ipcm n. 86 | March - April 2024

The

of carefully selected raw materials, but rather from the people who study, model and formulate powder coatings thanks to more than 40 years of experience, and provide customers with the best solutions on the market A clear corporate philosophy and a shared vision have allowed to supply a vast range of products for three generations With more than 1000 products available in stock and over 40,000 already formulated, Europolveri offers infinite solutions to customer requests

CONTENTS MARCH/APRIL 2024

Gema

CONTENTS MARCH/APRIL 2024

EDITOR’S LETTER

Richiedi la versione in italiano a info@ipcm.it

The human at the centre.

No, I am not about to delve into the humanist anthropocentrism of Petrarch, Boccaccio, and Erasmus of Rotterdam, but rather into the new horizon of the manufacturing industry, which is already projected towards overcoming Industry 4.0 and reaching the new production paradigm of Industry 5. 0. This collaborative model focuses on sustainability, on a “humancentred” approach to production, on solving all those critical issues that the previous paradigm left unresolved: respect for the environment, mass customisation and co-creation to meet consumer needs, resilience and adaptability to remain competitive, use of renewable energy, and the circular economy.

It is a cultural revolution rather than an industrial one, which takes advantage of the most advanced technologies developed by the fourth revolution (robotics, Artificial Intelligence, Internet of Things) to foster a development model that is more sustainable, more flexible, more resilient, more human. Such a model will have a greater impact on business organisational models than on technological advancements, rationalising and making sense of all the trends originated during the pandemic and post-pandemic periods: work-life balance management, adaptation to adverse situations and changes, the ability to remain competitive by overcoming the moments of weakness, and the key role of corporate responsibility and work ethics.

No longer just efficiency, optimisation, and cost reduction: this is about a production environment in which machines support humans without replacing them; in which renewable energies fuel technologies geared towards promoting the circular economy; in which individuals can unleash creativity and craftsmanship to offer hyper-personalised goods and services to satisfy increasingly demanding consumers.

The Industry 5.0 theme will be the focus of the next edition of PaintExpo 2024, the most important international exhibition for industrial coating technologies, which will take place from 9 to 12 April at the Karlsruhe Trade Fair Centre in Karlsruhe, Germany. We are going to see how companies from all over the world exhibiting at PaintExpo are adopting and interpreting this model and, above all, how they communicate this new anthropocentric and collaborative vision of industry.

Alessia Venturi Editor-in-chief Direttore Responsabile

You will also find many insights related to these topics in this edition of ipcm®, of which you have already perceived the significant “weight” and of which I am sure you will also appreciate the wealth of content, technological reports, case studies, innovations, research, and success stories. If you have been reading this magazine for some time, you know that ipcm® does not like to be self-referential and rarely writes about itself on this page. This time, I would like to make an exception. On the occasion of the 15th anniversary of eos Mktg&Communication Srl, the publisher of ipcm® and the other magazines of this international brand, I would like to thank all the companies that, year after year, continue to firmly believe in the high-quality, reputable, verified technical press.

In a somewhat difficult year for the economy and industry, it is heartening that companies continue to believe in growth and invest in storytelling.

We will see you at PaintExpo, Stand 1442, Hall 1, to toast our 15th anniversary together.

Errata Corrige: In issue no. 85 January/February 2024 on page 33, we mistakenly referred to the conveyor as a Power&Free, when it is actually a monorail.We apologize to our readers and those directly concerned.

AkzoNobel Completed the Expansion of its Largest Powder Coating Plant

The expanded Italian site of AkzoNobel in Como has now four new production lines, to better serve the powder coatings market in the EMEA region.

The international paints and coatings manufacturer AkzoNobel has recently announced that it has completed the expansion of its Italian powder coatings manufacturing plant in Como (Italy). The investment will allow the company to enhance its offering to customers in Europe, the Middle East and Africa (EMEA region).

The €21 million project resulted in four new production lines, two of which are dedicated to automotive primers and two to architectural coatings. In addition, new bonding equipment lines were implemented to ensure that products meet and exceed industry standards.

“Increasing our capabilities in Como is a significant milestone which supports our ambition to create safety of supply for our customers.

We’re now well equipped to serve all our customers in the EMEA region with highly efficient lines that are state-of-the-art in terms of consistency and quality,” has explained Sanal Limoncuoglu, Commercial Director of

AkzoNobel’s Powder Coatings business in South and East Europe (S&EE) and Middle East Africa (MEA).

The new installation at the Como site is located in a refurbished building dating back to 1992, originally dedicated to the production of powder coatings. The new lines use recycled energy and are geared to meet the highest standards of sustainable production – supporting the company’s ambition to reduce its carbon footprint by 50% by 2030.

The facility is the company’s largest powder coating production plant.

It supplies products for seven main market segments: white goods, architecture, automotive, agriculture and construction machinery, commercial coatings, furniture and general industry.

For further information: www.akzonobel.com

© AkzoNobel

BRAND-NEW AMPP Appointed its New CFO

The new Chief Financial Officer of AMPP Jennifer Colunga will further strengthen the financial position of the association. ©

The Association for Materials Protection and Performance - AMPPhas recently appointed Jennifer Colunga as the new CFO. She will oversee every financial aspect of AMPP and various organizational functions, including audit and operations planning and analysis (OP&A).

“Our organization’s continued financial strength is vital for AMPP’s capacity to fulfil our mission and generate enduring value for members and customers. Jennifer brings profound financial expertise and a proven track record of accomplishments. With these qualities, she is the ideal leader to guide our talented finance organization and deliver a comprehensive strategic financial vision to propel AMPP toward future growth and success,” has stated Alan Thomas, CEO of AMPP.

Colunga holds a Master’s Degree in Business Administration and a Bachelor’s Degree in Accounting from the University of St. Thomas (United States of America). Throughout her career, Jennifer Colunga held various management roles, such as Vice-President of Gridiron LLC and Microwave Networks Incorporated, as well as Corporate Controller at Pharos Marine Automatic Power.

“I feel fortunate to be part of AMPP’s leadership team and am enthusiastic about guiding its finance organization toward contributing to future success in its evolving strategy. I am fortunate to join AMPP’s leadership team and am excited to contribute my skills and expertise on this journey toward shared success,” has commented Jennifer Colunga, the new CFO of AMPP.

For further information: www.ampp.org

WB Coatings Provided Paints to Coat the World’s Largest Telescope

WB Coatings developed a combination of robust epoxy primer, polyurethane topcoat and matching clearcoat for the steel structure of the ELT.

WB Coatings – which is a brand belonging to the Mipa Group since 1st January 2023 – has recently announced that its paints have been employed to coat the steel structure of the Extremely Large Telescope - ELT of the European Southern Observatory – ESO. The ELT, that is currently being assembled in Chile, is considered to be groundbreaking for space exploration: due to go into operation in around five years, it will become the largest telescope for visible and infrared light. When planning the steel structure, the focus was on keeping the telescope stable under all conditions, including strong winds or earthquakes.

As a matter of fact, the structure must be absolutely stable to keep the components and equipment precisely aligned. At the same time,

however, it must be light enough so that the gigantic ELT does not collapse under its own weight.

The project required the deepest possible black dull matt surface, in order to minimise scattered light and prevent disruption during operation. WB Coatings then developed a combination of a robust epoxy primer, a polyurethane topcoat and the matching clearcoat. Since the construction was carried out by an international consortium, the products were supplied to two participating companies in Spain and Italy – where the individual steel components were coated before being delivered to Chile for assembly.

For further information: www.mipa-paints.com

ECHA Added Five New Chemicals in its List of Highly Concerned Substances

ECHA added five new chemicals to the Candidate List and updated the existing list for dibutyl phthalate to safeguard the environment and people.

The European Chemicals Agency – ECHA – has recently added five new chemicals to the Candidate List:

 One is toxic for reproduction;

 Three are very persistent and bio-accumulative;

 The last one is persistent, bio-accumulative and toxic. These chemicals can be found in adhesives as well as sealants and cleaning products. In addition, ECHA has updated the existing candidate list entry for dibutyl phthalate, which must include its environmental endocrine disrupting properties.

The Candidate List of Substances of Very High Concern – SVHCnow contains 240 entries for chemicals that may harm people or the environment. Companies responsible for managing the risks of these substances must provide customers and consumers with information on their safe use.

The entries added to the list of candidates, updated January 2024, are as follows:

 2,4,6-tri-tert-butylphenol: used in formulation of mixtures and in fuel products;

 2-(2H-benzotriazol-2-yl)-4-(1,1,3,3-tetramethylbutyl) phenol: used in coating products, adhesives and sealants;

 2-(dimethylamino)-2-[(4-methylphenyl) methyl]-1-[4-(morpholin-4yl) phenyl] butan-1-one: used in coatings;

 Bumetrizole: used in coating products, adhesives and sealants as well as cleaning products;

 Oligomerisation and alkylation reaction products of 2-phenylpropene and phenol: used in adhesives and sealants, coatings and polymers;

 Dibutyl phthalate: used in metal working fluids, washing and cleaning products, laboratory chemicals and polymers.

Under REACH, companies have legal obligations when their substance is included in the Candidate List, whether alone, in mixtures or in articles.

If an article contains a Candidate List substance at a concentration above 0.1%, suppliers must provide their customers and consumers with information on how to use it safely.

Consumers also have the right to ask suppliers whether the products they purchase contain substances of very high concern.

Lastly, importers and manufacturers must notify ECHA within six months if their article contains a listed substance. EU and EEA suppliers of substances on the Candidate List must update the safety data sheet they provide to their customers.

For further information: https://echa.europa.eu

Beckers And ArcelorMittal Developed an Innovative Technology for the Coil Coating Industry

The new paint formulations technology for electron-beam curing developed by Beckers and ArcelorMittal can reduce carbon emissions and boost efficiency in the coil coating industry.

Beckers and ArcelorMittal have announced a partnership to develop a radiation curing technology for pre-painted steels to be used in the coil coating industry.

The main objective of this innovative technology is to replace solvent-based paints with solvent-free solutions, in order to produce pre-painted steels for building envelopes. The regular thermal polymerisation is replaced by EB polymerisation to achieve the following results:

 Reduce CO2 and VOC emissions;

 Lower energy consumption - thus avoiding natural gas and the use of cooling water, given that the process takes place at room temperature;

 Limit waste treatment;

 Improves productivity.

The Coil Coating line n. 3 at ArcelorMittal Construction in Contrisson (France), was converted in early 2023 as part of a major project. The paint formulation for this project was developed by Beckers to match the performance and applicability of solvent-based products. Proprietary

application and curing technology were developed by ArcelorMittal to meet high-speed strip coating requirements.

The long-term partnership between ArcelorMittal and Beckers has been crucial to overcoming challenges with scaling up the technology from laboratory to industrial production in a very short timeframe. The first coils produced were processed to make sandwich panels that have already been installed on a pilot building. The new paint technology is expected to be used together with a high-speed galvanizing process in the future.

Furthermore, this collaboration was fundamental in overcoming the challenges related to the transition of technology from the laboratory to industrial production in a short time. The first coils produced have been transformed to make sandwich panels and, in the future, a new painting technology is also planned to be used in combination with the highspeed galvanizing process.

For further information: www.beckers-group.com

IGM Resins Welcomes Boudewijn

Morelissen as its New CEO Boudewijn Morelissen has been appointed as the new CEO of IGM Resins.

IGM Resins has recently announced the appointment of Boudewijn Morelissen as its new CEO, effective on the 1st February 2024. This change follows Wilfrid Gambade, who served as previous CEO since 2021, will now become an advisor to the Board of Directors of the provider of energy curing raw material solutions. Morelissen is renowned for his experience, in-depth knowledge of the chemical industry, strategic vision, and development skills. His appointment is seen as crucial for driving IGM Resins forward, while maintaining a focus on meeting the specific needs of customers and partners worldwide.

“We would like to thank Wilfrid Gambade for his significant contribution over the past three years, particularly during unprecedented challenges for the global chemical industry in the light of adverse macroeconomics conditions. Under his leadership, a new strategic roadmap Go Grow Green was introduced, and a comprehensive operational improvement plan was implemented which set solid foundations for IGM Resins’ future successes”, has stated John Huiberts, the founder of IGM Resins and current Chairman of the Board.

For further information: www.igmresins.com

ALIT Technologies Presented the New Industrial Masking Brand MAS-KING

The new brand MAS-KING of ALIT Technologies offers a high-quality and cost-effective service for the industrial masking market.

The Italian manufacturer of machines and products for the metal surface treatment ALIT Technologies has introduced MAS-KING, its new brand specialising in industrial masking. In an increasingly dynamic industrial world, it is essential for a company to innovate but also to renew itself to offer increasingly comprehensive services to the market. Strong on this approach, ALIT Technologies decided to expand its reach by creating MAS-KING, a new brand specialising in industrial masking based on innovation, progress and responsiveness to the demands of an increasingly demanding market.

The San Bonifacio (Verona) based-company is pleased to announce the transition from dealers to owners of a new line of business operating in the field of masking for coating and other surface treatments. MAS-KING, the brand chosen for this new business, presents a range of products

of the highest quality, designed with precision and made with advanced materials. The brand aims to set a new standard in industrial masking and represents the commitment signed by ALIT Technologies to excellence in the protection of parts during all stages of surface treatment.

The new brand has a strongly international vision made possible by the ALIT Technologies’ global network of agents. To Italian customers, MASKING offers an innovative service based on speed of delivery, suppliercustomer trust, problem-solving ability as well as on good price-quality ratio: a dedicated van, loaded with solutions for protecting parts during coating, will be available to customers directly at the workplace, thus guaranteeing immediate and customised supply.

For further information: www.alit-tech.com

Sherwin-Williams Aerospace

Introduced a New Chrome-Free Primer

The new primer developed by Sherwin-Williams can provide corrosion resistance and durability protection for the aerospace industry.

The international paints and coatings manufacturer Sherwin-Williams, through its Aerospace Coatings Division, has launched a new chrome-free epoxy primer, which consists of a two-component, corrosion-inhibitive technology able to provide good performance with several substrates and pretreatments as well as working with all exterior topcoat systems of the company.

The new primer is ready to spray with no additional reduction required for true ease of use. It offers a broad application range using a single activator, it flows out to a nice smooth surface and its wet edge is ideal for both large surface application areas and different environmental conditions.

Furthermore, it is environmentally tolerant of application conditions, provides excellent gloss hold out and can boast superior low-film wetting, levelling and dry-film profile. It also allows superior topcoat wetting for easy collapse, flow and levelling for a smoother finish. Lastly, it will be offered as individual kits and can be used with all spray equipment, including conventional air spray HVLP, electrostatic air spray and air assisted airless. The primer meets the U.S. VOC regulations, which require 335 g/L and will be available for sale in all Americas region.

For further information:

https://industrial.sherwin-williams.com

Lechler Presented the EvoEffects

Colour Collection with Over 500 Special Effects

Finishes

The liquid paints of the new EvoEffects colour collection from Lechler include pearlescent and metallic finishes.

The Italian liquid paints manufacturer Lechler has recently introduced EvoEffects: a new colour collection with over five hundred special effects finishes, including pearlescent and metallic paints, created with an innovative approach – combining the needs of product appearance and industrial design with a commitment to sustainability. The range of colours is produced with high-durability lead-free pigments, which satisfy the highest quality requirements and specifications of the industrial world.

With the colour cards included in the box, the clients can easily choose a colour and create the desired paint in the needed quantities with the Lechsys Hydro Tintometer or take advantage of the innovative and unique Intinta service, that allows customers to order any colour in the collection – even in small quantities, starting from a single 4-litre tin. It is

also possible to produce paints with binders compliant to CAM criteria, in order to offer products in compliance with the strictest international environmental protocols.

The collection has been produced only with the YD943 Hydroplast Semi Glossy WS enamel, which guarantees high levels of durability and quality. All the products feature very low solvent content, thus resulting in a marked reduction in the emissions of Volatile Organic Compounds. EvoEffects also complies with all the requirements of the ISO 9001:2015 and ISO 14001:2015 quality management systems, guaranteeing complete reliability and safety of use.

For further information: www.lechler.eu

©Lechler

New Sustainability and Automation Scenarios for the Dürr Group: Research, Innovation, and Investment to Seize the Opportunities of an Increasingly Informed Market

From an interview with

Patric

Pedruzzi,General Manager, Olpidürr SpA, a company of the Dürr Group

Matteo Minelli, General Manager, Verind SpA, a company of the Dürr Group

Alessandro Molè, General Manager, Verind SpA, a company of the Dürr Group

2018 report of the UN Intergovernmental Panel on Climate Change (IPCC) affirmed the urgent need to limit global warming to 1.5 °C by 2030. In recent years, it has become clear that, for this to materialise, we must not only transform our energy system but also rethink how we live, travel, and manufacture our goods. The

market itself has become more aware of both environmental and social sustainability issues, and it now demands technologies combining low environmental impact and high automation. It is precisely automation that has been the second industrial mega-trend of recent years, pushed to the extreme by the digitalisation processes of Industry 4.0

and now rethought to enable collaboration between machines and human operators in what is shaping up to be Industry 5.0. As a result, the market increasingly values those suppliers who invest in sustainability, social responsibility, and automation. In the coating and surface treatment industry, one of them is undoubtedly the Dürr Group, among the world’s leading mechanical and plant engineering companies and specialising in the fields of automation, digitalisation, and energy efficiency. As Dürr is going to participate in the 2024 edition of PaintExpo, the leading international trade fair for industrial coating technologies, we took the occasion to ask some questions to three of its Italian managers to understand how Dürr, Olpidürr (the Group’s Italian company that designs and builds coating plants and air treatment systems), and Verind (the Group’s Italian company specialising in automotive and industrial coating, surface protection, ultrafiltration, and water treatment, as well as the main integrator of Dürr products in the industrial market) are facing these new market scenarios.

From left to right, Matteo Minelli, Alessandro Molè, and Patric Pedruzzi. © ipcm

ipcm®: What is Olpidürr’s market strategy in light of the changes that occurred in its management and corporate structure in 2022?

P. Pedruzzi: First, a brief summary of the changes: At the end of 2022, the Italian partner of Olpidürr left the company, which means that Olpidürr is now 100% owned by the Dürr Group. At that time, I was head of the two divisions, Paint and Final Assembly and Clean Technology Systems, and was then offered the position of Managing Director, which I have now held for two years. At the end of 2024, Olpidürr’s headquarters will move to a new facility in the northeast of Milan. Our market strategy is closely aligned with the headquarters and focuses on technological innovation, efficiency and excellent customer service. Our goal in Italy is to consolidate our long-standing leadership position in the coating equipment sector. This is based on four main pillars: the first can be summarized under the name “Paint Shop of the Future”, i.e. we offer more advanced coating technologies that reduce operating costs, improve energy efficiency and reduce pollutant emissions. The second pillar is Industry 4.0-oriented digitalization, i.e. the implementation of digital and automation solutions that increase efficiency and productivity and optimize production processes. The third pillar is Service, which is the provision of excellent and comprehensive customer service, including consulting, design, installation, maintenance

and after-sales support. Finally, the fourth pillar relates to sustainability and responsibility, not only in the production facilities we build, but also within Dürr itself. It is an ongoing commitment to environmental and social sustainability to reduce the environmental impact of our activities and promote a culture of social responsibility. Thanks to this strategy, Olpidürr has maintained a leading position in the automotive industry, even though in recent years the Italian market has focused more on the modernization of existing plants than on new brownfield or greenfield plants.

ipcm®: Will Olpidürr remain the Global Competence Centre for wheel finishing?

P.Pedruzzi: Yes, definitely. Olpidürr continues to have a team dedicated to this sector to follow up on any opportunities in both the Italian and international wheel market. At the same time, it also has many customers outside the automotive market. We are seeing a trend towards a greater openness to investment in the wheel sector, where greater market stability is required to make major new investments.

ipcm®: What is the strategy and vision of the Dürr Group in general Business and in the Industrial market?

M. Minelli: The Dürr Group has strategically aligned itself with the

The pigging technology of EcoSupplyP Core reduces the consumption of coating and rinsing products by returning the residual paint in the feeding pipes to the original container.

important topics of the future: sustainability, electromobility, and automation. Over the past few years, it has invested substantially in the first two areas, and now it is investing in automation, also by acquiring external companies. Above all, the trend towards sustainability and decarbonisation offers many opportunities, as our company is a market leader in energy-efficient solutions in the relevant markets. We will leverage this technological advantage for profitable growth. At the same time, we will continue to invest in climate protection at our sites in order to contribute to the 1.5-degree target1 set out in the Paris Agreement. Dürr is pursuing a clear climate strategy for 2030 that includes ambitious, science-based climate targets in line with the global 1.5-degree target and validated by the Science Based Targets (SBTi) initiative, an independent initiative that reviews a company’s reduction targets based on the latest findings in climate science. In this case, the goal is to reduce the emissions of the Dürr Group’s individual companies worldwide by 70% by 2030, compared to their levels in 2019. This can be achieved through a variety of processes and virtuous behaviors:

1 The Paris Agreement pursues the goal of limiting average global warming to well below 2 degrees Celsius compared with the pre-industrial period, aiming for a maximum increase of 1.5 degrees.

producing non-polluting energy (photovoltaic panels, for example) for one’s own needs, buying green energy from third-parties if self-supply is not sufficient, electrification of the company car fleet, and encouraging employees to suggest and implement projects to reduce global pollution in the Group. The ultimate goal of this strategy, and the next key target, is to become carbon-neutral by 2050.

In terms of market demand, Dürr sees two trends in the field of industrial painting technology that we are pursuing: the desire for greater sustainability and for more automated painting processes. When it comes to sustainability, our customers are particularly interested in reducing paint consumption and saving solvents. This is why we always ensure that our new developments make a significant contribution to conserving resources, such as overspray-free painting with the EcoPaintJet and the EcoSupply P Core pigging technology. In combination with our standardised paint supply, the pigging components can be used to recover the paint in the hose line and significantly reduce the consumption of rinsing agents. In the field of automation, we continue to focus on our ready2integrate technologies. We ensure that individual components and products can be combined into sets. This makes it easier for customers to automate their painting

The source module (shown in the figure) is the starting point of the pig. The material pushes the pig from the source module along the distribution loop to the destination module.

processes. After all, if all the pieces fit together, the startup time can be shortened, project risks minimised, and integration made easier.

ipcm®: Your sustainability-related targets are ambitious – even before 2050, which is the globally recognised target.

A. Molè: These lines of development have always been part of Dürr’s core business. Today, the market is also focusing strongly on decarbonisation and increased automation. In recent years, for instance, we have worked on automating a whole series of operations in the automotive sector that were previously performed manually. One example of this is the introduction of hemflange sealing at Stellantis, which automates the manual sealing of aesthetic parts. This leads to further automation of car manufacturing and finishing processes, resulting in more consistent application of sealing beads.

ipcm®: Dürr will once again be present at the PaintExpo fair in Karlsruhe for the third consecutive edition. What new products will you present?

M. Minelli: We consider PaintExpo to be one of the world’s most important trade show for the industrial coatings industry. At this year’s edition, we will present four products based on our emission reduction and automation pillars. Let me illustrate them in detail.

EcoSupply P Core

It is a new paint supply system for industrial applications that minimises paint and rinsing agent losses. The new EcoSupply P Core is a modular paint supply system based on pigging technology. This paint supply method has already proven itself in the automotive painting world, but Dürr has gone one step further and developed it for use in other industries for the first time. The EcoSupply P Core is now adaptable wherever different paint colours are applied in small quantities, such as in the construction, woodworking, or automotive supplier industries. The system efficiently recovers unused paint, minimising rinsing agent consumption and speeding up colour changes. It was developed to meet the need for a highly diversified choice of colours in the industrial world in general: consumers use colours as an exclusive identity, whereas companies use distinctive tints as an exclusive selling point for their products.

