing landscape. These special

thriving environment. FABTECH has

absolutely thrilled. Traditionally, FABTECH

events provided attendees with a unique

consistently proven to be the ideal stage

is our go-to platform for unveiling new

opportunity to learn, network and gain

for unveiling innovations, where industry

products and introducing the industry

valuable knowledge to stay ahead in the

leaders and key decision-makers gather

to the latest solutions with our tools.

ever-evolving manufacturing industry.

to explore cutting-edge technologies.

This year has been exceptional, giving

Finally, the trade fair presented an

• “Overall, the experience was excellent.

us the perfect opportunity to showcase

extensive educational programme,

The show was incredibly busy, and we

our innovations.” – Ann Beaupre,

comprising over 180 sessions and

had some truly meaningful customer

Marketing Project Manager, Wilson Tool

workshops across 15 technology tracks.

conversations. It felt like we were back

International

Industry thought leaders and experts

to pre-COVID levels of attendance

• “This year’s event was truly excellent and

guided over 1,000 conference participants

and interaction, which was fantastic.

probably my favourite so far. We talked

through topics like automation, smart

We engaged with customers who

to the right customers, and it felt like the

manufacturing, welding, cutting, lasers,

were genuinely interested in exploring

right people were kind of working their

lean, workforce development and

technology and equipment. We had

way through. We connected with new

business management strategies.

some great leads and high-quality

accounts and customers who showed

conversations. We couldn’t be happier

genuine interest in our products, as well

with the show.” – Vince Iozzo, Head of

as reconnecting with those we’ve worked

Marketing, TRUMPF North America

with in the past. It was a very good mix of

• “FABTECH 2023 in Chicago has been

people, including enthusiastic students

truly outstanding for Wilson Tool

who represent the future of our industry.

International. It’s one of the best shows

Overall, it was a very positive experience.”

For further information: www.fabtechexpo.com

international PAINT&COATING magazine - SEPTEMBER/OCTOBER 2023 - N. 83

159

MEETING THE INDUSTRY

Covered by ipcm®

Aluminium Two Thousand World Congress Ended Successfully Bologna has hosted the international biennial on aluminium 12th ALUMINIUM TWO THOUSAND World Congress in collaboration with 7th ICEB (International Conference on Extrusion and Benchmark).

S

eptember the 23rd marked the end of

During the first three days of the event, the

Gnudi. Furthermore, great opportunities were

the Aluminium Two Thousand World

speakers covered themes encompassing all

reserved for those who stayed past the end

Congress, held at the Royal Hotel

fields of aluminium application; among the tens

of the congress sessions: on Friday a choice

Carlton in Bologna from the 19 to the 23 of

of highly qualified papers presented, some

between an advanced anodizing workshop with

September. The event, which has now reached

were selected by the university committee. The

field excellence dr. Jude M. Runge, PhD, and an

its 12 edition, saw the participation of more

list of awarded papers for each category can be

organized tour of three of the most important

than 80 highly qualified “aluspecialists” from

found on the event’s website.

museums of the close-by Motorovalley, ending

businesses, universities and associations from

Moving on from the beating heart of knowledge

then with the cultural tour of the historical and

more than 30 countries, all presenting the most

and innovation, Aluminium Two Thousand also

unique city of Ravenna on Saturday.

innovative technologies and their applications

confirmed itself, once again, to be a networking

Lastly, the constant feature of this congress: the

for aluminium to a specialized, international

opportunity like no other – not only for those

chance to register an accompanying person to

audience. An important mention goes to the

who decided to maximise their visibility by

an entirely dedicated program leading them to

prestigious collaboration with the Engineering

booking a booth in the exhibition area.

discover the wonders of Bologna, making the

Department of the University of Bologna and

Indeed, just as it had been at its dawning in

distance easier on congress participants and

of the University of Modena and Reggio Emilia,

1990, plenty of activities were arranged around

allowing the many foreign guests to make the

under the direction of prof. Lorenzo Donati.

the conferences to encourage socializing

most of their stay in Italy. For those interested

Indeed, ever since 2015 the congress has

among participants while at the same time

in the covered topics who didn’t get the chance

been hosting the International Conference on

facilitating their cultural enrichment. We’re not

to attend, it is possible to request the speakers’

Extrusion and Benchmark (ICEB), the biggest

just talking about the exhibits by renowned

program as well as information about getting

event in Europe regarding the analysis of the

artists next to the congress rooms, but also

the complete presentations at

most recent extrusion technologies by way of

and most importantly about the wonderful

aluminium2000@interallpublications.it

FEM simulation, thus promoting the ever-so-

classical concert offered in the historical

desirable exchange between university and

Basilica di Santa Maria dei Servi, as well as the

For further information:

industry.

elegant gala dinner held in the opulent Palazzo

www.aluminium2000.com

th

© Interall

160 N. 83 - SEPTEMBER/OCTOBER 2023 - international PAINT&COATING magazine

© Interall

SCAN ME

Products, networking, business and training.

under the patronage of:

MEETING THE INDUSTRY

Covered by ipcm®

The Varnishes, Paints and Coatings Industry Will Come Together Once Again for Paint & Coatings Italy 2023 Paint & Coatings Italy, which will take place from 17th to 18th October 2023 in Milan, is an event that offers a platform to address various aspects related to the paint, coatings and surface technologies industry, providing a broad vision of the trends, innovations and challenges that the sector is facing.