However, every colour change in the supply line results in

Dürr developed its Fluid Board as a connecting element between the control unit and the applicator.

paint and rinsing agent waste during the painting process. Here, the new EcoSupply P Core comes to the rescue. Current paint supply systems clean the hoses using solvent and compressed air to remove all paint and rinsing residues before preparing for the next color run. This process is laborious and time-consuming. The EcoSupply P Core pigging system uses a fitting body tailored to the internal diameter of the hoses – the so-called “pig” – to make the process more efficient and reduce paint and rinsing agent consumption. Paint flowing through the pigging hose, pushes the pig from the source to the destination module. In the process, the paint remaining in the hose is returned into the paint container.

Fluid Board

It is a compact and modular colour dosing and colour changing system developed by Dürr to provide a link between the control unit and the applicator for the industrial painting industry. The fully assembled colour dosing and colour changing system is unique on the market. The Fluid Board is designed to be fully controlled by the EcoAUC control

unit, encompassing the most common 1C and 2C processes across low and high-pressure ranges, and it supplies the EcoBell2 atomiser or the EcoGun spray gun with paint and rinsing agents. This makes the product ideal for tasks in industrial painting applications, such as the woodworking, construction and automotive. The EcoMCC3 colour changer is located on the Fluid Board and can supply up to ten colours. The Fluid Board significantly reduces engineering and assembly effort. For years, Dürr has pursued its ready2integrate concept, aiming to seamlessly align individual products to swiftly assemble a high-quality solution comprising a controller, dosing technology, and applicator. The Fluid Board is another piece of this puzzle allowingintegrators to quickly install application technology at the end customer’s site via plug-andplay.

The Fluid Board is Dürr’s first industrial painting product to come with digital, technical documentation. The EcoDocu streamlines the commissioning, operation, and maintenance of the paint dosing and colour changing system.

The EcoGun AS MAN DC/EC electrostatic spray gun has two versions, with direct or external charge.

EcoGun AS MAN DC/EC

Dürr expands its range of manual spray guns with an electrostatic air spray gun (ESTA gun) . The new EcoGun AS MAN DC/EC is a more sustainable way of painting, reducing overspray by about 40%. The spray gun is available in two versions, with direct or external charging. It is equally suitable for both solvent and water-based paints, and its ergonomic handle and light weight make it comfortable to use, even for longer periods. The new spray gun is ideal for applications where workpieces, such as tubes, rims, and two-wheeler or train parts, are coated manually. Benefits include electrostatic charging of paint and components and increased transfer efficiency.

EcoGun ACE

A new low-pressure spray gun for colour changes

in just a few seconds, without the need for solvents, to make colour changes much faster and easier. Dürr and HSM Lackiersysteme partnered to develop a new technology: a rapid-change system for the colour channel, including the nozzle and the cup, which allows the spray gun to be ready for use within seconds after a color change without solvents. This feature is ideal for the car repair sector, where small-batch painting is standard.

ipcm®: Let us now talk about Verind, the Italian company in the Group that specialises in application technology for both the automotive and general industry sectors. What is its most recent investment?

M. Minelli: Verind has carried out an investment campaign that has lasted a decade. First, we renovated our site in Aquino, in the province of

Hooks & CE Hooks

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

HOOKS & CE HOOKS

The main feature of the EcoGun ACE technology is the new quick colour change system, which ensures significant time and cost savings. ©

Frosinone, by completely refurbishing our building, which was quite outdated. Then, we focused on our headquarters, where we gradually rebuilt the sales offices, the workshop, the engineering and software area, and the purchasing offices. The last investment, carried out at the turn of 2023 and 2024, was the complete overhaul of the executive floor, which had been frozen for two years due to the pandemic and now finally sees the light of day.

Over the past ten years, we have invested more than 2 million Euros not only in our premises but also in sustainable solutions and in reducing the environmental impact of our production and commercial activities. For example, Verind’s headquarters in Rodano (Milan) boasts a stateof-the-art, high-performance boiler and solar panels producing a total power output of 75 kW (on the roof of the main building) plus another 30 kW (on the roof of the second building), which enable Verind to generate 80% of the energy required for its operations autonomously. We feed the surplus into the grid and sell it. This investment perfectly aligns with Dürr’s goal of reducing emissions from individual sites worldwide by 70% compared to 2019. Verind has also integrated its vehicle fleet with hybrid cars and installed a charging station. All materials used in the renovation of the executive floor, including a conference room, a boardroom, and HR, IT, and administrative offices, are environmentally friendly.

ipcm®: What is Verind’s 2024 market strategy?

A. Molè: Verind’s positioning remains the same: we maintain our presence in all three divisions relevant to the Dürr Group, namely Automotive, Industry, and Membrane Technology. As regards the automotive sector, in 2022-2023, we supported the investments of Stellantis, which honoured us with significant orders due to its Italian plants’ transition to primerless technology. We will continue working on this Stellantis project in 2024, as we are still supplying its plants in Pomigliano (Italy), Naples (Italy), and Kragujevac (Serbia), where the new Panda and the new Citroen electric model will be produced. In the industrial sector, on the other hand, we are pursuing different markets, from transmissions to universal joints and mechatronics for the ACE sector – for example, we are carrying out a project for a worldleading company in Emilia Romagna (Italy) – up to ecoating systems for eyeglass frames – together with Olpidürr, we are building a complete line in Thailand for the world’s most famous Italian group. As far as the industrial market is concerned, I am optimistic for 2024.

Dürr looks forward to welcoming you at PaintExpo 2024 in Karlsruhe (Germany) from April 9 to 12 at stand 3320, Hall 3.

The new executive floor of the Verind headquarters in Rodano, on the outskirts of Milan.

VP Verniciatura’s Steady Growth Continues with a New Automated Powder Coating Plant for Large-Sized Components

Gabriele Lazzari, ipcm®

Production flexibility, technological advancement, and environmental sustainability are key to business success in the contract finishing industry. Through close collaboration with Imel and Gema Europe, VP Verniciatura met all these requirements with a new automatic powder coating plant that also enabled it to reduce consumption, increase production, and improve the protective properties of its products.

The ability to dynamically adapt to market requirements by adopting state-of-the-art, environmentally friendly systems and equipment not only defines a company’s success but, in the contract coating industry, is a crucial prerequisite for successful growth. Striving for innovation and sustainability, VP Verniciatura confirms itself not only as an industry leader but also as an example of how using advanced technologies and responsible practices developed together with one’s suppliers can lead to concrete results in terms of quality, production efficiency, and environmental protection.

In fact, this company has just taken another significant step in its growth path. It turned to Imel Spa (Codroipo, Udine, Italy), a company specialising in the design and construction of metal surface treatment plants since 1964, to install an automated powder coating plant for improving its productivity and the corrosion resistance properties of its finished products but also achieving significant benefits in terms of resource consumption, environmental impact, and digitalisation, thanks to the implementation of i4paintshop software.

The interior of the Gema MagicCylinder® EquiFlow automatic spray booth with OptiGun GA03 guns.

The investment, which also involved Futura Convogliatori Aerei Srl (Robecco Pavese, Pavia, Italy) and Gema Europe Srl (Trezzano sul Naviglio, Milan, Italy), further consolidated VP Verniciatura’s positioning as a benchmark coating contractor. The MagicCylinder® EquiFlow automatic booth, the OC07 OptiCenter® powder centre for quick colour changes, and the OptiSpray® feed pumps with Smart Inline Technology have enabled it to reach a new level of efficiency and application precision, while the conveyor with a special in-line bypass device ensures smooth, optimal part handling.

VP Verniciatura’s exponential growth

Industrial coating expert Daniele Bellotto founded VP Verniciatura in Ponzano Veneto (Treviso, Italy) in 1998 to provide the many metalwork companies in the area with contract finishing services. With his sons Andrea and Edoardo joining the management team, the company then became VP Verniciatura S.r.l. - S.U. and embarked on a path of exponential growth characterised by investments in new machines, advanced production technologies, and highly qualified personnel, thus expanding its customer base and broadening its target sectors.

Currently, its factory is equipped with five industrial coating plants (four for powder and one for liquid paint products). It occupies an area of 25,000 m2, of which 17,000 are covered, and employs 90 people. Thanks to this structure, VP Verniciatura can quickly meet the requirements of more than 260 customers operating in a variety of sectors, from metalworking to the milling and agrifood industries, from architecture to the automotive and medical sectors, and even the agricultural, construction, and earthmoving machinery one.

“We started out to provide powder coating services on large parts and, over time, specialised in guaranteeing high durability and corrosion resistance, which is our core

Some examples of the many components treated by VP Verniciatura in the new plant supplied by Imel.

business. At the same time, we consider ourselves pure coating contractors because we can meet any customer need, from treating small volumes of small parts to liquid-coating large-sized and complexshaped components,” states Andrea Bellotto, the managing director of VP Verniciatura. “Over the past five years, our growth has progressed at a dizzying pace: we were among the first in Europe to obtain the QualiSteelCoat certification for coated steel, and we have since doubled our workforce. This is the result of our degree of production flexibility and our substantial investments in new 4.0 technologies, such as the plant recently supplied by Imel.

A flexible and customisable finishing process

Depending on its initial conditions, each component can be subjected to paint stripping (if it needs reworking), shot blasting to a SA 2 ½ finishing grade, and chemical pre-treatment with a nanoceramic conversion process. “The shot blasting plant can process components with a maximum size of 10,000 x 3,000 x 3,000 millimetres and a weight of 5,000 kg. We also perform a customisable chemical pre-treatment

cycle that can include alkaline degreasing, pickling or phosphating, multiple rinsing stages, passivation, no-rinse nanotechnology conversion, and drying. Afterwards, the components are taken to our various coating lines, which differ from each other in the type and size of the parts they can treat,” explains Bellotto. “We wanted to experiment with a higher performance pre-treatment cycle to achieve greater paint adhesion and corrosion protection properties up to the C5-H corrosion class for all metal substrates, from steels (carbon, hotdip galvanised, Senzdimir) to aluminium. At the same time, we needed a system that would allow us to speed up the cycle time for those components that only required the application of one primer coat but still enable us to perform two-coat cycles whenever required,” adds Edoardo Bellotto, VP Verniciatura’s co-owner.

The new powder coating plant

“The coating plant has a production capacity of 20 load bars/hour and can process workpieces with a maximum size of 2,200h x 3,500l x 1,000w mm and a maximum weight of 500 kg. Since VP Verniciatura’s

FOCUS

production flow does not include standardised machining stages, we jointly developed a solution combining high finishing quality and coating process speed and flexibility,” notes Imel’s president, Carlo Salvadori.

The new powder coating plant for metal components designed, built, and installed by Imel in June 2023 features a Futura power&free conveyor – with a continuous movement flow, a speed of 1.5 m/min, and a hanging pitch of 400 mm – that picks up the parts from the manual loading area and first takes them to the chemical spray pretreatment tunnel by going through a storage buffer area.

The standard pre-treatment cycle includes alkaline degreasing, three rinses, phospho-degreasing, one rinse, phospho-pickling, two rinses with mains water followed by a further rinse with demineralised

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A detail of the Futura Convogliatori Aerei power&free conveyor and the inlet and outlet of the multi-stage spray pre-treatment tunnel.

water, nanotechnology no-rinse conversion, and drying at 110 °C. The parts are then led through a cooling area and, subsequently, to a Gema MagicCylinder® EquiFlow booth for the application of the galvanising epoxy primer, which is gelled in the subsequent curing oven if a twocoat system is required. In this case, a bypass device specially designed by Futura Convogliatori Aerei leads the parts back into the electrostatic application booth for finishing with a low-temperature cure, Qualicoat class 1 or 2 polyester paint, depending on the specifications. Following curing and cooling to room temperature, the load bars finally reach the unloading area, where the coated products are checked by the QC operators and then labelled with a VP sticker that confirms their suitability and indicates the operator who carried out the checks, in order to guarantee total compliance with customer requirements as well as traceability. “Our factory is equipped with photovoltaic panels that generate 400 kW, almost enough to power this entire coating plant,” adds Bellotto.

The i4paintshop management system

To ensure greater flexibility and control of process parameters, Imel integrated VP Verniciatura’s line with its i4paintshop 4.0 management system, consisting of a series of digital modules that guarantee complete part traceability and processing of consumption data. Upon matching each load bar with a specific programme, the automation system allows the user to select the pre-treatment process to be carried out independently: the tunnel is structured to offer the possibility of choosing between different types of phosphating stages (phospho-degreasing or phospho-pickling), setting the required number of rinses, and including or excluding surface conversion. The management system also allows adjusting bath concentrations through metering pumps and pH and conductivity meters.

“Complete monitoring of the coating process is crucial to guarantee the traceability of our material’s quality. Our customers have access to a portal where they can check the progress of their orders and

The post-finishing station and the OC07 OptiCenter® powder centre.

better organise their own activities. This is why we expressly requested that the cycle be entirely controlled by a 4.0 management system to monitor the plant’s operation and set process parameters,” notes Greta Dal Col, quality control manager at VP Verniciatura. “Thanks to the i4paintshop system, we can obtain data on water and electricity consumption, schedules, and production volumes for each load bar. We can also manage the preventive maintenance of individual devices through a smart calendar based on the operating hours of the different system components, create daily, weekly, and monthly routine maintenance schedules, and manage the system’s self-learning functions.”

The ongoing collaboration with Gema for all things paint application VP Verniciatura had already been cooperating with Gema for many years and chose to extend the collaboration because it was happy with the performance of this supplier’s application

technologies. Its new plant features a MagicCylinder® EquiFlow booth equipped with twelve OptiGun GA03 automatic dispensing guns (six on each side) and two manual guns for the pre- and post-finishing stations, OptiSpray AP01 dense phase pumps with Smart Inline Technology, a MagicControl 4.0 plant control unit with the GemaConnect application for remote data readout on devices such as PCs, tablets, and even smartphones, and an OC07 OptiCenter powder centre for fast colour changes. The non-conductive plastic structure of the booth, in combination with EquiFlow extraction technology, prevents powder from accumulating on the bottom and adhering to the walls, while its “H”-shaped floor ensures excellent air distribution and balanced suction, as the three slits in the bottom guarantee optimal powder containment and ventilation in the application area. This creates a uniform airflow that ensures easy control of the application process and outstanding coating results. The booth is designed for 7-minute quick colour changes – VP Verniciatura performs about 50 per day – and automatic cleaning

The touch-screen panel of the MagicControl 4.0 control unit.

of internal circuits, the float, spray pipes, and spray guns. In anticipation of a further increase in production volumes, this Gema booth is also prearranged to allow the future implementation of other touch-up guns and stations with suitable suction systems.

The OptiSpray feed pumps with Smart Inline Technology use a single-channel circuit that generates a homogeneous powder flow and guarantees improved spray pattern management. This allows a precise quantity of powder to be dispensed, varying according to application needs, while maintaining a constant flow. Optimal pump penetration can also be taken advantage of when the two manual stations need to be used for touch-ups or painting special components. The user-friendly interface of the MagicControl 4.0 control unit, with its convenient icon-based touch screen, can be easily mastered by the operator to create standardised programmes for multiple batches by setting the required film thickness and changing it when different parts need to be coated.

The importance of strategic collaboration with Imel and Gema VP Verniciatura’s goal was to meet its own corrosion resistance requirements while increasing its production rates and improving its finishing quality. “The solution offered by Imel and Gema met all our needs. We decided to rely on Imel for the plant engineering aspects after conducting a market analysis: this is a renowned company, and we consider it the best in terms of technological level. We wanted to rely on experts because this plant makes our company a contractor of excellence in our area,” notes Bellotto. The dense phase pumps have improved film uniformity and spreading rate and ensured a 15% powder saving. “The geographical proximity of Imel and Gema to our factory is a further positive factor, as it gives us peace of mind should we need spare parts or specialised technical assistance. Gema’s service partner Tecnospray Srl, located in Pasiano di Pordenone, provides truly efficient technical assistance,” Edoardo Bellotto states.

Some coated components.

Walther Trowal: New Rotamat System for Coating Sealing Components for E-vehicles

Walther Trowal GmbH & Co. KG will launch its new Rotamat R 100 system at the PaintExpo exhibition (hall 2, stand 2310).

At the PaintExpo Walther Trowal introduces its new Rotamat R 100 system for coating elastomer sealing components with anti-friction and decorative lacquers. The new coater can handle work piece batches, which are three times bigger than the batches processed in its largest predecessor model. One reason for developing this new machine was that numerous customer coating companies requested a system that can handle large batches of big, flat sealing components.

An important application for the Rotamat systems is the coating of O-rings and flat gaskets, for example, for sealing individual cells in battery packs, but also in fuel cells, engines, and transmissions.

At numerous job shop companies the demand for coating of large volumes of big sealing components, used in cooling systems and control panels for electric vehicles, has rapidly grown. This created the need for highercapacity coating systems. The new Rotamat R 100 is in full compliance with such demands: It

has a capacity of 160 liters, respectively 100 kg. In one single batch it can handle about 300 sealing rings with diameters of up to 350 mm or batches of up to 50,000 O-rings. Compared to its predecessor model R 85, the new Walther machine can handle batch sizes that are three times bigger. Of course, the cycle times have remained the same, and the space and energy requirements have only increased marginally.

Frank Siegel, sales manager for coating technology at Walther Trowal explains:

“Until now our customers used the Rotamat systems mainly for coating of O-rings. But with increased sales of electrical vehicles the demand for big elastomer sealing components with a large surface area, used for battery cells, cooling systems for heat exchangers, etc. will rapidly grow”.

The new Rotamat system is also suitable for decorative coating of plastic components made, for example, from ABS or polyethylene. In addition, for thin-wall metal rings with diameters of up to 300 mm. The latter are used as oil seals for shafts and must be coated with a bonding agent, before elastomer material can be applied. Moreover, the company has expanded the application range for the Rotamat systems, now allowing the coating of sealing components with, for example, different types of oil and wax, as well as slow-drying lacquers.

For further information:

www.walther-trowal.com

Venjakob at Paint Expo 2024: the Innovative Spirit Meets the Technology

At PaintExpo, Venjakob will showcase a wide range of holistic overall concepts for efficient paints and coating operations.

At the next edition of PaintExpo, the international trade fair dedicated to paints and coatings systems, technologies and services that will take place from 9th to 12th April 2024 at the Karlsruhe Exhibition Centre (Germany), Venjakob Maschinenbau will present a wide range of surface pre-treatment, coating, drying and automation technologies with holistic overall concepts, in order to offer its clients efficient operations.

As a general contractor, the company offers the entire range of surface technology from a single source. With sixty years of cross-industry expertise – inspired by global industrial customers and the demand for resource and energy savings – Venjakob is constantly re-thinking and revising all processes and individualising them in every dimension.

All this in the interests of its customers and global sustainability.

The focus of PaintExpo is not on the ‘just one’ solution. Instead, the company will showcase its expertise in meeting a wide range of requirements for individual and extremely flexible system solutions: visitors should be inspired to rethink coating

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processes, since it is the process that becomes the solution. Visitors will also learn how they can use IoT, AR and innovative decisionmaking models to make their production processes more intuitive and smoother. The Venjakob R&D team invites visitors to

join the dialog and play a part in shaping the future of manufacturing. The company will exhibit in hall 2 at stand 2318.

For further information:

www.venjakob.de/en

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Wagner at PaintExpo 2024: Sustainable and Smart Solutions for the Coating Process

At the next edition of PaintExpo, Wagner will showcase its range of smart and sustainable solutions for the coating process, with a focus on savings, efficiency and automation.

JWagner GmbH has recently announced that it will showcase its range of smart and sustainable solutions for the coating process at PaintExpo, the international trade fair dedicated to paints, coatings and surface treatments that will take place from 9th to 12th April 2024 at the Exhibition Centre in Karlsruhe (Germany). The company will be in hall 3, at stand 3330.

Wagner will present several products, from individual components to fully automated coating systems with a major focus on saving solvents, materials and energy. For example, their manual and automatic liquid coating guns are characterised by high application efficiency and economical use of materials. Moreover, the new high-speed rotation atomizers for solvent-based and water-based paints developed by the company play a major role in the implementation of highly automated liquid coating systems and robot solutions – supported by updates in control technology.

In addition, the flushability of the liquid coating pumps has been significantly improved: the Cobra high-pressure double diaphragm pump has been optimised, so that the required volume of flushing agent and colour change time have been significantly reduced. Regarding powder coating, on the other hand, the focus will be on efficiency and automation.

Furthermore, the WALTHER Spritz- und Lackiersysteme GmbH subsidiary (known under the brand name Walther Pilot) will be represented at the stand with product highlights in material preparation and application technology. The event will be rounded off by field reports on analogue and digital services, including the COATIFY information & management platform, the service app and the Online Academy.

For further information: www.wagner-group.com

Sustainable and Economical Rinse Water Treatment: H2O GmbH at the PaintExpo 2024

H2O GmbH will showcase its new solutions at the PaintExpo 2024, Hall 1 - stand no. 1501.

The wastewater incurring in painting technology is increasingly posing an economic challenge for many companies operating in this arena. The solution from H2O GmbH: high-quality rinsewater treatment that saves costs. The experts for wastewater-free production will explain how this can work at the PaintExpo, the world’s leading trade fair for industrial painting technology that will take place in Karlsruhe from 9th to 12th April 2024.

By treating wastewater with a VACUDEST, companies can reduce the amount of wastewater they produce and significantly lower their disposal costs. However, the residual water content of the concentrate can still make complete disposal more difficult. This is where the VACUDEST ZLD post-concentrator comes in. It reduces the residual water content of the concentrate in a downstream evaporation stage and as such reduces the final quantity to be disposed of by a further 50 per cent.

Even more, it does so in a particularly energy-efficient way thanks to clever energy recycling: the ZLD uses

the excess heat of the vapour from the VACUDEST for evaporation. Particularly interesting: the residue often contains valuable raw materials, for example in the form of oils, whose recycling harbours additional economic potential. The VACUDEST ZLD secondary concentrator is available for wastewater volumes from 2,100 to 16,000 m³/year.

H2O GmbH is one of the world’s most experienced expert in the sustainable treatment and recycling of industrial wastewater. With their efficient and safe VACUDEST vacuum distillation systems, they achieve a wastewater-free production for customers in more than 50 countries around the world.

Since its spin-off from the Mannesmann Demag Group in 1999, H2O has gained an increasing number of loyal customers as an owner-managed company. More than 120 employees at the headquarters in Steinen in southern Germany and at the branches in Switzerland, Poland and China contribute to this high level of customer satisfaction.

For further information: www.h2o-de.com

Axalta Lights Up PaintExpo 2024 with ‘Total Solutions’ Portfolio and Sustainable Breakthroughs

At the next edition of PaintExpo, Axalta will showcase several sustainable solutions, such as its liquid and powder coatings for electric vehicles and corrosion protection.

From 9th to 12th April 2024, Axalta Coating Systems will showcase its comprehensive industrial portfolio at the PaintExpo in Karlsruhe (Germany).

The focus will be on a range of innovative products contributing to sustainability, including curing and thermoplastic powder coatings and liquid and electrocoat paints, as well as electric insulation materials.

The company will then address the diverse needs of various industrial markets with its groundbreaking solutions. The clear commitment to sustainability acts as a catalyst for positive changes in the industry, aligning with global sustainability goals. The

campaign ‘Sustainability, Together’ embodies the vision of Axalta, which aims to promote collaboration among stakeholders for shared sustainability objectives.

“For Axalta, ‘Sustainability, Together’ is not just a slogan but our guiding principle. Our participation in PaintExpo 2024 is a testament to our commitment to sustainability and innovation. Our mission is to provide our customers with exceptional total solutions that meet the evolving needs of industries and contribute to a more environmentally friendly future,” has stated Steffen Bormet, Regional Sales Manager for Central and Northern Europe at Axalta Coating Systems.

At the booth 3240 in hall 3, the company will highlight four thematic areas:

 ‘Sustainability, Together’: as part of this campaign, Axalta will present its latest developments in sustainable coating solutions. Bio-based powder coatings are a highlight of the booth, representing the commitment of Axalta towards environmentally friendly alternatives within the thermosetting category;

 Battery solutions for electric vehicles: amidst the shift from internal combustion engines to electromobility, Axalta focuses on advanced coatings for battery applications. Visitors can learn more about dielectric coating and thermal insulation coatings, enhancing the performance and lifespan of electric vehicle batteries;

 Corrosion protection: multiple product lines, including thermoplastics, thermosetting primers, industrial liquid and the environmentally conscious E-Coat AquaEC allow customers to choose the right product according to their requirements;

 ColourDesign: additionally, visitors can explore a special area dedicated to ColourDesign. Here, they can experience the complete colour spectrum of the company up close. The colour toolbox provides guidance for specifying coating systems in the right quality and colour, tailored to the individual needs of customer projects.

For further information: www.axalta.com

©Axalta Coating Systems

SPECIAL ISSUE - PaintExpo

FreiLacke to Present Cost-Efficient and Sustainable System Coating Solutions at PaintExpo

Oliver Zanner

FreiLacke-Emil Frei GmbH & Co. KG - Bräunlingen-Döggingen, Germany o.zanner@freilacke.de

FreiLacke will unveil a variety of system concept developments for powder coatings, liquid paints, electrophoretic deposition and composite solutions, as well as a new Trend Collection at PaintExpo 2024 (hall 1, stand 1420).

To ensure components coated with various technologies would ultimately present a flawless finish, a number of years ago

FreiLacke developed its system coating concept. Factors such as sustainability, energy efficiency, waste reduction and climate protection have an increasingly important role to play in this. In this endeavour, the system coating manufacturer has been driving ahead with developments in the fields of powder, liquid and electrodeposition coatings as well as composite solutions, and is also now even more committed to direct and close service and contact with customers in the development of an appropriate solution.

Components and parts are increasingly manufactured globally before ultimately being locally assembled and coated entirely or in part with various different coating systems. Workpieces not only need to be

perfectly compatible, but they must also present a homogeneous and coherent overall appearance in relation to colour, gloss and surface structure. Meeting these demands while maintaining or improving quality standards despite increasingly stricter VOC regulations and faster cycle times requires application solutions.

This is where FreiLacke system coatings come into their own: with its system coating concept of powder and liquid coatings, EC and composite solutions, the coating specialist from the Black Forest is focussing firmly on uniform surfaces irrespective of the diverse systems, application processes and facilities involved. Customers with various production sites, sometimes even located on different continents, are already using the system coatings with great success.

“As a system coating manufacturer, we have the means to perfectly

coordinate the coatings in the course of product development and production,” explained managing directors Rainer and Hans-Peter Frei. “Consequently, not only can we offer our customers all the principal coating technologies, we are also able to harmonise these to optimum effect in terms of coating structure and finish to provide a suitable solution, comply with stipulated framework conditions and ensure costeffectiveness and sustainability.”

Against this backdrop, FreiLacke is unveiling a variety of further system concept developments in all four product areas at this year’s PaintExpo.

EC without labelling requirements for greater sustainability

Aspects such as sustainability and VOC reduction have long been priorities for the coating manufacturer and are a prime reason for the continuous range expansion and development of new solutions at the Döggingen/Black Forest site. One example is the electrodeposition coating (EC) ‘EcoOne’, a two-component (2K) system free of any solvents and neutralising agents that require labelling.

The system is environmentally friendly and has no implications for the health of employees. Another exceptional feature of FreiLacke EC systems is their superb energy efficiency. The required baking temperature of the coating is around 30°C lower, which equates to a considerable conservation of energy during the combustion process. An outstanding uniform coating film that reliably protects the metallic component is nonetheless achieved. The coating layers are mechanically resilient and visually flawless.

Powder coatings: cost-effective, durable and eco-efficient

The established Black Forest company’s environmentally-friendly powder coating range has also been consistently developed. The product portfolio encompasses a broadly diversified selection for application areas

including steel and alloy wheel production, the automotive industry, mechanical and apparatus engineering as well as the wind power industry and rail vehicle sector. Particularly the solutions for large and bulky components that forego the baking process accentuate the cost-efficiency and sustainability approach.

Solutions have also been developed to meet the challenge of seamlessly distributing the powder coating layer thickness on sophisticated geometric workpieces, which is often possible only to a limited degree. In order to adequately cover undercuts or cavities, other areas of the component frequently feature denser layer thicknesses. “Here is what that means for conventional finely-textured powder coating systems: the denser layer thickness will exert an optical influence on the structure or even cause the powder coating layer to foam. In the end, this leads to defective goods or costly extra work”, explains Andreas Hepting, responsible for FreiLacke’s Sales Industry Groups. However, with the new PP5011A product range, FreiLacke has been able to successfully counter this issue: Even with layer thicknesses that are far greater than those specified in the technical data sheet, the surface will remain uniformly flat; that means the surface

structure in the range between 80 and 160 μm is very homogeneous. This has allowed FreiLacke’s coating specialists to successfully provide automated coating system processors and manual coaters with significantly greater flexibility and scope when it comes to coating their components with fine-textured powder coatings.

In the case of low temperature powder coating (NT), the baking temperature can be significantly lowered and heating energy consumption appreciably reduced. NT coatings also help to considerably shorten the oven throughput time and consequently increase the conveyor speed. FreiLacke has also successfully pressed ahead with further development in this key area.

New Trend Collection

This is a modern, matt powder coating with innovative colours, ideally suited for interior use – whether for ultimate design aspirations or for rugged applications. Powder coatings are similarly a suitable option for coating materials such as SMC/BMC in that they are simply sprayed into the mould. The highly reactive coating hardens within a few seconds allowing the SMC/BMC to be immediately placed and pressed. After pressing, the finished, coated component

© FreiLacke

can be demoulded as usual. The surfaces generated in the PIMC process feature excellent chemical and mechanical resistance and are well-suited for continuous use outdoors. The material is free of solvents, hazardous substances and carcinogenic raw materials. PIMC is fire-retardant in accordance with EN45545, HL3, R1 and, thanks to its good properties, it can be used for many applications – for example kitchen sinks, shower trays, facades, lights, athletic equipment or in vehicle construction.

A major benefit of this process: by combining pressing and coating into a single work step, the laborious subsequent coating (including the associated parts handling) can be eliminated, as well as the extensive logistics required when transporting the components to the internal coating plant or for external coating. When using the PIMC process, the components stay in-house until they are completed and can then be shipped to the customer right away. Another advantage: Added value for the operators and lower costs and higher quality for customers.

Liquid coatings:

from filler to top coat FreiLacke liquid coatings provide highly

efficient solutions for surfaces in industrial applications. Whether subject to corrosion, chemicals or weather, FreiLacke delivers the optimum protective coating for substrates such as steel, stainless steel, galvanised substrates, aluminium and plastic. The liquid coatings are used at every level of the coating structure: as a primer or filler, basecoat or top coat as well as in single coat systems. Industry coatings are available in a variety of finishes and gloss grades for interiors and exteriors. Increasingly stricter requirements placed on surface coatings and the continuous reduction of the VOC content in paints and coatings led FreiLacke to develop ultra-high solid systems (UHS). For conventional coatings, completely new coating systems with a solids content of up to 80 percent by weight and a VOC value of less than 350 grams per litre have been developed and brought to series maturity. They facilitate rapid drying and accelerated production processes. FreiLacke consequently has various single- and double-coat solutions on hand that offer high resistance for this purpose. Coatings are available in all RAL colours as well as special colours. Easy application – whether pneumatic, air-assisted, Airless or ESTA – and excellent resistance levels distinguish this system.

Cleverly manufactured composites

The benefits of glass-fibre or carbon fibrereinforced composites (GFRC / CFRP) are self-evident. They are light, extremely durable and they can be pressed into just about any shape. In addition to a diverse range of surface coating materials, FreiLacke now also supplies components for manufacturing parts. One example is the new CM powder technology. Due to a special two-stage principle, this innovative composite powder stands out against conventional composite material resin systems in that it can be melted on without starting the hardening process.

FreiLacke offers numerous coating solutions for composite materials, ranging from colour pastes and fillers to gel coats. These constitute durable-coloured coatings that are applied directly into the mould and provide moulded parts with long-term protection against moisture, UV radiation and impact damage. The system coating specialists have also succeeded in significantly reducing the percentage of styrene in the gel coats as the substance is deemed hazardous to health and problematic to the environment. “Using an alternative monomer, we have manufactured a reduced styrene gel coat that delivers even better results than conventional systems in terms of weather resistance and shelf life,” declared head of development Heiko Blattert. For components susceptible to increased erosion, such as wind turbine rotor blades, the coating professionals provide the highperformance edge protection coating Leading Edge Protection (LEP). New to the range is a modular production technology that no longer disperses, but only homogenises. Modular coating recipes comprise liquid components that can be metered fully automatically and are produced more quickly in order to respond promptly to customer requests.

© FreiLacke

Alum Alum finishing treatment finishing treatment

From Anodizing & P Waste Water Treatm

Since 1981 CIE Group’s mission is Since 1981 CIE Group’s mission is to realize plants for Aluminum to realize plants for Aluminum Finishing Lines. With more than Finishing Lines. With more than 200 realizations the CIE Group is 200 realizations the CIE Group is today one of the main today one of the main worldwide leaders. worldwide leaders.

Mirodur Develops a New Direct-to-Metal Coatings Range with Excellent Adhesion on All Metals

From an interview with Riccardo Vitelli, sales manager and Fernando Rosa, technical manager at Mirodur

Direct-to-Metal products have revolutionised the industrial coating industry, becoming popular in various fields of application, from agricultural machinery to heavy metalwork, thanks to their ability to streamline processes, reduce costs, and ensure long-lasting aesthetics and performance. Italian industrial coating manufacturer Mirodur has recently developed a high-end DTM product line providing better paint adhesion on any metal substrate than alternatives on the market.

Direct-to-Metal (DTM) products have been a major innovation in the industrial coating sector over the last few years. Thanks to their ability to adhere directly to metal surfaces and ensure effective protection against corrosion, they have become popular in many industries, from agricultural machinery and off-road vehicles to metalwork fabrications. Their

growing popularity is therefore due to their unique functional and aesthetic properties and ability to streamline and speed up the application process, as nowadays, users pay particular attention to consumption and cycle time duration and are constantly looking for high-performance solutions that, at the same time, reduce coating times, thus cutting both process and procurement costs.

The term Direct-to-Metal denotes twocomponent paint products acting as primers and top coats, whose formulations are specifically designed to adhere directly to metals without needing a base coat. This is possible thanks to resins (epoxy or acrylic) and special polymers that feature good adhesion properties and to additives or inhibitors that guarantee high resistance to corrosion and weathering.

Mirodur, an Italian manufacturer of industrial and protective coatings, has recently developed a new line of DTM products with high aesthetic and functional performance. Originally formulated and fine-tuned to meet the specific needs of a customer, this product range was then integrated into the portfolio of the company headquartered in Aprilia (Latina, Italy), further proof of its remarkable ability to adapt and respond to market demands in a timely and targeted manner. ipcm® interviewed its sales manager Riccardo Vitelli and technical manager Fernando Rosa to analyse the market and the state of the art of DTM coatings.

ipcm®: How did Mirodur get established? And how has it evolved in the industrial coating sector?

Riccardo Vitelli: The history of Mirodur began in 1957 when brothers Mario, Ugo,

A bird’s eye view of Mirodur’s headquarters in Aprilia.

© Mirodur

and Renato Vitelli started this business after acquiring a patent from a Belgian paint manufacturer. Production began in a modest factory on the outskirts of Rome, but the company was immediately successful and could move to a larger facility in nearby Pomezia in 1982. Here, the coating range was further diversified, especially in the field of corrosion protection. A few years later, to meet the ever-increasing demand and further improve our production process, we moved to an even larger factory – the production area is 15,000 m2 wide, of which 8,000 m2 are covered – in Aprilia, where Mirodur is still based today. Over the years, we have continued to evolve and adapt to the changing market needs. Today, we specialise in producing water- and solvent-based liquid coatings for the general industry and UHS coatings for the corrosion protection field.

ipcm®: Mirodur boasts a comprehensive product portfolio that does not only include industrial coatings. What is your core business?

Riccardo Vitelli: In addition to paint formulation, Mirodur specialises in the manufacturing of a wide range of industrial products, including the Miromix colour matching system for both water- and solventbased paints, our protective coatings mainly for the gas and water pipeline sector, and our ultra-thick coatings for the remediation of hydrocarbon and solvent tanks.

ipcm®: What DTM products do you have in your product range?

Fernando Rosa: Mirodur’s portfolio has always included a wide range of Directto-Metal coatings, including one- or twocomponent and solvent- or water-based products. Recently, we have seen a significant increase in the market demand for these coatings. Our standard DTM products, available with both glossy and matte finishes, are suitable for various metal substrates, including iron, aluminium, carbon steel, galvanised steel, and galvanised sheet metal,

and they enable to achieve a thickness of around 100-120 microns without surface defects with just one coat. Often, especially with formulations containing acrylic resins, it is difficult to achieve a thickness of 70-80 microns without the occurrence of surface defects, such as bubbles due to solvent entrapment in the film; our DTM products, however, can reach thicknesses of up to 110 microns in a single coat without any defects, even with glossy finishes.

Riccardo Vitelli: The top product in our DTM range is POLIACRIL DTM. It is a twocomponent coating based on non-yellowing, hydroxylated acrylic polyols with excellent direct adhesion on carbon steel and galvanised steel. Once cured, its film ensures excellent chemical and mechanical resistance. Particularly suitable for sectors such as heavy and light metalwork, industrial bodywork, and agricultural machinery, POLIACRIL DTM is characterised by exceptional colour and gloss

retention (Xenon test) and excellent impact, abrasion, and corrosion resistance (salt spray test). We have recently also launched a new DTM product line offering much higher paint adhesion properties on metal than the standard DTM coatings available.

ipcm®: Where did the need to formulate a new DTM range come from?

Riccardo Vitelli: The need to formulate a new range of DTM coatings emerged to meet the specific requirements of a major Polish customer that demanded exceptional paint adhesion on a variety of metal surfaces, including carbon steel, galvanised steel, and aluminium. This posed a significant challenge for us but was also an opportunity to demonstrate our ability to innovate and adapt to market requirements.

Fernando Rosa: The result of months of research and development was a new line of solvent-based 2K polyacrylic coatings with a

Mirodur’s laboratory.

© Mirodur

significantly higher degree of direct adhesion to metal than the standard DTM products currently available on the market. This was achieved through a series of targeted mechanical tests, including deep drawing, impact, cross hatch, and bending tests, which certified its excellent properties in terms of not only adhesion but also durability of the paint product on the metal substrate. To further enhance the performance degree of our product, we also included corrosion inhibitors in its formulation for additional protection against weathering and other environmental factors that can compromise the film’s integrity; the presence of UV filters also protects the film from external agents. The main challenge in developing this new DTM line was balancing several key factors: depositing a uniform film without aesthetic defects, achieving the required thicknesses, providing all the necessary mechanical and functional properties, and maintaining a price consistent with customer expectations. Although we did not face any cost pressure, as is often the case in this industry, the project still required careful work in terms of resource management.

ipcm®: Did you analyse the industry before formulating this DTM product line? What were the applicators’ primary needs?

Fernando Rosa: In recent years, the coating industry has been facing multiple challenges, from the increasing raw material costs affecting the

end products’ prices to the rising energy costs associated, for example, with the paint drying phase. In this context, DTM coatings are becoming increasingly popular because they allow reducing the number of coats applied, as well as the time and number of steps required for flash-off and drying. Unlike in traditional coating cycles, with DTM products, the parts to be treated only undergo one application phase (primer+top coat) and, consequently, one drying phase. This improves productivity, helps optimise energy resources, and reduces the operations’ environmental impact through lower greenhouse gas emissions. Therefore, DTM products are gaining in popularity because, in addition to providing economic and ecological benefits, they achieve the same aesthetic and functional performance as traditional coatings, thus guaranteeing a high degree of quality.

Riccardo Vitelli: Another issue we tackled was the need to avoid pre-treating (in the strict sense of the term) specific substrates before applying a DTM product. Traditionally, properly preparing a metal substrate before the coating cycle is paramount to ensure optimal performance and service life of the coating itself. Such preparation phase may include mechanical processes, such as shot blasting or sandblasting, or chemical processes. However, subjecting the parts to be treated to these operations is often difficult: for example, in the heavy metalwork sector, where DTM products are widely used,

The salt spray and Xenon test chamber.

© Mirodur

substrate preparation can be a critical challenge due to the size or weight of the components handled. This often makes conventional pre-treatment processes simply impossible. Our DTM products achieve suitable results even without any prior pre-treatment phase. They can be applied directly to bare metal (e.g. stainless steel or aluminium) after degreasing, thus eliminating the need for further pre-treatment operations such as sandblasting or shot blasting.

Mirodur awaits you at stand no. 3643, Hall 3, at PaintExpo, the most important event in the industrial coating sector, to be held in Karlsruhe (Germany) from 9 to 12 April 2024. It will be an opportunity to present the company’s wide range of coatings, but also its Miromix solvent-based and water-based colour matching systems.

© Mirodur

The Miromix colour matching system, one of the innovations Mirodur is going to present at PaintExpo.

Optimising a Zero Liquid Discharge Waste Water Treatment Plant: the Virtuous Example of Arco

Monica Fumagalli, ipcm®

A long-standing coating contractor in Northern Italy, Arco has optimised its already existing zero liquid discharge treatment system for waste water generated by its cataphoresis and powder coating processes by integrating it with a new plant designed and built by Simpec: a virtuous example of environmental sustainability improved by leveraging the equipment resources already present in a factory.

According to research institute Eurispes’ 2023 study1 on water consumption, Italy ranks third among Europe’s nations with the highest availability of water resources.

However, it is also the European country with the highest per capita consumption of drinking water and the second highest consumption in

1 EURISPES, Un sistema che fa acqua: lo stato delle acque in Italia 2023 - https:// eurispes.eu/wp-content/uploads/2023/09/eurispes-un-sistema-che-fa-acqua_2023.pdf

agriculture. Every year, more than 30 billion m3 of water are withdrawn within its borders, of which 17 billion are used in agriculture, 9.1 billion for civil use, and around 3.8 billion for industrial use, with the highest consumption recorded in specific sectors such as chemicals, metallurgy, rubber, plastics, and textiles. The study emphasises the alarming, constant reduction in the amount of renewable water in recent years and the increasingly urgent need to improve and update old water

Arco Srl, a long-established coating contractor in Northern Italy, is well known for its classic car restoration service.

systems and, at the same time, adopt water recovery and reuse solutions, particularly for the agricultural sector. The industry world is the most active and advanced in this context: technological innovation has already reached a high level of development, and numerous companies have long since adopted zero liquid discharge (ZLD) systems to treat the water used in their processes. In our sector, in particular, the largest volumes of water are utilised in cataphoresis pre-treatment and coating plants. Claudio Malaman, the owner together with his brother Johnny of Arco Srl (Gazzo Padovano, Padua), a long-established coating contractor in Northern Italy, confirms: “We have long since installed an evaporator for total water recovery and have recently implemented a new system to cope with the increasing water volumes required due to intensified production, which was designed and supplied by Simpec Srl (Nova Milanese, Monza e Brianza, Italy).”

The reasons for Arco’s success

“My father,” adds Malaman, “started this contract coating business almost by chance in the late 1970s. He originally focused on the construction industry, but soon the coating business took off, and the company grew rapidly. Today, we work in an 18,000 m2-wide plant with 62 employees and provide not only high-quality application processes and coatings but also all-round consulting services for small and medium-sized companies in our area.” According to Malaman, contract coating companies are firmly rooted in their communities due to their intrinsic characteristics: “This kind of business is highly localised because

it is rare to serve customers located many kilometers away for logistical reasons. Nevertheless, our company is highly sought after because we provide various sectors with a comprehensive service that includes the treatment of large-sized pieces. Arco’s main target markets include the automotive, ACE, HVAC, furniture, construction, and many other sectors.”

“Whereas this broad customer base shields us from market fluctuations, it also makes our business less streamlined than it could be if we focused on just one sector, as each workpiece is profoundly different in terms of peculiarities and treatment specifications. Moreover, thanks to our experience, we not only apply coatings with high functional and aesthetic performance but also serve as coating consultants for any customer requiring it – which is highly appreciated by the companies we work with daily. Our professional approach is based on using simple language, which makes our processes and treatments understandable even to those without expertise in our field.”

Another aspect for which Arco is well known in Northern Italy is its classic car restoration service, a market niche that is difficult to penetrate due to the high complexity of the body repainting task. “The size of our plants enables us to handle very large-sized products such as cars and vans. The treatment cycle we carry out for the restoration of classic cars includes paint stripping in a pyrolytic oven with a capacity of 6 x 2 x 2 m, effective with all types of paint for deep cleaning of the body; pickling for completely removing any oxides and traces of rust; and cataphoresis, which is the best coating solution to reach all areas of a car body evenly.”

The Arco’s headquarters in Gazzo Padovano (Padua).

The waste water treatment plant is prearranged for treating 3 different types of liquid waste: water, acidic concentrate, and alkaline concentrate. © Arco

Plant equipment

Arco’s factory has 3 plants: 1 for the black cataphoresis process and 2 for powder coating.

The cataphoresis plant

Cataphoresis coating is a surface treatment process designed to give the treated components considerable resistance to chemical and environmental corrosion. Arco’s pre-treatment phase involves 2 spray and immersion degreasing stages, a rinse, pickling, activation and phosphating with microcrystalline zinc salts, and a final rinse with demineralised water. “Our new-generation epoxy cataphoresis system,” explains Malaman, “can process parts up to 6.4 m in length, 1.8 m in depth, 2.5 m in height, and 1,500 kg in weight. If our customers require a particularly high level of adhesion, strength, and finishing performance, the resulting film can be used as a primer for a subsequently applied powder layer.”

The powder coating plants

“Our 2 powder coating systems are equipped with manual and automatic stations that guarantee consistent quality and constant control of the electrostatic application process, from small to extremely large parts. Applied as a top coat or primer depending on the type of paint product chosen and the part’s intended environment, powder coating is particularly suitable for materials that require an elastic, cosmetic coating.” Arco’s plant equipment includes an 8-stage in-line pre-treatment tunnel, a drying oven, 3 powder coating booths, and a curing oven that works with an average temperature of 180 °C and features 6 temperature control zones. The 8 pre-treatment stages are as follows: 2 phosphodegreasing stages, a rinse, acid deoxidation for aluminium surfaces, a rinse with mains water, a rinse with demineralised

water, nanotechnology application, and a final rinse with demineralised water. “This pre-treatment cycle deposits a high-thickness iron phosphate film on the workpieces,” notes Malaman. “On request for maximum performance, a nanotechnology film can also be applied to metal surfaces to increase corrosion resistance significantly. Our salt spray test results are 700 hours for the two-coat cycle (cataphoresis + top coat) and 1,000 hours for the three-coat cycle (cataphoresis + epoxy primer + top coat).”

The first powder coating plant, equipped with semi-automatic booths, can process parts with dimensions of 6.4 x 1 x 2.5 m and has a load capacity of 1,000 kg. The second line is an extremely flexible step-bystep system, ensuring fast colour change operations and handling even small batches. It can treat parts with a size of up to 8 x 2 x 2 m and a maximum weight of 1,500 kg. “We perform a minimum of 2 and a maximum of 7 colour changes per day because we organise our daily schedule to minimise them as much as possible, both to optimise our production flow and to achieve higher coating quality.”

Smart water management

Arco’s plant equipment ensures extreme flexibility and the ability to meet the most diverse customer needs. “Over the years, diversifying our production has enabled us not only to stay afloat at critical times but also to increase our volumes consistently. This, however, has recently led us to face an important choice related to the management of energy resources. We had long since installed an evaporator to purify the waste water generated in our cataphoresis and coating plants by distillation and recirculate the clean liquid into our production flow, but it could no longer handle the high amounts of water we now normally use: this is why we decided to implement a new, closed-loop water recovery system provided by Simpec.”