T

he new edition of Paint & Coatings Italy will take

rheology and aesthetic appearance. The correct and

place on 17th and 18th October 2023 at the NH

targeted use of polymers can therefore significantly

Congress Centre Milanofiori in Milan. The engaging

contribute to the creation of high-quality products with

and informative experience will be dedicated to exploring

excellent performance. Thanks to the support of the main

the fascinating world of paints, varnishes and coatings and

manufacturers and INSTM, the trade fair will therefore offer

to contributing to the continuous growth and innovation of

a programme full of technical content in this regard.

this key sector for the Italian and European economy. The

Paint & Coatings Italy will also include a scientific

new edition will host suppliers who have never been present

programme developed in collaboration with AssICC

before, allowing the major market players to come together

(Italian Chemical Trade Association) and Assovernici, which

to discuss current trends and industry prospects while

will delve into the main environmental and regulatory

showcasing innovative new technologies.

challenges linked to the paint, varnish and coating sector

Polymers play a crucial role in the paints and coatings

with important contributions from the Ministry of Health

industry, as they form a fundamental part of the formulations

and the Italian National Institute of Health (ISS).

of these products. They are in fact used to confer specific

Another crucial topic addressed will be packaging, with

properties such as adhesion, chemical resistance, durability,

discussions relating to the challenges and opportunities of sustainability in packaging with a focus on sustainable materials, development of eco-friendly products and environmental labelling. Finally, several important contributions from the university world dedicated to biocides and bio-based products are expected.

Pant & Coatings Italy therefore offers an ideal platform for sharing knowledge, experience and cutting-edge research, thus creating an environment leading to collaboration and development. All visitors arriving before 10am will receive a voucher for a free Italian lunch and coffee.

For further information: www.paint-coatings.it/en

© Paint & Coatings Italy

162

N. 83 - SEPTEMBER/OCTOBER 2023 - international PAINT&COATING magazine

MEETING THE INDUSTRY

SFCHINA2023 Will Allow the Finishing Industry to Re-Connect Again in Shanghai SFCHINA2023 will open its gates from 15th to 17th November at Halls E1 and E2 of the Shanghai New International Expo Centre, with a total gross exhibition area of more than 17,000 m2 that will allow industry players to reconnect face-to-face.

A

fter four years of absence at Shanghai, 227 exhibitors from

- Technical Forum

over fifteen countries are going to display a wide spectrum

Experts from the automobile market are going to share and exchange

of processes, materials, equipment and solutions in two

ideas on how to enhance the recycling and reuse of New Energy Vehicles

exhibit zones – namely ‘Electroplating & Finishing Technology’ and

(NEVs), in order to create a green environment and, most importantly, to

‘Coating Applications & Coating Products’ – at SFCHINA2023. The

protect and regenerate the ecosystem.

trade fair will open its gates from 15 to 17 November at Halls E1

- Technical Seminars and Webinars

and E2 of the Shanghai New International Expo Centre. Besides,

Exhibitors and their invited speakers are going to address issues of

SFCHINA2023 Online Show will be held from 1st November to 31st

industry concerns, share information on technology applications, market

December, allowing visitors from anywhere to participate digitally.

dynamics and industrial policies, so as to keep visitors abreast of new

A series of concurrent Technical Programmes will be organised

trends and developments.

alongside the exhibition. Industry experts and renowned

The Online Show continues to provide one-stop hybrid visiting experience

manufacturers are going to present cutting-edge technologies,

through a variety of multi-media digital contents, including Exhibitor

products and applications, offering opportunities for face-to-face

and Visitor Onsite Interviews conducted by the industry media service

learning, networking and business cooperation. The Technical

platform, ‘PCI&KM’, together with several interactive functions such as

Programmes include:

Chat, Company/Product Search and Business Matching.

th

th

The event will also allow to capitalise on the development opportunities offered by the in the Yangtze River Delta (YRD) City Cluster, which is one of the most vibrant regions of China – with a dynamic economy and strong innovation capabilities. The cluster consists of twenty-six cities from Shanghai municipality and Jiangsu, Zhejiang and Anhui provinces, covering merely 2.2% of the nation's land area but contributing to 24% of the nation's GDP in 2022. Some of its industrial clusters such as electronic information, high-end equipment, automobiles and household appliances are in leading positions. SFCHINA2023 will take place in Shanghai, where it serves as a strategic location to host such leading event that cannot be missed by any players in our industry.

For further information: https://www.sfchinaonline.net

©SFCHINA

international PAINT&COATING magazine - SEPTEMBER/OCTOBER 2023 - N. 83

163

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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

The smart journal for surface treatments

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INTERNATIONAL PAINT&COATING MAGAZINE

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