After passing through the decanter, the sludge is separated from the liquid, and reaches the thickener and then the filter press.

The ultrafiltration system.

Main features of the water treatment plant

The physical-chemical purification plant collecting waste water from both surface treatment processes was installed in a covered factory area, specially set to accommodate it. “The plant is prearranged for treating 3 different types of liquid waste: water, acidic concentrate, and alkaline concentrate. The concentrates are immediately sent to a collecting tank for disposal,” illustrates Andrea Bottini, Export Manager & Business Development expert at Simpec. “Waste water, on the other hand, is first collected in a homogenisation tank with a capacity of 10 m3 and then conveyed to 2 mezzanine tanks for adsorption with powdered activated carbon and acidification with sulphuric acid (1.5 m3), neutralisation, and coagulation (2 m3). This phase is subject to strict pH control by means of an agitator system that keeps the treated water in the optimal condition to trigger reactions at the right time. This is where sludge starts to form, which is conveyed to a flocculation tank together with water: the addition of a polyelectrolyte reagent favours the aggregation of the flakes made insoluble in water and their transfer to a decanter, where the sludge is separated from the liquid. It then reaches the thickener and, finally, the filter press, which it leaves in the form of panels ready to be disposed of by authorised companies. Meanwhile, the water is conveyed towards a tank and, subsequently, a sand filtration system that cleanses it of any residue

and an activated carbon system that absorbs any organic pollutants still present.”

Such purified water can be discharged into the environment or recovered, as is the case with Arco. “From the activated carbon filter, it is sent to a storage tank, from where it is drawn by an ultrafiltration plant. After pH is corrected by dosing an acidic agent, it is conveyed to a reverse osmosis system, recovering 70% of the purified water with an electrical conductivity of less than 100 microsiemens/ cm, whereas the remaining 30% is discharged. The latter is then sent to a 25 m3 storage tank and, finally, to the evaporator; this produces

EVERY CHALLENGE IS DIFFERENT.

concentrate to be disposed of, whereas the distillate and permeate are filtered in a UV debacterisation system and recirculated back into the production flow. In total, therefore, we recover and recycle 95% of water, of which 70% is water recovered by reverse osmosis and 25% is distilled water resulting from the evaporation process.”

Optimising consumption as a sustainability driver

“This new plant was started up in September last year,” says Malaman, “and has reduced the volume of water sent to our evaporator,

And so are our finishing solutions.

The evaporator unit.

allowing it to continue working. Designed and installed by Simpec, it is excellent in terms of both technology and component quality. For my employees and me, this is our first experience with a system of this type, and we have yet to fully master all its functions. Just like the kidneys in the human body, it is also important to learn that the treatment system of a production plant cannot just take in any kind of waste water to be purified, but it must rather be fed correctly.”

As the system has only been in operation for a few months, it is not easy to estimate the savings achieved in terms of water consumption. However, the company has already seen an improvement. Malaman confirms that “the pre-treatment rinsing baths are cleaner, and this is reflected in the aesthetic quality of our coating, which is much higher.” In terms of maintenance, the Arco team has also experienced significant benefits: “The fact that waste water was treated with the evaporation plant alone meant that our heat exchanger was often covered in fouling that needed to be removed by an external company. This resulted in a considerable loss of time for the disassembly and reassembly of the

system. Today, thanks to the new plant, our performance is also better in this respect. And, in addition to considerable cost savings, the quality of our products has also improved. Simpec also helped us leverage the existing evaporator, previously integrated into a sub-optimal recovery system. This is the most environmentally sustainable aspect of our investment: not so much the technology selected – since we had already opted for a ZLD system before – but precisely the choice to make the most of the plant resources already in use by optimising them thanks to the collaboration of a strategic partner such as Simpec.”

Arco’s physical-chemical plant recovers 95% of waste water and is a virtuous example of how to make the most of a key, limited resource: water. The Eurispes study mentioned at the beginning of this article concludes that “Italy would have all the natural, cognitive, financial, and technological resources to solve the current water crisis. What is lacking is an institutional and organisational system that is effective in implementing projects and efficient in managing and maintaining infrastructure.” The industry would have much to teach in this respect.

The control electrical panel of the water treatment plant.

The HMI control panel.

Gema Presented the OptiCenter ®

All-in-One OC11 and OC10, New Powder Management Systems with the Latest Application Pump Technology

Edited by Gema Switzerland GmbH St. Gallen, Switzerland

The company has presented two new upgraded versions, specifically developed to meet the ever-changing requirements of the paints and coatings sectors.

Gema Switzerland GmbH is a leading supplier in the area of electrostatic powder coating, with a worldwide presence. From simple manual coating through to fully-automated powder coating equipment, this Swiss company offers solutions that meet the high demands and requirements of customers around the world in a wide range of industrial sectors. Its All-in-One® units are the first in powder coating industry that merge electrostatics and powder feed technology in one very compact device, while its OptiCenter® powder management systems have become the core of the coating process, offering high quality and quick colour changes.

OptiCenter All-in-One OC11 - Powder management with dual powder hopper and latest application pump technology

The OptiCenter All-in-One OC11 is the new powder management system with two OptiSpeeder powder hoppers combined with latest OptiSpray All-in-One pump technology, which combines advanced powder loading technology with second generation SIT dense phase powder delivery technology in one compact unit.

The OC11 has two OptiSpeeder powder hoppers (DualSpeeder), which enables coating of two independent colours in succession with ultra-fast colour change. It employs the MultiColor Switch technology, which provides the fastest switching between OptiSpeeder hoppers and the cleanest colour change between alternating colours. A switch occurs in as little as 60 seconds, providing colour flexibility and operational efficiency for short-batch production. Another feature is its ability to coat simultaneously from both powder hoppers. On the one hand, it is possible to coat in parallel with only fresh powder from one container and recovery powder mix from the other, allowing independent application. Fresh powder is used for surfaces requiring ‘A’ quality, while recovery powder is applied to visually less critical areas. This optimisation ensures the highest product quality and maximum powder utilisation, which ultimately reduces scrap and increases cost efficiency. In addition, the two powder hoppers can be used as a dual fresh powder source of the same powder. The user benefits from continuous automatic fresh powder supply, especially for long production batches. This prevents plant downtime due to powder shortages.

With the integration of electrostatics and powder conveying via the proven Gema OptiSpray pump technology in one compact unit, the new OptiSpray All-in-One pump is the first of its kind in the powder coating industry. This combination ensures seamless interaction between pneumatic and electrostatic functions, resulting in responsive powder delivery, instantaneous powder cloud control and the highest application efficiency.

Up to 36 OptiSpray All-in-One can be integrated directly in the OC11 in a very space-saving way, eliminating the need for the otherwise commercially available gun control cabinet, which saves space and provides ergonomic plant layouts that can be installed quickly. With OptiCenter powder management and the integrated OptiSpray All-in-One pump, users benefit from the fastest colour changes, stable coating results, intuitive operation and trouble-free maintenance.

The OC11 can be tailored to individual requirements with various equipment options, such as the US07 ultrasonic sieve insert. In addition, customers can choose between various internal fresh powder systems, including the standard cone, the cone with weighing device, the vibration table for the powder box or the external fresh powder supply with the OptiFeed FPS series.

OptiCenter All-in-One (OC10) - Powder management with latest All-in-One application pump technology

OptiCenter All-in-One OC10 is the new powder management system with unique OptiSpray All-in-One pump technology, combining advanced powder charging technology with second generation SIT dense phase powder delivery technology in one compact unit.

Integrating electrostatics and powder delivery via Gema’s proven OptiSpray pump technology in one compact unit, the new OptiSpray All-in-One pump is the first of its kind in the powder coating industry. This combination ensures seamless interaction between pneumatic and electrostatic functions, resulting in responsive powder delivery, instantaneous powder cloud control and the highest application efficiency. Up to 36 OptiSpray All-in-One can be integrated directly on the OC10’s OptiSpeeder in a very space-saving way, eliminating the need for the gun control cabinet, which saves space and provides ergonomic plant layouts that can be installed quickly.

The OC10 can be tailored to individual requirements with various equipment options, such as the US07 ultrasonic sieve insert. In addition, customers can choose between various internal fresh powder systems, including the standard cone, the cone with weighing device, the vibration table for the powder box, or the external fresh powder feed with the OptiFeed FPS series.

With OptiCenter powder management and the integrated OptiSpray All-in-One pump, users benefit from the fastest colour changes, stable coating results, intuitive operation and trouble-free maintenance.

© Gema Switzerland GmbH

The OptiCenter All-in-One OC10.

Thank you

+10% forecast 2024

60% export share

Growth Chart 2008-2023

The analysis of the Eurotherm S.p.A. turnover shows a steady positive trend thanks to the growth in recent years. This growth has been supported by the development of international markets, by the creation of a dynamic commercial structure and by significant investments in technologies and machines for the production of coating installations.

90% internal production

Eurotherm S.p.A. Volpiano

Eurotherm

Eurotherm France S.A.S.

Eurotherm Benelux Srl

GSB International at the PaintExpo 2024

GSB International, the leading quality association for surface coatings in the areas of aluminium and steel, will attend PaintExpo 2024 in Hall 1, Stand 1118.

The PaintExpo is the place to be for the entire coatings industry. Needless to say, GSB will be present. Quality assurance for coatings on aluminium, steel and galvanised steel is a hot topic across the board when it comes to outdoor architectural applications.

The GSB offers a reliable quality assurance system that provides building owners with long-lasting value retention.

At GSB, the entire coating process chain is assured by independent accredited testing institutes - the pre-treatment, the coating materials, and the coating companies.

Over the years, GSB Coatings gained widespread recognition in the market and became part of many tenders. It is therefore not surprising that coatings from GSB-certified coating companies are also demanded by many tendering bodies outside the architectural sector. GSB Coaters, for example, fulfil the Deutsche Bahn Standard (DBS 918 340) if they carry out a small additional corrosion test as part of their inspection and can offer their services to the Deutsche Bahn with little effort.

You might ask yourself where this success of the Quality Seals comes from. Ultimately, it is the people who are committed to the organisation. Leading experts from the entire coating process chain continuously develop the Quality Regulations in close connection with the industry and always go beyond the requirements of the norms. Changes to the Quality Regulations are then voted on democratically every two years at the General Assembly.

In addition to the pure work on the Quality Regulations, the GSB is involved in various projects relating to quality assurance and the topic of coating. For example, there are ongoing round-robin tests related to testing and a dedicated working group on the topic of sustainability.

For further information:

https://gsb-international.de/en/

Werner Mader, Managing Director of GSB at PaintExpo.

Saving Energy with Liquid and Powder Coatings - the Solutions by GEHOLIT+WIEMER and KABE at PaintExpo 2024

GEHOLIT+WIEMER and Karl Bubenhofer will jointly present their latest innovations in powder and liquid coatings at PaintExpo 2024 in Hall 2, stand 2410.

As system providers of powder and liquid coatings, GEHOLIT+WIEMER and Karl Bubenhofer traditionally present their latest innovations together at PaintExpo.

The focus is on sustainable high-solid liquid coatings with over 70% solid content, enabling faster drying and efficient coating processes. Transitioning to a single-coat system also offers significant time, energy, and cost savings.

In the powder coating area, material selection for CO2 reduction is crucial. KABE Farben supports companies in adopting the POLYFLEX® PES-165-NT-GU system for quicker curing cycles and reduced energy consumption. This fast-reactive polyester powder is suitable for outdoor use, proven to lower costs and energy demands. Additionally, KABE Farben provides an extensive range of low-temperature solutions for various applications.

For further information: www.kabe-farben.ch/it/

The New Generation of Air Nozzle

XLINE by Krautzberger

Krautzberger is a name with tradition and innovation behind it and the company uses its leadership position to set new standards for the market.

Albert Krautzberger from Friedland, near Breslau, filed a patent application for a “painting device operated by compressed air” on 9 October 1902. With that he laid the foundation of today’s Krautzberger GmbH and of a complete revolution for paint application. As a matter of fact, Albert Krautzberger’s invention made it possible to achieve a significant simplification in the day-to-day use of the devices. Even today, the vast majority of compressed air guns work with the system by Albert Krautzberger.

Krautzberger GmbH has been a family-owned business from the start and is currently managed by the 4th generation.

In 2011, Krautzberger received the Hermes Award, an international technology award. Today, Krautzberger GmbH is a medium-sized family business with 90 employees and customers all over the world and is one of the leading industrial companies specialising in surface technology. Krautzberger products combine proven technology with innovative methods. Be it small parts or series production – with Krautzberger product range, painting processes can be improved effortlessly, efficiently, and sustainably.

Following the launch of the first XLINE manual and automatic sprayers in 2017, Krautzberger has converted all manual and automatic sprayers to XLINE over the next 6 years until 2023. All spray guns are equipped with XLINE material and air nozzles: available in anodised aluminium (60% weight reduction) or stainless steel for heavy duty application, the air nozzles come in the conventional and HVLP range. The new and ultramodern production process of the XLINE series offers to the customer a number of advantages:

Optimisation via numerical flow simulation

 Further improved transfer rates through the optimisation of interior geometry

 Reduced soiling due to new exterior design

Automated 100% control integrated in production process

 Zero defect strategy for continuous quality improvement

 Improved reproducibility of the spray pattern

Functional improvement of the air nozzles

 Optimal centring of the fluid nozzle and the air nozzle through a spherical system

 Improved separation of flat and round jet air

Improved handling and simple nozzle adjustment

 Trapezoid threads enable insertion and tightening in one step

 Simple and exact positioning and fixation of the air nozzle

Colour-coded identification of the spray procedures

 BLUE: conventional compressed air

 DARK GREEN: HVLP procedure

 LIGHT GREEN: LVLP procedure

Krautzberger looks forward to welcome you at PaintExpo 2024, Hall 3 booth 3360, to present the new XLINE nozzle range and all its industrial benefits.

For further information: www.krautzberger.com

© Krautzberger

Shoemaker Increased its Production Capacity by Investing in a Wagner Powder Coating System

The new system developed by J. Wagner GmbH allowed Shoemaker to automate and enhance its powder coating process.

Shoemaker, headquartered in Cle Elum (Washington, U.S.A.), has been a pioneering manufacturer of air diffusers and heating coils since 1947.

The company employs an advanced powder coating process to impart colour to their intricate multi-layered parts, fabricated from various metals.

Initially, the coating process involved automatic booths for white and brown colours, while all other shades were applied manually. However, as the demand for non-white or non-brown components surged, Shoemaker encountered formidable challenges. Substantial manual involvement, which resulted in potential variance in coating quality, depending on the expertise of the operator performing the task, slowed down the production pace. Furthermore, inadequate powder extraction mechanisms undermined overall process efficiency. Shoemaker, committed to meeting escalating market demands and staying ahead of the competition, embarked on a journey to optimise its coating process. The objectives were crystal clear: the company needed to automate the coating process for all colours applied with minimal transition time, ensure a consistent quality of the coating layer, minimise rework, enhance the efficiency of the powder extraction cycle and also accelerate the production speed and its volume. In just nine months, Wagner has engineered a groundbreaking facility that revolutionised production methodology of Shoemaker. The white components are now expertly coated in an expanded

automatic booth equipped with the SprayPackE, a user-friendly application control system that ensures impeccable coating results while optimising material consumption. For all other colours, the specialists from the company introduced the E-Line system, complemented by the PXE powder centre. This compact and efficient system seamlessly blends superior coating quality with exceptional productivity. It boasts strong application efficiency, rapid colour transition times and an intuitive interface, providing Shoemaker with consistent results under all conditions.

Thanks to this state-of-the-art Wagner coating system, Shoemaker has achieved remarkable milestones: it has automated the coating of all parts in a full spectrum of colours, obtained a 90% reduction in personnel needed for rework during each shift and a production boost of up to 30% coupled with a significant reduction in powder consumption through intelligent powder recovery as well as a drastically improved efficiency through automatic colour change.

For further information: www.wagner-group.com

Environmental Product Declaration to the VIVENDI SDS Collection by Adapta Color

Adapta Color has renewed the Environmental Product Declaration for the years 2024-2029 for its VIVENDI SDS (Super Durable System) Collection.

Adapta Color, a Spanish company specializing in manufacturing powder coatings, remains faithful to its commitment to provide appropriate environmental information about its products, as stated in its management policy. With a clear and transparent strategy to showcase the environmental aspect of its activities, the company has prepared an Environmental Product Declaration (EPD) for its superdurable product line, ADAPTA VIVENDI SDS.

Environmental Product Declarations (EPDs) transparently include information – verified by an independent third party – regarding the environmental performance of the product based on its Life Cycle Analysis (LCA). The information is divided in several impact categories (global warming, ozone depletion, acidification, etc.), along with additional details such as emitted emissions, generated waste, and more. The EPD allows for the comparison of environmental information among products or services that perform the same function. The Adapta Color’s environmental product declaration has been verified according to ISO 14025 and EN 15804:2012+A2:2020, in accordance with the Product Category Rules (PCR) RCP 100 (version 3 – 27/05/2021 General

construction products). It is crucial to verify the reference PCR (Product Category Rules) followed when comparing EPDs of similar products. The PCRs define the rules that must be followed by the LCA studies, and the information to be displayed in the EPD. This allows understanding the working parameters followed to obtain various indicators.

The Carbon Footprint, which is a highly relevant indicator of the contribution to climate change, is one of the indicators obtained in the development of the EPD. It measures the amount of greenhouse gases associated with that product or activity. In reality, the carbon footprint is a simplified version of the Life Cycle Analysis (LCA), focusing on a single environmental impact category, specifically related to global warming.

The VIVENDI SDS Collection has also been tested according to the ISO 16000-9:2006 standard for determining the emissions of volatile organic compounds from building and furnishing products. Based on the results, the company has achieved Class A+ (very low emissions) for wall, ceiling, window, and door panels.

For further information: www.adaptacolor.com

Design

Chemical-physical

Sludge treatment and

Ion exchange

Oil

Filtering systems

Batch type systems

Flotation units

Chemicals

Technical service,

wastewater treatment plants

In over 15 years, WaterEnergy developed its proved and consolidated industrial water treatment technology specifically designed for chemical and mechanical engineering area

We are happy to be “falsified”, it means that our systems are efficient

An Automatic Pre-Treatment Pilot Plant, Tailor-Made for Chemetall’s New Global Aluminum Competence Centre

From an interview with

Monti and

Chemetall Italia inaugurated a new global Centre for the research and development of aluminium surface treatment solutions, which will also offer technical assistance and laboratory testing services to all the Group’s customers. It integrates multiple pilot lines to faithfully reproduce any operating condition, including a new, custom-developed, automatic, multi-metal pre-treatment plant from O.M.SA.

The surface treatment global business unit of BASF’s Coatings division, under the Chemetall brand, opened its new Global Aluminum Competence Centre1 in Giussano (Monza e Brianza, Italy) on Tuesday, 13 February 2024.

1 Further information on the event at page 228.

The centralisation of the Group’s research and development activities in the aluminium sector in this new facility will allow the testing and development of new technologies more quickly and efficiently, as well as innovations in the anodising and pre-treatment areas. The new hub aims

Andrea

Fabrizio Grassi from Chemetall Italia and Gilberto Riva from O.M.SA.

O.M.SA.’s automatic multi-metal pre-treatment pilot plant.

to encompass all the company’s competencies in the field of aluminium surface treatment, especially for the architectural and wheel sectors, within one structure. The choice of Chemetall’s current Italian site resulted from an intensive analysis of the existing capacities, which took into account development priorities, market requirements, and customer needs.

Chemetall’s new Global Aluminium Competence Centre

Indeed, BASF selected the Giussano plant for two main reasons: the multidisciplinary nature of its personnel’s skills, covering all its served markets’ supply chains, and its existing infrastructure, which was the most suitable for expansion works. The new Global Aluminum Competence Centre, therefore, strengthens Chemetall’s position in the aluminium finishing segment while, at the same time, giving a solid boost to the development of technologies and solutions for all industries.

“The Italian aluminium market is the second largest in Europe in terms of turnover, making an Italian hub a significant strategic opportunity. We decided to create a centre of excellence for the treatment of aluminium that also deals with architectural and wheel-related solutions within one site with multiple additional competencies, thus handling all the main operational phases in one place and creating a world-class benchmark hub for the processing of aluminium surfaces. This is a concrete investment perfectly in line with Chemetall’s strategy of focussing on its customers by providing them with tailored services,” says Andrea Monti, the technical director and lab manager of Chemetall Italia. With this appointment, the company has also had the opportunity to expand its laboratory by renovating the upper part of its existing building, creating a new office area and allocating the previous one for testing and R&D activities. This also made it possible to accommodate equipment from the German

subsidiary: an anodic oxidation pilot line called “Jacqueline”, 5 climatic chambers for accelerated corrosion testing (neutral, acetic, cupro acetic, and SCAB corrosion tests), and 2 humidistats with the ability to perform filiform corrosion tests. In addition, the Centre also accommodates instrumentation for testing anodised aluminium according to QUALANOD specifications, glossmeters, a pilot line for spray pre-treatment on car wheels (performing 5 process stages and 2 rinses), and an 11-stage automated spray-dip pilot plant for multimetal pre-treatment. The latter was supplied by O.M.SA. Srl (Besana in Brianza, Monza e Brianza), a company working in the plant engineering sector since 1967 and specialising in designing and constructing automatic systems for surface treatment and finishing.

Beyond aluminium: an all-round service

At the same time, the new Centre is not devoted exclusively to aluminium, but takes advantage of the Chemetall Italia personnel’s expertise to provide an all-round service.

“Our Centre plays the role of a technical hub, a laboratory capable of actively listening to our customers’ needs and meeting them with innovative, cutting-edge solutions within the market’s required timing,” explains Monti. The new Global Aluminum Competence Centre employs 13 Chemetall technicians working on specific tasks. Besides VIANT, the new coating technology that combines conversion coating and primer paint in a single layer, and other pre-treatment technologies, the Centre also deals with product development in the fields of metalworking fluids, interoperational degreasers, beverage cans, waste water disposal, electrochemical surface characterisation, and optical and ionic microscopy (SEM-EDX), as well as performing laboratory and customisation analyses. Indeed, all the Group’s customers can use this hub in different ways with the company’s weekly

The spray and immersion tanks that make up the line.

The sideshifter designed by O.M.SA.

or monthly assistance, offered as part of customised service packages. Depending on the type of supply relationship established, through the “Gardobox” service, Chemetall sends special sheets or vials for collecting bath samples that will then be analysed in the new research centre to give personalised feedback with valuable tips to maintain or improve the existing processes.

“Besides being a global hub for aluminium, our Giussano laboratory has been assigned several tasks over the years: we have been responsible for wastewater treatment worldwide for more than two decades and for mechanical plastic recycling since 2012. Since 2018, we have been in charge of R&D on inter-operational degreasers and the deputy staff for the product group of alkaline cleaners, acid pickling agents, inhibitors, and surfactants. In 2020, we became responsible for R&D on metal packaging treatment, and now for the Aluminium Finishing & Wheels division. So, in addition to conducting research and development activities on aluminium, we also provide technical support for all these product types,” adds Monti.

The company, therefore, wanted to find a solution that would allow it to expand its aluminium-related research activities while also being able to provide technical assistance for the treatment of other substrates and the many processes analysed and tested at its Giussano plant. That is why, in addition to incorporating technologies from the German site, Chemetall requested a new customised pilot plant from O.M.SA.

O.M.SA.’s automatic multi-metal pre-treatment pilot plant

This 6-metre long and 4-metre wide pilot plant, featuring 100-litre spray and immersion tanks, carries out 11 stages: 2 stages of alkaline spray degreasing, 2 rinses, spray and immersion deoxidation, nanotechnology conversion, passivation, and 2 final rinses. The plant also includes an additional 200-litre tank for applying VIANT technology for black and light grey, an in-line drying oven, and a sideshifter.

The integrated PLC enables to programme the sideshifter so that recipes can be entered to include or exclude certain tanks, to measure and calculate immersion and drying times reliably, and to adjust parameters such as the operating temperature for precisely simulating what happens in the paint shop of each customer. It also allows managing the recirculation and spray pump and it can be combined with the Gardocam technology (which enables to use a camera inside customer tunnels to find the cause of any problems, such as clogged nozzles, and quickly resolve them) to reproduce in an accurate way the customer process.

“When we were selected to host the new Global Aluminum Competence Centre, we also decided to capitalise on that investment. Although not exclusively devoted to aluminium, O.M.SA.’s plant plays an essential role within our Centre because it enables us to conduct tests on any metal substrate and analyse and set parameters such as cycle times, dripping times, and travel times from one stage to the next. As a result, we use it both to develop new solutions and to analyse our customers’

The numerous technologies available to Chemetall Italia.

processes for optimising their performance,” illustrates Fabrizio Grassi, the coordinator of the analytical and technological laboratory at the Giussano plant.

Project challenges successfully overcome

Although the site was selected as the most suitable to host the new Centre, Chemetall Italia still had to request that the pre-treatment system be custom-designed and built to occupy as little space as possible. “We needed a pilot plant that was versatile and capable of operating on a very cross-sectoral basis to faithfully reproduce the various processes implemented by our customers and meet the requirements of their different businesses. We turned to O.M.SA. because we knew it had the expertise and production flexibility needed to develop this compact, small-scale line without sacrificing precision and performance,” states Monti.

Gilberto Riva from O.M.S.A.’s technical sales department confirms: “I must admit that transferring our knowledge of large-scale plants to a very small pilot machine was a challenge in terms of both design and construction. However, after carefully analysing Chemetall’s requirements, we were able to develop the pre-treatment tanks and their connected devices as if they were those commonly found in pretreatment and coating plants.”

“Such a combination of versatility and compactness was a great success. O.M.SA. proved to be a helpful and reliable partner, able to meet our special, highly customised requirements. This is why we have decided to rely on them for future maintenance work in the new workshop, including the revamping of a line consisting of 3 small spray pre-treatment machines. Moreover, seeing how they successfully overcame all the challenges of this project, our company’s foreign subsidiaries are also considering relying on them to set up other Competence Centres throughout Europe, where in EMEA we are present with dedicated labs in 12 countries ,” says Monti.

The test stations in the new Global Aluminum Competence Centre.

From left to right: Gilberto Riva from O.M.SA. with Fabrizio Grassi and Andrea Monti from Chemetall Italia.

Innovation and Quality Research in the Powder Coating Sector: the Virtuous Technological Choices of Univer 2000

Ilaria Paolomelo, ipcm®

Univer 2000, a company specialising in contract powder coating, liquid coating, and sandblasting services, has been standing out for over thirty years for its constant focus on state-of-the-art technologies to offer excellent finishing results. Its latest investment dates back to 2022: the installation of a new powder coating plant designed by a pool of leading Italian companies in the surface treatment industry, equipped with Wagner’s new generation IPS powder centre and a Morris-type chain conveyor supplied by Nuova Catena.

Univer 2000 headquarters located in Zané (Vicenza, Italy).

Within a production process, the coating phase is of crucial importance because it is responsible for giving the end product not only an attractive aesthetic finish but also a series of functional properties. These include corrosion protection, resistance to scratches, impacts, and aggressive chemicals, and durability without compromising the coating’s integrity. Given this process step’s importance, many companies prefer to rely on a specialised contractor whose core business is coating.

The activity of a contractor is thus characterised by significant complexity due to the need to meet the most diverse quality requirements, depending on its customers’ sectors. Coping with such diversity means using different plant technologies and adopting a flexible approach to respond to different requests while ensuring the highest possible quality output. Sectors such as automotive, architecture, and design, known for their strict technical and aesthetic requirements, put any contractor’s management and production capabilities to the test, also calling for significant investments in plant and technology.

Univer 2000 is an excellent example of how to successfully meet these challenges: with over thirty years of experience in the powder and liquid coating industry, this company based in Zané (Vicenza, Italy) constantly strives to improve quality and guarantee high-level aesthetic and functional performance. This commitment translates into a continuous search for innovative solutions and the implementation of advanced technologies to always meet its customers’ needs and maintain high quality standards. The latest investment made by Univer 2000 concerned the installation of a new powder coating plant equipped with a Morris chain conveyor capable of handling large-sized components, supplied by Nuova Catena (Uboldo, Varese, Italy), and an IPS powder centre provided by Wagner (Valmadrera, Lecco, Italy). Innovation and quality research: a perfect combination that describes Univer 2000’s philosophy

Founded in 1991 in Zané, in the province of Vicenza, Univer 2000 has established itself in the industrial coating sector thanks to its constant commitment to innovation, quality, and service excellence. Initially specialising in powder coating alone, the company has grown over the years, expanding its factory in 1996 and adding liquid coating and sandblasting to its portfolio of contract services.

“Our steady growth has been driven by a continuous search for innovative solutions and exclusive finishes to meet our customers’ needs. The quality of our service has also been ensured through the training and specialisation of our personnel and the constant upgrading of our equipment and technological systems,” states Günter Panozzo, the owner of Univer 2000. Today, the company has a factory of over 18,000 m2, one of the most advanced technological facilities in Italy and Europe. It collaborates with the most important Italian interior design brands, as well as with major companies in the civil and

industrial automotive sectors. “Our ability to manage complex and delicate projects, offer rapid responses to customer requirements, and always guarantee the highest level of excellence at every stage of the coating process is ensured not only by our operators’ expertise but also by the state-of-the-art technologies and systems we have chosen to install,” confirms Panozzo. “One of them is the new plant designed and installed by a pool of Italian companies in 2022, which has enabled us to further improve our coating cycle while increasing plant flexibility, productivity, and finishing quality.”

The new powder coating plant

In operation since July 2023, the new powder coating plant has been designed to serve as many sectors as possible and meet the greatest number of customer requirements. It can coat both small and large batches of parts up to 7 metres in length, 2.2 metres in height, and 1.5 metres in width. “In our factory, we process different metal substrates for a wide variety of industries, from automotive to interior design and from agricultural machinery to electrical components. Therefore, we can subject the components to two different pre-

Univer 2000 has over 30 years of experience in the powder and liquid coating sector.

treatment cycles, one specifically developed for aluminium and one for iron. Both pre-treatment cycles, using chemicals supplied by Henkel, consist of the following steps:

 alkaline degreasing;

 rinse with mains water;

 rinse with demineralised water;

 nanotechnology passivation.

“The pre-treatment cycle has been completely revolutionised compared with the past, bringing qualitative improvements, especially in terms of aesthetic results,” illustrates the owner. Afterwards, the components undergo an oven-drying phase and then, once cooled, they reach a coating booth equipped with an IPS powder centre, both supplied by Wagner. The curing and unloading phases end the process.

This new powder coating system is going to further expand Univer 2000’s pool of potential customers, reaching even niche sectors that require extremely high quality standards. “When designing this plant, one of the main challenges we faced was related to part handling. Before it was installed, we processed several large and heavy parts on a static plant. On the other hand, this new in-line system guarantees a very high level of quality that enables us to also serve a new customer segment, especially thanks to its conveyor operating with a continuous flow at a fixed, regular speed and its automatic application booth,” notes Panozzo.

The reliability of Morris-type chains and of Nuova Catena

Nuova Catena supplied the track, bearings, chain, and all supporting structures for the conveyor system integrated into Univer 2000’s new powder coating plant. “During the design phase of the new plant, we assessed several conveyor technologies available on the global market and thoroughly analysed the advantages and disadvantages of each solution. Eventually, we opted again for a Morris chain system, which we had already used before, relying on the expertise and professionalism of Nuova Catena’s team,” states Univer 2000’s owner. “The Morristype chain proved the ideal choice for us thanks to its ease of use, reliability over time, and load capacity. This is especially important for a contractor working on three shifts and handling a wide variety of workpieces to be coated,” explains Panozzo.

“Reduced maintenance requirements are another key benefit of Morristype chains: by lowering the frequency and intensity of maintenance activities, plant downtime is minimised, greater operational continuity is ensured, and maintenance costs are reduced. Finally, Morris chains are known for their reliability. This is particularly significant in an industrial context where continuous plant operation is essential to meet customer demands and maintain efficient production,” says the owner of Univer 2000. “Finally, the versatility of Morris-type chains allows for easy system upgrades, adapting to changing customer requirements in terms of trolley weight and interchangeability.”

Günter Panozzo then emphasises the professionalism of Nuova Catena’s team, highlighting how this supplier’s expertise has enabled

Overview of the conveyor supplied by Nuova Catena and a detail of the Morris-type chain.

© Nuova Catena

FOCUS ON TECHNOLOGY

such a long collaboration to be established and then continued with his company’s decision to rely on it once again for the new plant. The partnership is also going to continue in future as Univer 2000 and Nuova Catena are assessing a project to further upgrade the new system by integrating a more robust chain, capable of transporting larger and heavier components.

“Another important feature of this plant is that, unlike classic systems with only one control unit, it is equipped with two control units, providing even a conveyor with such a considerable length and high flow rate with greater flexibility,” adds Mauro La Guzza, production manager at Nuova Catena.

Paint application takes place in a Wagner booth equipped with a last-generation IPS powder centre

“The IPS powder centre developed by Wagner is an innovative, complete solution ensuring consistently high quality results for longer periods than conventional powder centres. It is a system integrating four key functions, i.e. powder preparation, feeding, and dosing and colour change, into a completely automatic unit, ensuring significant improvements in the powder coating process,” states Marco Spada, powder sales specialist at Wagner.

The IPS system increases productivity, ensures consistently high quality, streamlines handling, and reduces the time needed for colour change operations. “Univer 2000 has over 470 different colours in stock and our new plant is currently performing 10 to

LEADING MANUFACTURER OF PVD COATING SOLUTIONS

An advanced technology that provides distinctive characteristics to substrates: high hardness, strong adhesion, great uniformity and unique aesthetic features.

Specialists in the production of highthroughput industrial PVD equipment: sputtering, CAE, Evaporators, HiPIMS, PECVD, clusters and patented deposition technologies.

Efficient and customizable turnkey solutions. A complete service of conception, production, installation, start-up and support throughout the life cycle of the system.

20 colour changes per day. Therefore, a technology capable of rapid colour change operations is essential to handle customised batches with varying sizes,” notes Panozzo.

The entire system is operated by a user-friendly touch-screen panel that allows for quick learning by all operators, even with frequent shifts. It also ensures consistency of production within the day without the type of operator present affecting its operation. “In addition, process traceability is guaranteed by integrated sensors that automatically record powder consumption for each coated batch, ensuring cost optimisation and constant monitoring that also allows immediate action to be taken in case of faults or other issues,” concludes Maffoni.

The drive for innovation does not stop

“Innovation is the leitmotif of our company’s success. We are constantly investing in new technologies to offer consistently high quality standards. The efficiency of automated industrial coating systems and state-of-the-art machinery and equipment, together with the most advanced control software, not only improves the quality of our processes and services but also reduces delivery times and costs in line with market expectations. This is an advantage for both our customers and us,” confirms Panozzo. The new plant, although only operational since last July, has enabled Univer 2000 to gain a new customer base. The company has also obtained several quality certifications in recent months, including in the automotive field, and is awaiting Qualisteel Coat certification for aluminium coating.

“These achievements are undoubtedly the result of the know-how and expertise of Univer 2000’s employees, but also of our collaboration with reliable, attentive, and dependable suppliers. That is why we are already working not only to upgrade the new plant but also to install further powder coating systems in the short to medium term,” states Panozzo.

The IPS powder center supplied by Wagner.

© Wagner

Specialità chimiche per il trattamento delle superfici

Lavaggio Industriale

Lavaggio di precisione

Sgrassanti interoperazionali

Miscele di tensioattivi

Protezione temporanea

Galvanica Funzionale

Zinco e leghe di zinco

Passivanti e Sigillanti

Rivestimenti resistenti all'usura

Pretrattamento

SurTec Italia Sas di Externa Holding Srl

Via Boito, 251

41019 Soliera (MO)

Tel.: +39 059 8579901

E-Mail: info-it@surtec.com

Italia Web:www.SurTec.com

Pretrattamento metalli alla verniciatura

Processi di conversione esenti

Cromo e Fosfati

Fosfatanti a bassa temperatura

Passivanti per acciaio zincato a caldo

Passivazione conduttiva su Alluminio TCP

Galvanica Decorativa

Rame, Nichel e Cromo

Deposizione su plastica (POP)

Stagno e leghe di Stagno

Pretrattamento

Thermoset: the Future of 3D-Printing

Alessia Venturi ipcm®

By collaborating with its customers and partners, TIGER Coatings aims to drive the adoption of 3D printing as a transformative technology that enables new possibilities for design, manufacturing, and sustainability by providing innovative and sustainable SLS 3D printing thermoset materials that enable customers to bring their ideas to life with greater speed, precision, and cost-effectiveness. In this article we will explore the full potential of TIGER’s TIGITAL® 3D-Set thermoset polymers for additive manufacturing.

TIGITAL® 3D-Set is a thermoset material. Thermosets are polymers which are produced by curing reactive resins. Curing irreversibly transforms them into a hardened, infusible, and insoluble state. Unlike thermoplastics, which can be melted and re-moulded multiple times, thermosets cannot be reprocessed once they have been cured. The curing process of thermoset materials involves a crosslinking reaction, where the polymer chains form a three-dimensional network structure. This crosslinking is typically triggered by heat, chemical catalysts, or radiation. Once cured, the material retains its shape and mechanical properties even at high temperatures, making it suitable for applications requiring dimensional stability and resistance

to heat or flames, chemicals, and electrical conductivity. Common examples of thermoset materials include epoxy resins, phenolic resins, polyurethanes, and unsaturated polyester resins. Thermosets realize the full potential of 3D-printing to achieve the highest industrial standards.

Benefit of thermoset materials

The material is used in Selective Laser Sintering (SLS) and can be processed at a very low printing temperature and a very low laser energy at the same time, which makes it an excellent choice for energy and time efficient production.

© TIGER Coatings

TIGITAL® 3D-Set SLS thermosets enable the end-user to produce functional parts in small batches up to serial production. Thermoset polymers can withstand higher temperatures without losing their structural integrity and exhibit excellent mechanical and chemical properties due to the high cross-linking density of the thermoset polymers.

Application fields

The outstanding properties of thermosets make them suitable for a wide-ranging field of applications in a variety of different industries such as the automotive-, aerospace-, railway-, electrical appliancesand consumer goods industries. The focus is on industries wanting to overcome the typical weaknesses of thermoplastic materials and to take advantages of TIGITAL® 3D-Set, which are:

 higher flame retardancy

 higher mechanical properties under heat

 no dripping behaviour under heat and higher dimensional stability under heat (no melting)

 high electrical insulation

 high chemical resistance.

Selective Laser Sintering: the technology

SLS involves the use of a high-powered laser to selectively fuse powdered materials, typically polymers or metals, layer by layer. The laser heats and melts the powdered material, allowing it to solidify and

form the desired shape. SLS can produce complex geometries and functional parts with good mechanical properties. It is often used for prototyping, low-volume production as spare part production, and in industries like automotive, rail and aerospace.

The new TIGITAL® 3D-Set materials is a cutting-edge technology for Selective Laser Sintering (SLS) with a focus on flame-retardant and UVresistant characteristics of the final object.

TIGER Coatings’ 3D SLS printers utilize the latest advancements in additive manufacturing technology. With high precision and exceptional detail, TIGER can produce complex designs with unparalleled accuracy and part properties. From prototypes to functional parts and even small series production, TIGER’s 3D printing services cover a diverse range of applications. In addition, TIGER provides customization options, allowing the customers to choose surface finishes from its TIGER Drylac® products. Beside the 3D-printing materials, TIGER offers top-of-the-line SLS 3D printing services with its TIGITAL® 3D-Set materials to help the end-user to transform his own concepts into tangible objects. Among these services, there is the TIGITAL® 3D design guide that provides a comprehensive overview of the key principles and best practices for designing 3D printed parts with TIGITAL® 3D-Set materials and to avoid common design pitfalls. In addition, TIGER provides the service of calls with its experts for constant support of the customer during his production process and a large FAQ section in its website that contains the answers on all whats and whys about thermoset materials, 3D printing technology, and much more.

Thermoplastics: linear or branched structure.

TIGITAL® 3D-Set: interconnected cross-linked structure.

© TIGER Coatings

TIGITAL® 3D-Set SLS Main Features

Flame Retardant

These materials1 are designed to resist or slow down the spread of fire, reducing the risk of damage and injury.

They can be used in a wide range of industries such as construction and building, public transportation vehicles and electrical equipment. They work by either inhibiting the combustion process or forming a protective layer that prevents the material from igniting. It is important to choose flame retardant materials that are effective, safe, and environmentally friendly.

TIGITAL® 3D-Set materials are certified to the highest demand industrial standards as for example DIN EN 45545. The material prevents the parts not only from burning but as well no dripping and a low smoke density. With this comes a very process and environmentally friendly behaviour of a 70% reuse factor.

UV Resistant

These materials are designed to withstand the damaging effects of ultraviolet (UV) radiation from the sun. They are commonly used in outdoor applications, such as in building materials or components for vehicles, where they are exposed to sunlight and other environmental factors over time. UV radiation can cause materials to fade, crack, or degrade, reducing their effectiveness and lifespan. TIGITAL® SLS 3D printing materials are formulated to resist these effects, preserving their appearance, strength, and durability over time.

Rigid

Rigidity is a measure of a material’s ability to resist deformation or bending under applied stress. Materials that are highly rigid are resistant to bending, twisting, or compression, and are typically used in applications where stability and structural integrity are important, such as in machine parts and structural components. Rigidity is often influenced by factors such as the material’s density, composition, and shape, as well as the type and amount of stress applied. In general, materials with higher rigidity are stronger, more durable, and better able to withstand harsh environmental conditions.

1 https://www.tigital-3dset.com/materials

From the top:

Properties of TIGITAL® 3D-Set.

TIGITAL® 3D-Set – printed parts.

TIGITAL® 3D-Set Materials Overview

PPP-Series

TIGITAL® 3D-Set Series PPP (Premium Performance Polymers) stand out due to excellent flame-retardant properties. They fulfil international standards according to UL94-V0, DIN EN 45545 R22/23 - HL1, 2 & 3, UN ECE R118 for a variety of applications in public transportation.

Benefits:

 Superior flame retardancy

 Usable on all open SLS printing machines

 User friendly printing parameters

 Very high re-use rate (>70%)

 High stiffness and dimensional accuracy.

TPP-Series

TIGITAL® 3D-Set Series TPP (Top Performance Polymers) stand out due to excellent UV-resistance and high stiffness. They are printable at vastly lower printing temperatures than standard printing materials. Quality

TPP materials have great electrical insulating properties and very low moisture uptake. They are ideal for application in the Transportation, Outdoor, Electronics, Aerospace and Defence industries.

Benefits:

 Usable on all open SLS printing machines

 User friendly printing parameters

 Very high re-use rate (>70%)

 High UV-stability

 Minimal moisture uptake (<1%).

HPP-Series

TIGITAL® 3D-Set Series HPP (High Performance Polymers) show very accurate and excellent dimension stability. They have very low shrinkage even at very high wall thicknesses. It exhibits superior rigidity and is easy to print with vastly lower printing temperatures than standard printing materials on all SLS devices. Typical applications are in the Bus and Rail, Automotive, Aerospace and Defense, Prototyping industries.

Benefits:

 High reuse-rate

 Vastly lower printing temperatures

 Ability to print high wall thickness (>10mm)

 Superior rigidity

 Minimal moisture uptake (<1%).

Recyclability

PV3357

Typically, TIGITAL® 3D-Set thermoset polymers show a re-use rate of approximately 70% to 30% with new powder. That means after sieving and recycling the powder you can use 70% again without any pre-processing. A

Flame retardancy for interior of mass transportation cars as buses, Annex 6,7,8

FMVSS 302, burning speed, JIS D1201, ISO3795

Burning speed horizontal Dripping behavior

Burning speed vertical

Typical mechanical properties of TIGITAL® 3D-Set materials.

The Household Appliance Industry Pioneers New Pre-Treatment Solutions and Tests a New Nanotechnology Passivating Agent

Monica Fumagalli ipcm®

The household appliance industry in Italy’s Marche region confirms itself as the cradle of the most innovative pre-treatment solutions, as BS Service Group S.r.l. trials a new nanotechnology passivating agent from DN Chemicals to increase the salt spray performance of its cooker hoods.

BS Service Group S.r.l. specialises in the production of cooker hoods and hobs both for third parties and under its own brand. Pictured is the company’s showroom.

Some of the most significant technological innovations in the pretreatment sector were tested for the first time by companies in the white goods sector and, in particular, in Italy’s Marche region, a key district for this industry, which is currently recovering after the contraction that followed the boom unexpectedly witnessed during the Covid period. Lorenzo Biagini, the managing director of BS Service Group S.r.l. (Fabriano, Ancona), a company specialising in the production of cooker hoods and hobs both for third parties and under its own brand, confirms: “The pandemic gave our industry a boost because many people, forced to stay at home, were prompted to focus on the quality of their home environments and invest in improving not only their comfort but also their aesthetics. As well as other small appliances, cooker hoods fit perfectly into the category of those designer products that make the kitchen a favourite place in every home and, therefore, require increasing attention to their finishing quality.

The development of increasingly highperformance technologies for coating household appliances goes hand in hand with the widespread implementation of a 5-stage pre-treatment process: alkaline degreasing, 2 rinses with mains water, 1 rinse with demineralised water, and the application of a nanotechnology passivating agent, possibly by atomisation. Despite the optimum level already achieved, research and development of new chemicals to further improve performance never stop, also in the wake of increasingly stringent specifications relating to salt spray test results. The laboratories of DN Chemicals, a Milan-based company of the Dollmar Group specialising in the formulation of chemical products for pre-treatment cycles, are among the most advanced in this field. The company’s latest patented product, Dollcoat RS103, has more than double salt spray resistance values, and its further development, engineered in collaboration with a first-class

The component loading area in the paint shop.

The 5-stage pre-treatment tunnel.

partner and for which an international patent request will be filed by the end of 2024, will further increase its degree of performance on all metals.

Investing: the non-conformist choice of BS Service Group S.r.l. to face the crisis in the sector

Founded in 2001 by the Biagini family, BS Service Group S.r.l. has continued to invest in new plants and test cutting-edge products even in the most challenging period after the pandemic. “We started our business as a manufacturer of components for the major household appliance producers in our area, but we soon decided to differentiate ourselves from the other companies in this supply chain by conceiving our own dedicated product line, which was highly appreciated by the market. In a critical period like the current one, we have managed to confirm ourselves as a benchmark supplier for both our longstanding partners and new OEM customers, thanks to the finishing quality of our stainless steel and powder-coated products, which are now becoming predominant, especially in our contracting line of business.”

Surface preparation before coating is one of the most critical steps to ensure the high aesthetic and functional performance of cooker hoods. “Complying with our customers’ strict specifications means keeping the importance of this process phase clear in mind to ensure high corrosion protection and excellent paint adhesion. This is why, aiming to further improve the quality of our products, we were among the first companies to test the new nanotechnology passivating agent developed by DN Chemicals.”

BS Service Group S.r.l.’s cooker hoods and hobs:

Italian style and design

The company has been producing cooker hoods since 2007. “Initially, it was our secondary activity, but as the years went by

Components entering the pre-treatment tunnel and a component pre-treated with DN Chemicals products.

The outside of the Siver-Nordson powder coating booth with dense phase technology.

and thanks to continuous investment in R&D and sales, it became our core business as early as 2011, although we also maintained our contracting line of business,” explains Biagini. In 2018, the company acquired the brand and main assets of Tecnowind S.p.a., which had been operating in the household appliance sector for over thirty years and was Europe’s leading independent manufacturer of domestic cooker hoods. This initiated a rapid growth that would not otherwise have been possible in such a short time. “It was an important investment, which allowed us to cope with the Covid period with a solid structure and know-how. In 2020-21, we then invested almost 3.5 million Euros in new equipment, including for our paint shop.”

Now, BS Service Group S.r.l.’s development strategy is focused on diversification, with the Tecnowind brands for mid- to low-end products with an excellent quality/price ratio, intended for a general customer base and OEM customers, and the Uniqa brand for customers looking for exclusive, non-standard solutions. “Quality, design, style, and innovation are our core values, inspiring the creation of new products that become an expression of high quality combined with Italian style and design.”

The production structure

BS Service Group S.r.l.’s 4 factory halls in Fabriano occupy a covered area of 22,000 m2, accommodating 10 assembly lines for cooker hoods and hobs. “Our production internalisation process led us to open a plant in Arad (Timisoara, Romania), which covers an area of 9,600 m2 and guarantees the same Italian quality and production standards,” indicates Biagini. “At the same time, all research and development, quality-related, and customer care activities are centralised in Italy to always present ourselves as an innovative company rooted in the Marche region. Our strong focus on innovation is also proven by the numerous international patents we have filed for new technologies related to both hoods and hobs, thanks to which we are also reaching far-flung markets such as the US and Asia, where we are trying to establish ourselves more and more firmly despite fierce local competition.”

A production flow with a dual, industrial and artisanal soul

The production process is very streamlined and starts with receiving coils or sheets in 304, 316, and 430 stainless steel or carbon steel, which are processed with mechanical and hydraulic presses in the cold forming department. After sheet metal cutting, carried out with 2 punching machines and 3 fibre laser machining centres, the parts reach the bending department, consisting of 12 manual machines, 3 robotic islands, and 2 automatic panelling lines. “This is the most

industrialised part of our production flow,” says BS Service Group S.r.l..’s plant manager, Manuel Silvi. “On the other hand, the finishing department’s activities are more artisanal, in line with the handcraft traditions of our region. Indeed, one of our company’s strength is the ability to offer a finishing quality above average market standards on both uncoated stainless steel components and powder-coated parts. “The coating process takes place in one of the plants acquired from Tecnowind, which will soon be the subject of a replacement project in the context of a broader development plan for a new production facility. Together with the staff of DN Chemicals, in anticipation of such production expansion, we are now optimising the pre-treatment process prior to the powder coating step and the products required for it.”

When innovation means experimenting with new products

With DN Chemicals, BS Service Group S.r.l. has developed a pretreatment cycle that has enabled it to move from salt spray resistance values of 300 hours to the current 530 hours, with a notch detachment well below the 3 mm required by the specifications. “This company applies the cycle now widely established in the household appliance sector, which we have optimised with higher-performance products

and application technologies,” illustrates André Bernasconi, the general manager of DN Chemicals. “Today, BS Service Group S.r.l. is among the first companies to use the new patented passivating agent from our Dollcoat line, called RS103, which is the evolution of our long-established standard products SA115 and SA118. It is also closely following the development of another passivating product called temporarily GP107, which is the evolution of Dollcoat RS103 in terms of both formulation, which is more complex, and performance.

“Indeed, it is no longer only about synthetic oligomers obtained from silanes: we have created a conversion nanoprimer that is applied in the submicron range (between 50 and 80 nanometres). The result of close cooperation with one of the most important international industrial Groups in the research and development of innovative chemical solutions, this new product was tested on CRS, rolled aluminium, extruded aluminium, and galvanised steel coated with polyester powder alone. It easily reached classes C3H (504 hours in salt spray) or CH4 with almost zero penetration in a strict test performed by blowing with high pressure at 9 bar for 5 minutes. Our ultimate goal is to reach class C5M with one coat.

“Finally, we are assessing the feasibility of replacing the alkaline degreaser with a nanoceramic product that is perfectly compatible and

Manual retouching after coating. White is one of the currently most popular colours in the household appliance sector.

capable of acting in synergy with both the product that BS Service Group S.r.l. is using at the moment, Dollcoat RS103, and the new product that will be patented by the end of 2024.”

Passivating agent atomisation

These passivating agents’ properties, combined with atomisation technology, have made this type of pre-treatment cycle indispensable for this sector. “The atomisation module,” emphasises Bernasconi, “has brought significant benefits in the white goods industry over the past two decades – the first module was installed in this very district in 2008. This application process guarantees consistent quality because the product used is always fresh. Currently, it is disposed of, but solutions are already available to enable it to be recirculated and reduce consumption.

“An important innovation is that the performance of the new Dollcoat family of passivating agents is independent of the type of application method: they can also be applied by dipping or spraying, by recirculation in tanks, and with standard nozzles. Of course, if combined with the effectiveness of atomisation, they offer an added value to the final quality of the pre-treatment process.”

After drying, the parts are taken to the automatic, dense phase coating booth applying epoxy and polyester powders, which includes a manual post-finishing station supplied by Siver-Nordson, then to the curing oven and finally to quality control.

Continuous research

“For some years now, finishing has been the main focus of our industry,” concludes Biagini. “For BS Service Group S.r.l., it is the added value with which we differentiate ourselves from our competitors and consolidate our presence in a fiercely competitive market that is navigating a bumpy period. At the Salone del Mobile to be held in Milan in April, in the Eurocucina area, we will present many new products, with new finishes and materials. Thanks to continuous research and the high quality and performance degree of our products, we put our customers in the position of not needing to look for alternatives. And, despite the less than rosy situation, we already have very important projects in the pipeline, such as the new factory and the new paint shop. Experimenting with new pre-treatment solutions is instrumental to this investment, and our collaboration with DN Chemicals is very stimulating in this respect: we have recently started testing a new product and are already planning to use its future evolution. It is precisely thanks to the desire to keep innovating of companies like DN Chemicals and BS Service Group S.r.l. that this industry has become a pioneer in developing pre-treatment solutions and will certainly remain so for a long time to come.”

From right to left: Giacomo Corinaldesi, Mara Pege, and André Bernasconi from DN Chemicals with Manuel Silvi and BS Service Group S.r.l.’s production team.

Another picture of the showroom with a cooker hood and some induction hobs made by BS Service Group S.r.l.

© ipcm

© ipcm

Technical characteristics of DOLLCOAT RS 103

DOLLCOAT RS 103 (patent pending) is the first product in a new family of surface conversion agents for highperformance processes with minimum C3H corrosion class.

It has unique characteristics compared to currently available conversion products and gives the pre-treated surfaces very high protection and corrosion resistance properties, whatever the nature of the coatings used.

DOLLCOAT RS 103’s main features include as follows:

 multi-metal no-rinse product to be used at room temperature;

 applicable with atomisation modules through traditional recirculation or immersion nozzles;

 no sludge formation;

 compatible with any powder or liquid coating;

 excellent pre-treatment before cataphoresis;

 does not cause any aesthetic defects, even when used at high concentrations.

Table 1 compares some CRS panels pre-treated in B.S. Service’s plant with the old process (amorphous phosphating) and the new one. The electrochemical impedance spectroscopy (EIS) analysis shows an almost 4 times higher polarisation resistance value (Rp). The ACET analysis on similar CRS panels coated with polyester powder (60-80 microns) shows a clearly superior degree of pre-treatment quality, as confirmed by the salt spray tests, whose results consistently reach 504 hours with penetration of less than 1 mm after compressed-air blowing at 9 bar for 5 minutes (Table 2). The Bode diagrams represent the different behaviours of the two pre-treatment cycles and the significant improvement achieved using DOLLCOAT RS 103 (Figs. 1 and 2).

TABLE 1

DOLLCOAT RS 103

PHOSPHO-DEGREASER

The

A PVD Treatment Hub: Kenosistec’s Innovative Project

From an interview with Mauro Margherita, CEO of Kenosistec Binasco, Milan - Italy

Kenosistec is opening a new state-of-the-art Innovation Hub and Coating Centre to offer contract PVD coating, process development, and staff training services.

Technological evolutions in the field of surface coating have resulted in increasingly advanced, versatile, and environmentally sustainable processes ensuring excellent aesthetic and functional performance. These include Physical Vapour Deposition (PVD), a process for the vacuum application of thin-film coatings, in which solid-state material is brought into the vapour phase and allowed to deposit on the substrate, where it condenses. This forms a film with various functional characteristics, such as resistance to abrasion and thermal shock, and exceptional aesthetic properties. In a market where sustainability is a key requirement for many companies, PVD stands out as a green technology offering numerous advantages in terms of performance and reliability. “Unlike other deposition coating processes, which may generate toxic waste or require the use of polluting chemicals, PVD releases no residues at the end of the process,” confirms Mauro Margherita, the CEO of Kenosistec (Binasco, Milan, Italy), a company

specialising in the development of engineering solutions for PVD application since 2005.

About Kenosistec and its target markets

Belonging to the Angelantoni Industrie Group, Kenosistec was founded in 2005 through the merger of Kenotec and Sistec, two companies specialising in sputtering and PECVD, respectively, and the acquisition of Microcoat, specialising in cathode arc technology. Having established itself early on as a benchmark manufacturer and a multi-technology hub in the European PVD industry, it has been steadily growing in terms of experience, reliability, and production capacity. With a team of 22 employees, Kenosistec produces customised PVD coating systems for various sectors, including eyewear, lenses and mirrors for telescopic systems, photovoltaic panels, and electronics.

“In recent years, we have noticed that more and more industries are

approaching the PVD technology, which they appreciate for its ability to give different functional and aesthetic properties to the treated surfaces while meeting sustainability requirements. In particular, the bathroom accessory and jewellery sectors are expanding their range of products treated with this process. The same applies to the automotive industry, especially for interior and exterior chrome parts. Such increased interest from markets that were previously unfamiliar with our technology is the reason why, in addition to continuing to supply our main target industries, we are leveraging our solid know-how to balance deposition process and performance-related requirements to meet the needs of any company that is considering PVD as an alternative to traditional technologies.

One of the major difficulties in implementing PVD technology in the automotive industry is related to the strict tests to which components are subjected. “Research and development of new solutions will soon enable PVD to meet these requirements as well. After all, this coating process has many undeniable advantages, including the possibility of being applied to any type of plastic material, as opposed to electrodeposition, which can only be carried out on acrylonitrile butadiene styrene (ABS) and polycarbonate/acrylonitrile butadiene styrene (PC-ABS) plastics. This peculiarity could even pave the way for

replacing some metal car components with lighter plastic ones. For example, if PVD had been adopted earlier and a number of automotive parts currently made of metal had been manufactured with plastic, it is likely that the range of today’s electric batteries would not have been 400-500 km but would already have exceeded 700-800 km. This would have guaranteed a convergence point between the batteries’ capacity and range requirements, significantly impacting the efficiency and emissions of cars.”

With the aim of expanding the huge application potential of PVD treatments and developing solutions better suited to its target sectors, Kenosistec has thus decided to move to new premises and establish a genuine “PVD Hub”.

The state-of-the-art Coating Centre and the new Innovation Hub

“This year, we moved to a new building in Casarile (Milan), transitioning from an area of 700 m2, of which 150 m2 were devoted to office space, to premises that cover almost 3000 m2 and are also significantly higher. Of the total area, 1200 m2 will be allocated to the Coating Centre and Innovation Hub, whereas 600 m2 will be used for offices. The new facility will enable us to expand our equipment fleet, enhance

Kenosistec has specialized since 2005 in the development of engineering solutions for the application of PVD.

© Kenosistec

our manufacturing capabilities, and further improve our expertise in producing PVD systems.”

The new Coating Centre will initially focus on two types of substrates, metals and plastics, and will later embrace other materials, such as glass. “The Centre is also a service technology hub, offering both contract PVD treatments and assistance in developing new processes. It is conceived to help potential customers explore any PVD processes still unknown to them, analysing their characteristics and advantages and offering innovative solutions, such as selecting new colours or adopting new application technologies for the future. The Innovation Hub will also have the critical role of training the staff of customers that choose to insource this operation. To ensure such a level of support, we put our specialised team, our plants, and our extensive experience to our customers’ disposal, helping them to effectively manage their production and maintenance operations as well as supervise critical process parameters during the transfer stage.”

Physical vapour deposition must take place in a controlled environment with precise temperature and humidity conditions. Therefore, the personnel managing the process must become familiar with several required practices. “Regular cleaning of the machine, both during and after certain process stages, is essential because metal is deposited not only on the treated substrates but also on the plant’s internal screens, with the risk of contaminating the workpieces. Therefore, it is crucial to understand that periodic cleaning of the machine is necessary to

avoid contamination and achieve optimal results. The maintenance and management of the machinery and the optimal management of the clean room processes, must become standard practices.”

The Innovation Hub will also be a centre of technological innovation for developing and implementing new technologies and methods. “This means not only devising cutting-edge processes and solutions but also combining different technologies to achieve different results, adaptable to the specific needs of each target sector.”

Future projects

The new Centre will not only be equipped with PVD deposition systems but also with a coating plant. “I believe that the best innovations result from synergy among different technologies: there are cases where one is preferable to another, but there are also cases where the integration of different coating solutions brings the best results. We also aim at collaborating with new industrial partners to manage their machines and identify optimal changes, developing processes that best meet the needs and demands of end customers.”

Kenosistec’s new PVD Hub will be completed in two distinct phases. “The first phase will be completed by the end of 2024 and will include the installation of PVD metal deposition equipment, cleaning plants, and final testing devices. The second phase will be completed by the end of 2025 and will include the installation of the coating system. We plan to complete this Centre within two years. The number of people

© Kenosistec

A step of the vapor phase deposition process.

who will work at the Innovation Hub and Coating Centre will depend on the final size of the facility, but we expect to hire no less than 30 employees. At the same time, we are also supporting the creation of another technology hub designed by one of our partners, focusing on green chrome plating of plastics. We are active on several fronts because, in our opinion, diversifying our activities and market presence as much as possible is of the essence.”

Institutional collaborations

“For many years, we have been collaborating with different universities, laboratories, and research centres, with which we have also developed some PVD-related patents. We welcome PhD students for practical internships in our laboratory, where they can test new deposition processes on our machines, in line with their academic programmes. Our Coating Centre provides the ideal environment to test these processes, allowing different institutes to test the current technological capabilities of the market. In addition, for the past seven years, we have been conducting a research study to develop a new PVD process capable of replacing hexavalent and trivalent chromium electrodeposition, which is still prevalent in the automotive industry. When this study is successful, we will be able to involve many Italian and European institutions, demonstrating our ability to offer solutions on a global scale and develop environmentally friendly technologies.”

© KARL BUBENHOFER AG / Photo by Lukas Roth Cologne

Mauro Margherita, CEO of Kenosistec.

© Kenosistec

Very Good Signs for PaintExpo 2024: World Premieres as well as Advancements in Sustainability and Efficiency in the Spotlight

Preparations for the ninth edition of PaintExpo are in the final stages, and the signs for the world’s leading trade fair for industrial coating technology from 9 to 12 April 2024 in Karlsruhe are very good: around 430 exhibitors from Germany and abroad are expected. The globally unique concentration of companies from the coating technology sector ensures a strong attraction for users from contract coating companies, in-house coating services and all players in the coating technology sector. The trade fair is the industry’s most important international platform and visitors will have the opportunity to experience numerous world premieres and find out about technological developments in sustainable and energy-efficient coating processes for the future.

Around 430 exhibitors - including the who’s who of the coating technology industry with its market and technology leaderswill fill three exhibition halls for four days at PaintExpo 2024 in Karlsruhe. The exhibitors at the world’s leading trade fair for industrial coating technology will cover the full range of products and services across the entire supply chain.

Over 40 per cent of exhibitors are international. Most companies from outside Germany are from Italy, Turkey and Switzerland. However, the trade fair attracts exhibitors from far beyond Europe and companies from countries such as the US, India and China are also represented. “The signs for PaintExpo 2024 are very good - despite the current challenging conditions. We can already sense tremendous excitement

© Leipziger Messe GmbH/Tom Schulz

building for PaintExpo among exhibitors and visitors alike. The world’s leading trade fair for industrial coating technology will once again offer the industry the perfect venue for holding in-depth technical discussions, planning concrete projects and making investment decisions. Visitors can also expect to experience a wealth of innovative product highlights at the exhibition stands,” says Markus Geisenberger, Chief Executive Officer of Leipziger Messe.

Smart solutions in coating processes

One of the companies showcasing smart solutions at PaintExpo in Karlsruhe is WAGNER, exhibiting manual and automatic spray guns with highly effective coating performance and low material usage. WAGNER’s new high-speed rotating atomisers for solvents and water-based coatings play a major role in implementing fully automated wet-coating systems and robotic solutions. The company has also made its pumps for wet coating significantly easier to flush. The Cobra high-press double diaphragm pump has been optimised to significantly reduce the amount of flushing agent and therefore also the amount of time needed for changing colours.

When it comes to powder coating, WAGNER will be emphasising efficiency and automation. In manual coating, the focus will be on how the use of assistance functions can help even inexperienced staff carry out coating tasks in accordance with requirements. Visitors to the company’s stand can also learn how to master the transition to fully automated coating processes using axis and robotic technologies.

Numerous world premieres in electrostatic powder-coating technology

At the Gema Switzerland stand, several products are being presented for the first time. The Swiss company’s innovations include a new series of automatic spray guns with models for organic and enamel powders as well as robotic applications. Gema will also be showcasing new application pumps that combine an advanced powder-loading technology with the second generation of SIT dense-phase powder delivery technology in a single unit.

Furthermore, Gema is presenting a fully automated powder management system featuring an intuitive user interface for switching colours efficiently. The system also comes available with two powder hoppers, allowing users to apply two different colours one after another in rapid succession.

Innovative technologies for sustainability and efficiency

The range of products and services on display clearly shows the extent to which exhibitor awareness of the significance of sustainability and efficiency in the coating technology and production industries is increasing. In line with this trend, POMA Systems is introducing its i-GLUE automated adhesive application system. By dosing and applying

© Leipziger Messe GmbH/Tom Schulz

adhesives precisely, this system not only makes more efficient use of materials but also optimises the quality of the joints.

The exhibitor is also focusing on predictive maintenance as a way of minimising downtimes and maximising efficiency. Leveraging sensor systems and data analysis makes it possible to continuously monitor machines so that problems can be identified and fixed early on before the equipment fails.

Experience four different themes up close at one exhibition stand

Axalta Coating Systems is likewise focusing its trade fair appearance on a series of products geared towards sustainability. At the company’s stand, four topics will be highlighted. As part of its “Sustainability, Together” campaign, Axalta is presenting its latest sustainable coating solutions with a particular emphasis on biobased powder coatings as an environmentally friendly alternative. With a view to electromobility, Axalta will also be showcasing coatings for battery applications, including dielectric and thermally insulating coatings.

Corrosion protection is also a major theme. Multiple product lines including thermoplastics, thermosetting primers, industrial liquid solutions and their AquaEC electrocoat products mean that customers can select the right product for their needs. Visitors to the stand can also look forward to a ColourDesign area displaying the full spectrum of colours available from Axalta.

Comprehensive exhibitor directory, tickets only available for purchase online

A number of exciting exhibitor innovations can also be found in the digital exhibitor and product directory on the PaintExpo website. In addition, visitors can plan their time at the trade fair in advance and on-site by using an interactive map of the halls, creating bookmarks lists and browsing the special interest topics on sustainability, careers and live experiences.

At the ticket shop on the event website, visitors can purchase tickets for the trade fair and redeem invitations from exhibitors. The online ticket gives visitors fast and easy access to the PaintExpo in Karlsruhe.

© Leipziger Messe GmbH/Tom Schulz

Expert in high viscosity dispensing

Expert in rotary bell atomizer

Expert in powder coating

Expert in paint application

FOCUS ON TECHNOLOGY

SPECIAL ISSUE - PaintExpo

Coating of Machines for Ice and Snow Removal at Bucher Municipal: Corrosion Resistance is the Key!

Alessia Venturi, ipcm®

A mixed coating system with a zinc rich liquid base coat and a powder top coat, a mechanical pre-treatment process for controlled surface roughness, and a flexible plant designed by Eurotherm (Volpiano, Turin, Italy) in cooperation with Giletta’s technicians and the company’s advisor Fabio Balbo, owner of Tecniver: these are the technical choices made by Giletta Spa, a company of the Bucher Municipal Group, to meet two fundamental requirements for the production of its snow and ice removal machines: the qualitative one of corrosion resistance exceeding 2000 hours in salt spray tests and the operational one of a maximum of three weeks from order receipt to delivery of the finished machine.

100% fully electric heavy-duty professional spreader from Bucher Municipal in action for ice removal.

Snow emergency: these two words are enough to conjure up imagery of snowploughs, salt spreaders, and salt and saline solutions sprayers, essential to restoring the road system in the event of a snowfall. The management of such a situation should be carefully planned in advance by municipalities and road and motorway operators so that it does not turn into a nightmare for users and citizens. We have gone from more frequent medium/ low intensity snowfalls to infrequent but high intensity precipitations (similar to snow storms): therefore, the adoption of a sound winter emergency management plan is essential for the authorities in charge. This includes the necessary instrumentation for acquiring meteorological data and, in urban areas, along road and rail routes, and at airports, a fleet of machines for ice and snow removal consisting of vehicles of different types and sizes.

“We live in an era where precipitations are less and less frequent but also more intense and destructive. As a result, the suppliers of snow and ice management equipment must be highly responsive and able to deliver their machines within the short time frames customers require. We no longer operate in a market characterised by long-term planning. Today, we have to meet short-term demands and even be able to cope with unexpected orders for last-minute deliveries,” explains Fabrizio Abello, the plant manager of Bucher Municipal, a Group owning several long-established snow management and ice removal equipment brands, including Giletta Spa (Revello, Cuneo, Italy).

“We are the Group’s competence centre for the production of machines for winter road maintenance. The main characteristic of our production is its seasonality, with a peak from September to January. In addition, it is highly tied to the tenders of municipalities, public and private organisations managing roads, motorways, and transport infrastructure, which often require delivery times of three/ four weeks from order receipt to shipping.

The metallic belt extraction system borrowed by Giletta from the agricultural machinery field is the key factor that determined the company’s success in this sector.

Front view of the Eurotherm coating plant installed at Giletta’s premises.

From left to right: the cell cleaning tunnel, the shot blasting machine for large-sized parts, and the loading station.

© ipcm © ipcm

Great responsiveness, plant flexibility, automation, and digitalisation are the factors that allow Giletta to serve this market with a just-in-time approach, with an attitude for managing sudden changes in planning and with a very short time-to-market.”

In its history, Giletta has made major investments to transform its production department into a perfectly efficient mechanism, the latest of which was the installation of a modern 4.0 coating plant designed and built by Eurotherm (Volpiano, Turin, Italy), a benchmark plant engineering company in the heavy vehicle sector.

Production organisation: a perfect mechanism

“Giletta Spa has always been the most innovative company in the field of snow removal and road deicing,” says Fabrizio Abello. “We invest over 2 million Euros a year in research and development, even in recent years when snow is falling less and less. We take much pride in this approach, enabling us to have such technological systems available that our machines are always one step ahead of those of our competitors. The Revello site’s core activity is the manufacture of salt spreaders and sprayers, but we also produce snowploughs, snow blowers, airport runway deicing equipment, and special equipment for various types of vehicles. Finally, we import the sweepers produced by our colleagues at Bucher Municipal. All the electronic controls of our machines are developed by a subsidiary, SAET srl – leader in custom electronics - to ensure the Group keeps its know-how in-house.

From the top:

Parts in the loading station proceeding to the automatic shot blasting machine.

A container inside the Carlo Banfi automatic shot blasting machine.

The OMSG automatic cluster shot blasting machine with two hoists.

In recent years, due to the increasing demand for flexibility, customisation, and faster delivery times, a lot of work has been done to re-design our products with the aim of offering more and more modular machines. At the same time, we also reorganised our production flow. In 2019, we added a sheet metal machining department to our Revello production site, equipped with a fibre laser cutting machine, an automatic storage unit, and 3 last generation bending machines, in order to be independent and speed up our production cycle. We also increased our number of welding robots to 4; in 2024, the welding department will be further expanded. Of course, we also work with external suppliers because reaching such a high metalwork production capacity to supply all our product lines is nearly impossible. Our main strength is the ability to manage our workload to always meet delivery dates. Coating is the only production step we perform exclusively in-house for all our components: Giletta has always coated its parts in-house to retain total control over the process and meet the high quality standards required by machines intended for contact with aggressive agents.”

A mixed, two-layer coating system for increased corrosion resistance

“For Giletta, coating has an aesthetic function focused on performances. Our first requirement is high corrosion resistance, over 2000 hours in salt spray tests, and this has affected all the technical and plant engineering choices relating to our coating process. Aesthetics are secondary,” illustrates Fabrizio Abello. “Before installing our new Eurotherm coating line, we used an automatic chain machine with the mechanical pre-treatment stage taking place in an automatic shot blasting machine for large parts from Carlo Banfi (now an OMSG Group’s company, Ed.), followed by a two-layer powder coating cycle applying an epoxy primer and a polyester top coat and a curing stage after the application of each layer. What motivated the investment in a new coating plant was a change in our finishing system, as we switched from a powder-onpowder to a mixed system with a liquid base coat and a powder top coat. We carried out numerous tests before moving on to this new system and we have obtained excellent results so far.

“The main reason why we decided to replace the powder base coat with a liquid one is that, although the former is very easy to apply and needs less trained operators to achieve good aesthetic results, it has less penetration than the latter, especially on components like ours that include many welded castings or complex-shaped surfaces. Secondly, with a view to increasing the corrosion resistance of our coated parts, we believe that the chemical formulation of a liquid product is more flexible and adaptable. Finally, opting for a mixed system has also made our

production more sustainable, as we have eliminated a curing stage, thus lowering energy consumption and costs. Not to mention increased production speed: the liquid primer developed for Giletta by Sircolor (La Morra, Cuneo, Italy) has a water-based epoxy matrix with metallic zinc, only requiring a 10-minute flash-off phase at room temperature with forced ventilation before being overcoatable with the polyester powder top coat supplied by Pulverit (Milan, Italy). This translates into significant operational, economic, and time savings, especially considering that heating the high mass of the parts we coat on this line to 180-190°C requires considerable expenditure of energy.

“On the other hand, we have maintained the use of a powder top coat because it gives the surfaces a more robust, harder, and damage-resistant coating with better aesthetics, even if applied by less experienced operators. Today, with this coating cycle combined with mechanical shot blasting pre-treatment to clean the parts and reach a surface roughness of 30 microns for greater paint adhesion, we effortlessly exceed 2000 hours of salt spray resistance.”

Features of the new coating plant

Giletta turned to Eurotherm to develop a plant suitable for this new finishing cycle. “This project goes back a long way: we started with a market survey on possible suppliers in 2018-2019. Initially, we were thinking of an automatic in-line plant. However, the Covid pandemic slowed the project down, and when we took it up again, we realised that such a system would be difficult to manage, since our production is seasonal and alternates between peaks and substantial slowdown. Giving it the right size to meet our high-season needs would have meant leaving it almost idle in the low season. This is why the concept that convinced us most was the box design presented by Eurotherm. In the same period, we also began assessing a possible switch to a mixed coating system.”

“We provided Giletta with a manual coating system to replace its old step-by-step in-line plant,” says Rocco D’Aloia, project manager at Eurotherm. “Among other requirements, the new machine had to double the previous production rate while increasing management flexibility and energy savings. We achieved all these goals: the company moved from

Powder top coat application in one of the two dedicated booths.

© ipcm

Liquid base coat application in one of the two vertical-flow pressurised booths.

© ipcm

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.

Pulverit S.p.A. Italia

Via Carlo Reale, 15/4

20157 Milano-Italy

Tel +39 02 376751

email: pulverit@pulverit.it

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.

Pulverit Polska Sp. z o.o.

ul. Strefowa 16

43100 Tychy-Polska

Tel. +48 32 329 14 11

email: biuro@pulverit.pl

Pulverit Deutschland GmbH

Im Wert 3

73563 Mögglingen- Deutschland

telef.: +49 7174 7193000

email: info@pulverit.de

www.pulverit.com

Pulverit Iberia s.l.u.

c/ Caravis, 28, 1º 3ª

50197 Zaragoza

Tel. +34 607163259

email: iberia@pulverit.it

working on two shifts, including Saturdays, to one shift for processing the same quantity of coated parts, with significant gas and electricity savings compared with the old in-line plant. Apart from some components that are pickled, most of Giletta’s production is coated. The company prefers mechanical pre-treatment: all small to medium-sized parts are shot blasted in a cluster machine, except for the containers, treated in the already existing Carlo Banfi shot blaster, which we revamped in terms of both software and mechanical aspects to lengthen it and connect it to the blowing station shared by the two systems, which can work simultaneously. The automatic cell pre-treatment tunnel is used to clean all parts, such as hydraulic cylinders and gearboxes, that cannot be sandblasted. Although integrated with the rest of the line, the cleaning cell is now used for treating other components that are coated off-line.”

Giletta’s current production cycle is as follows:

1. Sandblasting with metal grit or 3-stage pre-treatment (ready for 5)

2. Liquid zinc coating followed by booth drying at 25 °C

3. Powder coating

4. Curing.

The machines installed by Eurotherm were as follows:

 1 3-stage cleaning cell

 2 vertical-flow pressurised liquid coating booths with an air handling unit for heating and drying at 70 °C, with a size of 4x9 m

 2 vertical-flow powder coating booths, of which one is equipped with a cyclone for colour recovery, with a size of 4x9 m

 3 curing ovens with temperatures up to 250 °C

 3 semi-automatic transfer carts

 2 lifting stations for loading/unloading

 overhead conveyor

 1 climate-controlled paint storage module

 1 existing Carlo Banfi in-line sandblasting machine, revamped with 4.0 digital software and connected to the manual blowing station

 1 OMSG cluster shot blasting machine with maximum workpiece dimensions of ø 2500 x 3000 H mm.

The latter machine has a Y-shaped handling system with two hoists, each with a load capacity of 2000 kg. When one hoist is inside the machine for the shot blasting phase, the other is outside for loading/unloading parts, thus reducing idle times of the machine. The machine has four 15-kW turbines with special alloy components in K110. It meets the Industry 4.0 parameters and is equipped with an inverter to adjust the kinetic energy of the abrasive projected by the centrifugal turbines, thus avoiding possible damage and deformation of thin metal parts.

The maximum hanging capacity of the coating system is 2200 kg, with a

© ipcm © ipcm

The three curing ovens.

Coated parts inside one of the ovens.

maximum length of 7.5 m. The powder top coat is applied with a state-ofthe-art manual unit from Zeus Electrostatic System; the liquid base coat is applied with manual electrostatic units from Wagner, fed by an Intellimix mixer installed in a separate compartment.

“The plant’s lifting devices facilitate the operators’ work in loading and unloading heavy parts,” adds Rocco D’Aloia. “After the hanging operation, the first transfer cart enters the sandblasting machine, equipped with a one-rail ring. At the exit, the parts pass through a manual blowing station for cleaning. A second transfer cart takes them to the masking station, if required, or directly to the base coat application booths, applying the same light grey liquid paint on all components. The same cart transfers the workpieces to the coloured powder top coat application booths and, afterwards, to the curing ovens. Finally, a third cart takes them to the unloading area with the second lifting device. The powder coating booth devoted to the RAL 2011 orange, our company colour, is equipped with a paint recovery system, whereas the one applying all other tints requested by customers (mainly gray, white, yellow, and red) is not.”

Speed, flexibility, and independence of treatment phases: a goal successfully achieved

“Eurotherm’s box concept with four booths and three curing ovens gave us a degree of flexibility and speed that an automatic in-line system could never provide,” emphasises Fabrizio Abello from Giletta Spa. “Depending on output demand, we decide whether to use one or more ovens, whereas having two booths available for both base coat and colour application enables us to use them two by two or all four at the same time during production peaks: in some periods, we use one or two booths per day, whereas if necessary we can paint with the four booths operating simultaneously. Our goal was to implement a highly technological but at the same time flexible system: Eurotherm has fully met this requirement.”

Gianpaolo Candelero from Eurotherm with Fabrizio Abello from Giletta.

Bucher Municipal: A Group of Excellence

Founded in 1950 in Revello (Cuneo), Giletta began as a manufacturer of agricultural machinery. In the first years, it carried out both production and sales activities. Then, in 1966, at the request of an entrepreneur providing snow-clearing services on the Saluzzo provincial road, Giletta designed its first sand and salt spreader. This had a double drive chain, a technology derived from the agricultural machinery field, and had a capacity of 11 cubic metres, suitable for a 6x4 truck. Considering that, at the time, the largest spreader in Europe had a capacity of 6 cubic metres, this new machine was a great innovation for the market, as it reduced the number of vehicles in circulation.

“The main innovative feature of the machine designed by Michele Giletta, was its system for extracting material from the container: whereas all competitors used augers, our machine had a crossbar belt that gave it the great advantage of always remaining loaded, thus enabling it to work on a continuous flow and with any material, as it was able to transmit a higher traction force than other known systems. To this day, this technical feature guarantees the great flexibility of use, reliability, and spreading precision of our machines – a design detail that, still today, is a distinguishing feature of the Bucher brand,” says Fabrizio Abello.

Close cooperation with customers, attention to detail, and high machine quality have made Giletta one of the most innovative manufacturers in the industry. In 1978, it launched a 15-cubic metre spreader. In 1980, it introduced its first chloride spreader with a humidifying system, which revolutionised the field of winter maintenance.

In 1989, it took further steps towards digitally controlled spreading operations with the coming of Ecosat microprocessor. Fully automated satellite control of chloride spreading operations dates back to 1998. In 1999, at the request of Italy’s largest motorway management company, which operates a large number of snow-clearing vehicles, Giletta developed the first digital system for remote tracking and control of winter operations.

In 2002, the company joined the Bucher Municipal Group.

In 2003, to offer a complete range of equipment for winter maintenance, the Group acquired SnowTec, a French manufacturer of innovative snowploughs. This have been then merged with Arvel, a company founded by Giletta in 1997 and located in Coudes, in central France. In 2009, the company invested in Saet, a firm specialising in designing and producing electronic controls and wiring harnesses, to expand its know-how in the electronic field and further strengthen the development of smart products.

The growth of Bucher Municipal continued its run with the acquisition of the German manufacturer Gmeiner, the Spanish distributor Maquiasfalt in 2011 and, in 2012, with the acquisition of Assaloni.com, a long-established manufacturer of snow clearing equipment, renowned above all for its patented telescopic snowploughs. In 2014, the company inaugurated a production plant in Kaluga (Russia), built to manufacture all types of systems intended for this crucial market, some of which are specially designed for the region’s extreme conditions.

A Bucher Municipal runway deicing machine.

© Bucher Municipal

PPG's Partnership with Maker of Iconic Italian Coffee Pots

PPG has continued the partnership with the nearly century old company Bialetti, whose products are known for their iconic design and exceptional quality, in order to provide them with sustainable powder coatings befitting their high-end coffee makers.

Steeped in Italian culture and synonymous with high design and quality, Moka coffee makers made by Bialetti are cherished for producing bold and great-tasting brews. Whether it is made in the original Moka Express or one of the many models produced by the Italian manufacturer throughout the years, the aesthetically beautiful pots are beloved by coffee enthusiasts around the world.

In 1933, engineer and entrepreneur Alfonso Bialetti began manufacturing the Moka Express, the aluminium coffee maker that revolutionised the way coffee was made by using high pressure to force steam through the grounds. The name derives from the city of Mokha in Yemen, one of the first and most renowned coffee production regions of that era.

© Bialetti

Since then, more than 300 million units have been sold, almost unchanged from their original octagonal shape that is widely heralded as the pinnacle of Italian design. Today, the iconic appliance is a staple in kitchens around the world, particularly in Europe and Latin America. But the Moka Express is not the only popular pot sold by Bialetti, headquartered in Coccaglio (Brescia, Italy). Every year, millions of the company’s pots are bought by coffee aficionados in various models and colours.

A new era of colours

For generations, all Bialetti models had uncoated aluminium exteriors. That all changed about twenty years ago, when the company wanted to add beauty to the daily ritual of making coffee through colour. Bialetti then reached out to an Italian-based industrial coatings company whose powder business was acquired by PPG in 2021. The first collaboration yielded the Mukka Express, a cappuccino machine with a cream and black powder coat that resembles the spotted hide of a cow. The two companies worked in partnership to develop several polyester and epoxy-polyester coatings for various Bialetti coffee maker lines, including:

 Matte colours for the Fiammetta;

 Green for the Break Alpina;

 Pink for a special edition Moka Express for the Giro d’Italia cycling race;

 Golden yellow for a top-selling Christmas collection

 Various other colours for the Dama “Glamour” version.

Trendy aesthetics and sustainable solutions: the new Moka Exclusive line

The Moka is a more sustainable device that brews coffee from powdered coffee beans, eliminating the need for disposable plastic pods. In addition, it only requires water to clean – no soap or detergent needed. In 2023, the PPG team began development of a series of PPG Envirocron® powder colours for the new Moka Exclusive line, a collection that would launch for that year’s Christmas holiday season. “We wanted something new, elegant and refined to fully enhance the Moka Express icon. By researching and examining aesthetic and stylistic trends, our style department proposed a new Moka Exclusive collection featuring seven trendy colours to fit a wide variety of tastes,” explained Marco Vanoli, Bialetti product manager.

One challenge was to create a powder and application process that would cover the entire pot with the exception of the embossed Moustachioed Man icon and the company logo. These two visual elements were integral parts of the new line’s branding and helped to create a high-end and trendy aesthetic.

“This was a challenging project,” commented Cristoforo Brendas, PPG business development manager, powder coatings. “It took several trials to find the right balance between the colour and the final effect that Bialetti wanted. The work done in our laboratory was key.”

Once the colours were developed, the testing process began in Bialetti’s own laboratory to ensure good adhesion, stain resistance and durability

over high heat. The tests were very aggressive, yet crucial to ensure that an optimal coating was used. The PPG powder coatings products met every requirement, from performance to beauty. The new collection launched in time for the 2023 holiday season.

“We are highly satisfied that our coating has been chosen for the top exclusive colours of the 2023 Moka Exclusive collection and we are particularly happy to continue collaborating with Bialetti Industries. We share the same passion for Italian excellence, innovation and attention to quality of the company” declared Brendas.

For further information: www.ppgindustrialcoatings.com

Metalux Revolutionises Its Pre-Treatment Process by Adopting the PRONORTEC Nanotechnology for Efficient and Sustainable Powder Coating

Federico Melideo ipcm®

Italian powder coating contractor Metalux has recently implemented Chemtec’s PRONORTEC nanotechnology in its pre-treatment processes to ensure environmentally sustainable operations and increase the operational flexibility of its plants.

In an increasingly competitive industrial landscape, Metalux stands out as a cutting-edge powder coating contractor capable of combining innovation and sustainability. Located in Castelfidardo (Ancona, Italy), this company of excellence has obtained the prestigious QualiSteelCoat certification for steel, Sendzimir steel, and hot-dip galvanised steel, becoming Italy’s southernmost business to have achieved this milestone. Giacomo Bettucci, at the head of the company, underlines the importance of this certification while illustrating a journey characterised by commitment and dedication to quality: “This certification not only attests to our company’s high quality standards but consolidates it as the benchmark contractor for customers in central and southern Italy demanding impeccable finishes. Our current systems guarantee C4H class protection for steel and Sendzimir steel and C5H class protection for hot-dip galvanised steel with a pretreatment + primer and powder coating application cycle.”

Facing the challenges of the post-pandemic market, this Marche-based company adopted a growth strategy geared towards sustainability and efficiency, renovating its paint shop with a focus on chemical pre-treatment. In particular, it took a big step forward by abandoning the now obsolete phosphating + trivalent chromium process to adopt a more efficient and environmentally friendly approach. This is why it chose the PRONORTEC nanotechnology developed by Chemtec, an Italian company specialising in the formulation, production, and marketing of speciality chemicals for surface treatment.

The modernised paint shop

Metalux currently has four powder coating lines, of which one is equipped with a shot blasting machine for mechanical pre-treatment and three implement a chemical pre-treatment process in a cleaning tunnel. “Since last summer, we have been using Chemtec chemicals on two of our four lines, one of which employs the innovative PRONORTEC nanotechnology,” explains Giacomo Bettucci from Metalux. “From a practical point of view, this choice was driven by the need to replace the phosphating + trivalent chromium process and align our operations with a more environmental sustainability philosophy, thus making Metalux a chromium-free company. At the same time, we wanted to improve the operational flexibility of our plants, which treat

components for both indoor and outdoor use.”

“Besides its chemicals, we adopted two technical devices designed by Chemtec: a complete skid for spraying the PRONORTEC product and a reverse osmosis system for producing pure water, which replaced our old demineralisation plant fed by well water. These machines completed an extensive renovation of the cleaning tunnel we used for the phosphating + trivalent chromium cycle, as chromium had eroded its stainless steel sheets over time,” says Bettucci.

The two coating lines using Chemtec products

Line 2 is devoted to indoor components that are pre-treated with multi-metal phosphating agents supplied by Chemtec, suitable for treating steel, aluminium, and galvanised sheets. Its process is optimised to meet the needs of customers requiring standard durability in salt spray tests. It includes a pre-treatment cycle consisting of a phosphodegreasing stage and a series of rinses, the last of which is with pure osmosis water.

Line 4, which recently underwent revamping, is devoted to mediumand large-sized components with maximum dimensions of 3000 x 1000 x 2500 mm. It treats parts for both indoor and outdoor use and in all types of metal alloys, which are pre-treated with the nanotechnology passivating agent PRONORTEC and then coated with specific indoor,

The two new automated warehouses for powder coatings from different suppliers.

outdoor, or silicone coatings. “The objective is to ensure high corrosion resistance, which is why we have conceived a pre-treatment cycle including phospho-degreasing, a rinse with osmosis water, and the rinsefree application of the PRONORTEC nanotechnology solution,” explains Carlo Guidetti, Chemtec’s CEO & co-founder. Bettucci confirms: “We aimed to implement a versatile line capable of handling a wide range of materials, a goal achieved thanks to the exceptional user-friendliness of PRONORTEC.”

Technical and application characteristics of PRONORTEC

“PRONORTEC is a nanotechnology based on organic phosphorus compounds that deposits a layer of approximately 50/60 nm, thus guaranteeing excellent adhesion on any metal substrate that has been suitably degreased and rinsed, while ensuring excellent corrosion resistance thanks to its hydrophobicity. This is why PRONORTEC can replace obsolete and environmentally impactful yet high-performance technologies, such as trivalent chromating, with nanotechnology guaranteeing the same degree of quality but with environmentally sustainable operations. Unlike other nanotechnology processes on the market that take advantage of the chemistry of zirconium, titanium, or organic silanes, we have developed an innovative solution that simplifies industrial applications and does not require rinsing to ensure high results,” illustrates Guidetti.

corrosion resistance compared to a standard degreasing step or even reach the performance levels of trivalent chromium phosphating, as in the case of Metalux. Chemtec offers two options to implement PRONORTEC: a fully automated 4.0 system and a more user-friendly one. Both are designed for ease of use and efficient product application on all metal surfaces, as well as being lowmaintenance and easy to integrate into the plant’s control panel.”

The advantages of the new nanotechnology

“The PRONORTEC nanotechnology’s application represents a significant advance over traditional phosphating processes, offering a remarkable improvement in pre-treatment performance. However, what makes this new nanotechnology so effective is its extreme ease and flexibility of use, which translates into greater operational efficiency, easier cycle planning, and the ability to treat a wider range of products, especially when using Qualicoat 2 instead of Qualicoat 1 certified coatings,” says Bettucci.

“Two conditions are necessary to achieve this quality improvement with PRONORTEC: the first is a rinse with essentially pure, osmosis or demineralised water performed upstream of the PRONORTEC application; the second is sufficient space available in the existing pre-treatment tunnel to integrate a simple spray bar. This can improve

Metalux conducted several corrosion resistance tests to validate the performance of PRONORTEC, which were carried out by Chemtec directly at its laboratory. This is equipped with two new 4.0 salt spray chambers, one devoted to neutral salt spray tests and the other to acetic salt spray tests for non-ferrous metals, as well as electrochemical impedance spectroscopy and ACET test devices. “This approach guarantees real-time results, enabling us to analyse the kinetics of electrochemical reactions on metal surfaces and identify any problems or issues that may arise during the process,” adds Guidetti.

Conclusions

Thanks to its investments, Metalux has established itself as a company specialising in high-quality powder coatings for indoor and outdoor

The atomising ring for the nanotechnology passivating product PRONORTEC supplied by Chemtec.

use, constantly striving for excellence in its services – a mission accomplished not only thanks to its improved pre-treatment and coating processes but also to the use of high-quality paint products, such as those supplied by TIGER Coatings, one of Metalux’s suppliers. “Despite our powders sometimes being associated with a high market segment, it has been proven that the longterm benefits – including higher performance and superior quality of finished products –actually make them highly competitive, if not even more cost-effective than other coating products. The QualiSteelCoat certification obtained by Metalux in 2022 has further strengthened this partnership, enabling TIGER Coatings to offer primers and finishes in line with the needs of the most demanding customers,” notes Emanuele Zepponi, sales

The PRONORTEC product’s automatic mixing and dosing system.

Hydro Italia Revolutionises Waste Water Treatment for ICA

Gabriele Lazzari, ipcm®

ICA has recently installed Hydro Italia’s HYDROFLOTY 12M physical-chemical treatment plant, which recovers 90% of waste water through a closed-loop clariflocculation cycle to reuse it in its cleaning processes while complying with current environmental regulations. The company relied on an experienced and qualified partner to help it optimise the environmental sustainability of its production and reduce disposal costs by 20%, confirming its position as a leader in the water-based coating sector.

In an ever-changing world, social responsibility and sustainability cannot be considered an option but rather a moral and strategic imperative that can be summarised with three verbs: Inspire - Commit - Act. This mantra has always guided the growth of ICA, an Italian company founded in 1971 and run by the Paniccia family until its acquisition by The SherwinWilliams Company, which was formalised in December 2022. Specialising

in the production of water-based coatings for wood substrates, ICA also stands out in the market for other features, including water-based and bio-paints – i.e. with raw materials from renewable sources –, the chemical-physical analysis laboratory available to customers, the professional training service provided by ICA Academy, and the always high focus on environmentally sustainable practices and technologies.

The HYDROFLOTY 12M physical-chemical treatment plant from Hydro Italia.

© Hydro Italia

“The HYDROFLOTY 12M physical-chemical plant was built by Hydro Italia for the treatment and purification of waste water generated in our paint drums and containers’ cleaning operations," says ICA’s Communications Manager, Valentina Cesari. Commercial Director Davide Solmi has closely followed the project for this turnkey, complete, closed-loop purification plant and, thanks to the technical direction of Hydro Italia, has developed the most effective process combining the most suitable equipment and chemicals from this supplier.

The company’s sites in Civitanova Marche (Macerata, Italy) and Romano d’Ezzelino (Vicenza) produce wood and glass coatings, whereas its foreign subsidiaries are mainly devoted to customer support services and the production of new colours with innovative tinting systems. As a production plant, the Marche site uses large quantities of cleaning water, which have increased considerably in recent years due to rising production volumes. Therefore, ICA identified the need to reduce its environmental impact and disposal costs resulting from these manufacturing operations as part of its commitment to sustainability. Initially, the company decided to focus on the waste water generated

when cleaning its mobile drums, but also its stationary production and treatment lines’ mixers, cleaned automatically with maxi brushes and a combination of mains and osmosis water.

“The goal was to find a treatment and purification system that would substantially reduce our amount of waste water, enabling us to efficiently reconvert it into water to be fed back into the cleaning cycle. As we are certified by three schemes (ISCC Plus, EcoVadis, and Sedex, including the ISO 14001:2015 standard), reducing our environmental impact was a categorical imperative,” explains Federica Paggi, Quality, Safety, Health & Environment Specialist.

The analysis phase and the selection of a clariflocculation process

The company thus embarked on an analysis phase to identify the best suited process for its needs and the right partner for developing the purification technology. The process began with a laboratory step, where treatment tests were conducted to assess the feasibility of reusing waste water in the cleaning process. This initial study, which lasted

The clariflocculation tank.

© Hydro Italia

about a year due to some delays caused by the COVID-19 pandemic, involved external accredited laboratories and led ICA to choose a clariflocculation-based approach because it has little effect on the environment and is easy to implement and manage. Subsequently, the company compared different proposals from expert suppliers, including Hydro Italia, which presented a pilot project to confirm its treatment’s effectiveness.

“Once the best solution, namely clariflocculation, was identified, we proceeded with a basic process engineering phase through discussions with several companies and a tender. Of all the technologies presented, Hydro Italia’s one was the one that most convinced us,” says Paggi. “Therefore, we commissioned a test with a tailor-made pilot plant to field-test the waste water treatment process and validate its effectiveness. About three months later, happy with the results we had achieved so far, we finally commissioned the system.”

Hydro Italia’s HYDROFLOTY 12M physical-chemical treatment plant

The automatic, closed-loop plant supplied by Hydro Italia, called HYDROFLOTY 12M, can treat 12 m3/hour of waste water by using specific chemical agents, appropriately dosed depending on the concentration of the contaminants to be treated, such as thickeners, polyelectrolytes and PH correctors. The process creates light flakes that incorporate the contaminants while remaining suspended on the surface so they can be mechanically skimmed off and easily removed. The closed cycle treatment process starts from the collection of waste water from the cleaning of production equipment, conveyed and stored in a storage tank prior to the process. It is then fed into the clariflocculation and homogenisation tank where, once the flakes have surfaced, a blade sends them into the

The hopper, placed on a support equipped with a discharge grid.

© Hydro Italia

hopper, placed on a support equipped with a discharge grid. Here, the solid residue is left to dehydrate. The resulting leachate is taken to a pre-filtration tank where two sand and activated carbon filters eliminate any suspended solids that may still be present and traces of other organic pollutants that have escaped the treatment of clariflocculation. The clean water can then be used again for cleaning operations, whereas the sludge is collected in big bags and disposed of by external companies.

ICA specifically requested that a sanitisation phase with 10% sodium hypochlorite be included to eliminate any bacterial colonies that might proliferate in waste water. Sensors have also been installed on the plant to detect the amount of raw materials in the tanks and the treatment tanks’ levels. This enables to monitor process progress and consumption from both the PLC and ICA Energy’s management software programme.

Another view of the plant.

“Most control and maintenance steps can be managed from the operators’ computer. The internal decision to remote the main functions of the treatment unit onto one of our PLCs addresses needs related to optimising intervention times and monitoring the performance of the purification process,” continues Paggi.

90% water recovery and 2-year ROI

The system was installed in June 2023: after six months of operation, ICA is fully satisfied with the results. The investment was supported by a specific study linked to environmental sustainability and cost reduction objectives with a view to continuous improvement aimed at achieving Zero Waste for washing operations. “The plant has proven highly sustainable in several respects. From an environmental point of view, it enables us to recover over 90% of the water used for our cleaning operations, contributing to a significant improvement in the mass balance. The sustainability of the plant is supported in relation to numerous environmental matrices: reduced energy consumption, treatment efficiency, recovery of material and consequent reduction in the depletion of water resources, reduction of waste generated and sent for disposal. Finally, since almost all waste water can be reused for subsequent cleaning operations, we have reduced our disposal costs by 20%,” states Paggi. “We anticipate that we will achieve a return on our investment in just two years. Moreover, Hydro Italia has built a modular plant allowing for future expansions to follow any increase in production capacity. The daily cycle in current conditions involves using the system for a few hours a day; future projects under study may include an upgrade of the plant and an increase in the waste water to be treated.”

The flakes incorporaing the contaminants suspended on the surface.

The filtered water that can be reused in the cleaning process.

PASSION FOR MASKING SOLUTIONS

BEEP Srl: a Long-Standing Collaboration with a Pool of Italian Companies Enabled the Installation of a New Powder Coating Plant for High-End E-Bikes

Ilaria Paolomelo, ipcm®

As a company specialising in the coating and assembly of bikes and e-bikes marketed under the Decathlon brand, BEEP Srl has recently opened a new factory designed to coat and assemble up to half a million bicycles per year. For this ambitious project, it turned to the company Visa Impianti, which designed and installed its new coating line in collaboration with Futura Convogliatori Aerei and Wagner Italia.

BEEP specializes in powder coating and assembly of bicycle and e-bike frames.

In the vibrant two-wheeler scene, Italy is steadily one of the world’s leading bicycle manufacturing countries, combining traditional craftsmanship and cutting-edge technology. The beating heart of this sector lies within the Turin-Milan-Genoa “industrial triangle”, an area steeped in passion and expertise, which has been attracting talent and investment over the years to become a beacon for companies aspiring to excellence in this world. BEEP, an acronym for Bike E-bike European Production, stands out among them: headquartered in Tortona, in the province of Alessandria, it specialises in powder coating and assembly of bike and e-bike components on behalf of the world’s leading sports retailer, Decathlon.

It recently installed a new frame coating system, and when it came to choosing the technological partners to rely on, it had no doubts in turning to three Italian companies with which it has already been successfully collaborating for years1: Visa Impianti (Triuggio, Monza e Brianza), which designed and installed the new powder coating line, Futura Convogliatori Aerei (Robecco Pavese, Pavia), which supplied the power&free conveyor, and Wagner Italia (Valmadrera, Lecco) for

1 In 2021, Visa Impianti, Futura Convogliatori Aerei, and Wagner supplied SMW, a Romanian company owned by two of BEEP’s owners, with a powder coating plant to process Decathlon frames: https://www.ipcm.it/en/open/ipcm/2023/79/80-84.aspx

the installation of Super Cube booths. One of the main peculiarities of this new plant is the possibility to apply decals in-line, thanks to the integration of an infrared oven with panels provided by Infragas (Mappano, Turin). “Applying decals off-line can cause several operational issues, including longer cycle times due to the need to manually handle the components among different workstations. However, the layout devised by Visa Impianti with an in-line infrared oven has allowed us to optimise and make our entire coating process more efficient,” says Nicholas Giaime, project manager at Telai Olagnero.

Excellence in the bicycle sector

BEEP Srl was established in 2021 in Tortona, founded on a passion for sport and the relentless pursuit of technological innovation, and has since been specialising in powder coating and assembling bicycle frames. “BEEP’s creation stemmed from the need for a factory that would coat and assemble electric and mountain bikes exclusively for French multinational Decathlon, which is actually one of this company’s shareholders together with Vittorio Olagnero, the owner of prestigious manufacturer Telai Olagnero, and Francesco Russo, a former Decathlon executive,” illustrates Nicholas Giaime.

Overview of the coating plant.

For several years now, e-bikes have been winning the hearts of cycling enthusiasts worldwide, who increasingly demand bicycles with highquality components and customised finishes. “Most of the parts used to produce e-bikes come from Asian markets. This new factory was established in response to Decathlon’s need for a production and assembly hub for e-bikes in Italy to limit the geographical distance and, consequently, all costs and any logistical issues,” adds the project manager. With a total area of 11.000 m2, the new BEEP facility will be able to coat and assemble up to half a million bicycles per year within five years.

The production cycle and the new coating line

In its plant, BEEP produces a wide range of bicycles, ranging from classic mountain bikes to electric bikes, both with frame-integrated batteries and with external batteries (for adults only). “The coating of e-bikes accounts for 80% of our production and that of regular bikes for the remaining 20%,” explains Giaime. BEEP’s production process begins right with the preparation of the surfaces to be coated. Components such as frames, forks, and rear racks are supplied directly by Decathlon and stored in the company’s adjacent warehouse. After quality control,

the operators manually load the frames onto the coating line. Each load bar accommodates four frames regardless of their type and size. The pre-treatment phase uses chemicals supplied by Chemetall (Giussano, Monza e Brianza) and includes the following stages:

 Pre-degreasing

 Degreasing

 2 rinses with mains water

 1 rinse with demineralised water

 Nanotechnology passivation

 1 final rinse with demineralised water.

“Currently, we process exclusively aluminium, but in future we plan to treat steel substrates as well. Therefore, we opted for a multi-metal nanotechnology product,” says Giaime.

After the drying phase, which takes place in a conventional bell furnace with an indirect heat exchanger and a heat recovery unit, the power&free conveyor designed by Futura Convogliatori Aerei takes the frames to the Wagner Super Cube booths. “We have two booths, applying coloured base coats and clear coats, respectively. However, the system is prearranged for integrating an additional booth in future,” indicates Telai Olagnero’s project manager. As for the paint applied,

A detail of the pre-treatment tunnel.

BEEP exclusively uses polyester powders supplied by Adapta Color (Peñiscola, Castellón, Spain) and Tiger Coatings (Wels, Austria). “The coating process ends when the components enter the curing oven, whose residual heat is conveyed to the drying oven. They then reach the cooling tunnel and are finally unloaded,” explains Paolo Massari of Visa Impianti. The takt time is 72 seconds per load bar, but BEEP plans to lower it to 65 seconds. As well as the entire production department, the coating plant was designed to meet Industry 4.0 requirements. “Our management software package enables us to control every data and parameter of each production and coating phase, both on-site and remotely. In addition, each frame is assigned a unique QR code, which ensures a high degree of traceability and prevents any errors during the coating process: as the programme matched with each type of frame is set to apply a given colour, the system will stop if the operator mistakenly selects a different tint from the powder centre.”

Following finishing, the coated parts are stored in the adjacent warehouse, waiting to be assembled. When BEEP receives an order, they are ready to undergo the assembly process, which includes installing all the components required to complete the bicycle, such as handlebars, wheels, pedals, brakes, and the saddle. Once assembly is complete, every detail is carefully checked to ensure the quality and safety of the end product before it is packed and

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© Visa Impianti

The frames at the entrance to the coating booth.

prepared for shipment to one of Decathlon’s sorting centres across Europe.

The flexibility of the new coating plant also allows for sticker and decal application

To further customise these bikes with stickers and decals, the plant was designed to allow the components to undergo differentiated processes. “The sticker and decal application phase varies depending on several factors: the type of stickers, the bicycle model and, above all, the customer’s requests,” indicates the project manager. The coating and cosmetic finishing cycles the Visa Impianti system can perform are as follows:

 Base coat application – Sticker application

 Base coat application – Sticker application

Clear coat application

 Base coat application – Clear coat application – Sticker application

“We are also developing a finishing cycle that includes the application of water-based decals, a state-of-the-art process used exclusively for the top-of-the-range bicycles in Decathlon’s product range. From a technical point of view, similarly to polyester decals, water-based decals can also be applied both before and after the clear coat,” adds Giaime. “To ensure the highest level of flexibility, the plant is equipped with an in-line infrared oven equipped with panels supplied by Infragas (Mappano, Turin), which is switched on and off as required, as it is only used with two-coat cycles, namely when BEEP needs to apply a base coat, stickers, and a clear coat. For the clear coat to adhere at best after the stickers’ application, the IR oven heats the frame’s surfaces to around 50 °C and evaporates the alcohol-based product that the operators use to clean them of excess sticker glue and remove any fingerprints. On the other hand, if only a base coat and stickers need to be applied, the components do not have to be taken to the infrared oven,” explains Massari.

The self-learning robot provided by CMA Robotics.

© Visa Impianti

Wagner's Supercenter Evo powder centre.

© ipcm

Flexibility is also ensured by the power&free conveyor supplied by Futura Convogliatori Aerei. “At BEEP, decals are applied in-line and manually. Therefore, it is essential that the plant is adapted to the working speed and height of the people in charge of this operation. This is why, during the design phase, we conducted numerous tests with the company’s operators to identify the ideal timing and height for correct sticker application,” says Stefano Gerletti from Futura. To meet this requirement, Futura has supplied a power&free conveyor that works with a continuous flow to ensure consistent, smooth load bar movement. “Finally, we designed an upstream storage buffer so that, should there be any stoppages or slowdowns during the decal application phase, all the other technologies in the line can continue to work,” states Gerletti.

The powder coating phase

At BEEP, paint products are applied inside the Super Cube booths supplied by Wagner, which are air-conditioned and located inside a clean room. “We identified the ideal number and type of nozzles through laboratory tests in cooperation with BEEP itself. We also jointly developed a gun positioner that determines the positions from where to dispense the paint,” illustrates Cristian Boem, powder coating area manager at Wagner. The booths are equipped with the Supercenter Evo powder centre, which ensures fast colour change operations and precise parameter management for higher application uniformity and consistency. The application operations are carried out by self-learning robots supplied by CMA Robotics S.p.A. (Pavia di Udine, Udine, Italy) to improve process consistency and repeatability even further. “The system is prearranged for installing a second booth for coloured base coat application. Currently, we perform about 2 or 3 colour changes per day, but in future we plan to reach 7 per day. The colours needed

The PLC of the coating plant.

Detail of the unique barcode present on each scale to allow maximum traceability of the process.

to cover the whole Decathlon portfolio are over 50. At BEEP, we are currently applying 22 different tints, but we will certainly be using more and more of them in the coming months. Therefore, we are going to install another Wagner booth to further speed up and optimise our coating cycle and better manage the necessary colour change phases.” “As far as paint products are concerned, we decided to continue working with Adapta Color and Tiger Coatings, which were already the suppliers of the SMW factory in Romania, our company’s other subsidiary that coats frames on behalf of Decathlon,” says Giaime. “We decided to continue this partnership based on the high quality of the coatings supplied by these manufacturers. Another key factor in choosing to collaborate with Adapta and Tiger was that both companies only have one production site in Europe: we consider this a significant advantage because it guarantees greater reliability and quality consistency of the supplied paint products. Past experiences with other manufacturers have taught us that mixing two paint batches from different production sites often leads to slight colour differences. If not detected by our operators, such inconsistencies risked adversely affecting the quality of our finishes. However, by using Adapta and Tiger powders, we can be certain that even if we mix two different batches, the finish will be uniform and the quality will be consistently high, helping us avoid issues such as lengthened processing times and increased costs for part paint stripping and re-coating,” states Giaime.

A successful partnership

“When deciding on the coating system to be installed, we did not do any market research but turned immediately to suppliers we had already worked with. The decision to rely on manufacturers with whom we already had positive experiences was a crucial element in the success of this partnership during the installation of our new plant. Relying on the same team, whose skills and dependability had already been proven in previous collaborations, guaranteed optimal operational efficiency right from the start of the project. Although the plant is not yet at full capacity – it will be at the end of March 2024 – having already worked with the same partners on two other plants and, of course, with the same customer, namely Decathlon, we can accurately predict our short and long-term results. Our goal is to coat 150,000 bicycles in the first year, 250,000 in the second year, and over half a million by the fifth year, working in two shifts,” indicates Giaime. “We are confident that, by continuing to collaborate with this expert and reliable pool of companies and using the cutting-edge technology they provide, we are going to fully meet Decathlon’s needs and achieve excellent results in terms of both production capacity and coating quality,” he concludes.

From left to right: Paolo Massari of Visa Impianti, Stefano Gerletti of Futura Convogliatori Aerei, Nicholas Giaime of BEEP and Cristian Boem of Wagner.

New Horizons in Paint Curing Technology: Helios

Italquartz Enlightens the

Future

of the Industry with its IR and UV Lamps

From an interview with Luigi Gastaldo, sales manager at Helios Italquartz Srl

Change is always synonymous with growth, innovation, and new goals. However, abandoning certain habits can prove difficult, especially in the surface treatment industry. Despite this, aware of the sector professionals’ wish to always work with the most advanced technologies and of the PaintExpo visitors’ interest in innovations, Helios Italquartz sales manager Luigi Gastaldo is enthusiastic about presenting the company’s infrared lamps, bound to become protagonists in the polymerisation and drying of liquid and powder coatings.

© Helios Italquartz

Working closely with its customers, Helios Italquartz customises its modules’ design according to the specific needs of each application, also providing infrared modules.

The history of Helios Italquartz dates back to 1940, when its founder, Armando Giro, took over Actinia, a company specialising in infrared and ultraviolet lamps. Since then, several ups and downs have led this business to evolve, change names, and undergo mergers, but always maintaining the same focus on quality standards of excellence. Today, the Helios Quartz Group, with its sites in Cambiago (Milan, Italy) and Novazzano (Switzerland) and representative offices in America and Asia, has become one of the main international benchmarks for the production of quartz lamps.

“We specialise in producing and processing quartz and all its derivatives and our core business is infrared lamps. Manufactured in our Cambiago and Novazzano plants, they have a variety of fields of application, including glass, plastics, rubber, textiles, and research equipment for universities. In addition, to meet the needs of the most varied industries, we have been producing and marketing complete systems for about ten years now, that is, infrared lamps fitted inside customised

modules according to specific needs, which can be managed through switchboards and control systems also supplied by us.

“The outstanding know-how gained over these ninety years has enabled Helios Italquartz to become extremely flexible and able to meet the demands of different markets despite its small to medium size,” says Luigi Gastaldo. Today, the company is ready for a new challenge: conquering the industrial coating sector, where quartz infrared lamps are not so widespread and well known, yet. For this reason, it will once again participate in PaintExpo, the major global trade fair for industrial coating technologies, to be held in Karlsruhe (Germany) from 9 to 12 April 2024.

Helios Italquartz at PaintExpo 2024

Indeed, besides the sectors mentioned above, Helios Italquartz strongly believes in the positive impact that its infrared and UV lamps can have on the surface treatment industry. “Participating in PaintExpo for the

Quartz infrared lamps.

© Helios Italquartz

second time is a significant occasion for us because the feedback we received during our last participation in 2022 was extremely positive. This trade fair is well focused on the technological aspects of processes and its visitors are very knowledgeable: this enables us to have interesting exchanges of technical information and, of course, continue to be up-to-date on new materials and technologies, which ultimately helps us produce reliable solutions for an ever-changing market,” notes the sales manager of Helios Italquartz.

The objective pursued by participating in PaintExpo is, in Gastaldo’s words, “piercing the veil of power of traditional systems”. As mentioned, infrared technology still struggles to emerge in the surface treatment sector and is often perceived as a usurper of the technologies classically used for curing and drying paint products. “There is a sort of diatribe between infrared and hot-air processes that leads operators to believe they necessarily have to opt for one of the two alternatives. Helios Italquartz, however, aims to champion the possibility of integrating these

two options. “Our company would like to inform the industry about infrared technology because “piercing this veil” means bringing infrared lamps into drying processes, making it commonplace, practical, and above all usable in mixed systems to optimise consumption, machine flexibility, and energy savings – all factors that are truly relevant today,” adds the sales manager.

Infrared lamps: how does this technology work, and what are its benefits?

Quartz infrared lamps use radiation heating to bring heat to a surface without any contact with it or the presence of “intermediary” agents such as air. These lamps can emit infrared radiation in a wavelength range of 0.9 µm (short waves) to 3.5 µm (medium waves), which allows the heating cycle to be adapted to the specific requirements of the treated material. Compared to traditional forms of heating, such as hot air, infrared lamps emit more energy per unit area. In addition, this energy

© Helios Italquartz

Quartz infrared lamps use radiation heating to bring heat to a surface without any contact with it or the presence of “intermediary” agents such as air.

can be focused, concentrated, directed, and reflected in a light-like manner, ensuring greater precision and control in the heating process.

Helios Italquartz’s systems also have the advantage that they are extremely flexible and easy to install because they only require mechanical support and mains power, as they do not consist of heavy machinery requiring special insulation or suction mechanisms. Moreover, compared with other technologies, infrared lamps guarantee high temperature accuracy on paint through easy power adjustment, thus preventing over-curing. Another significant benefit relates to energy saving: infrared lamps switch on in maximum 60 seconds and do not require pre-heating time, speeding up the process and reducing consumption.

The flexibility of these lamps also lies in the possibility of integrating them into both new and revamped coating systems. “In brief, we can provide a solution for any application that is presented to us because we manufacture lamps with all wavelengths and carry out preliminary tests in our laboratory to offer each customer a system that is truly satisfactory, as economical as possible, and with the highest possible degree of quality,” states Gastaldo, emphasising that the real benefit of

infrared technology is precisely the vast range of possibilities it offers.

UV lamps and other technologies from Helios Italquartz

Besides infrared lamps, this company also specialises in designing and producing medium-pressure, low-pressure, amalgam, and black light (Wood’s light) UV lamps. The result of many years of experience in the industry, guaranteeing advanced technology, careful selection of materials, and maximum reliability, this type of lamp is suitable for a wide range of applications, including the curing and drying of UV glues, paints, and coatings.

Helios Italquartz’s catalogue also includes scientific equipment and laboratory devices such as diode lamps. “Helios has been manufacturing scientific instruments that take advantage of ultraviolet and infrared radiation’s properties for over seventy years, providing its customers with professional and reliable solutions for applications in multiple sectors. From drying UV-reactive inks and paint to glass bonding, from detecting the glass watertight side to material ageing tests, Helios Italquartz’s scientific equipment has been developed through close collaboration between our R&D department and

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research centres, universities, and laboratories of leading private companies operating in various industries,” says Gastaldo.

Helios Italquartz between distinctive features and future challenges

Luigi Gastaldo reports that the company’s main target market is Europe, but says he is seeing significant developments in the United States of America and to a lesser extent in South America, but also in China, where demand for quality machines for the domestic market is growing exponentially. “Conquering new markets is only possible by working daily to ensure our product quality consistently comes to light. That is why, at Helios Italquartz, we strive to offer not only products but also services and pre- and after-sales assistance of excellence,” notes the sales manager. Continued growth has also translated into the need to expand the company’s available spaces: the Cambiago site is now undergoing

a renovation project that will soon lead to tripling the area devoted to production. This will enable it to always meet customer demands and ensure timely processing, production, and deliveries.

“PaintExpo will be the perfect setting for meeting both installers and end customers. We will be happy to present our technologies to both categories. Usually, the former are intrigued by new solutions but always keep their focus on costs and the need not to revolutionise the machines they market to avoid carrying out major redesign work, whereas the latter are often in search of a solution to specific production problems and are very keen to embrace innovation. We will be open to understanding everyone’s needs and present ourselves as an ideal partner for continuous development,” concludes Luigi Gastaldo. Do not miss the chance to meet the Helios Italquartz team at PaintExpo, awaiting you at Stand 3245 in Hall 3 to show its technologies and discuss new horizons in the industry.

© Helios Italquartz

UV lamps manufactured by Helios Italquartz.

Dry quattroClean Technology by acp

When it comes to cleaning before painting or coating, the dry quattroClean technology allows significant efficiency and sustainability potential to be exploited.

When removing loosely adhering, particulate contamination, the newly developed rotary two-substance ring nozzle enables a high area performance with minimized carbon dioxide and compressed air consumption. The quattroClean snow jet technology is the ideal solution if, in addition to particulate contamination, filmic contamination also needs to be removed reliably over the entire surface or partially. acp systems has developed the quattroClean power jet technology for the complete or partial removal of stubborn particulate

and film contamination. The liquid carbon dioxide is compressed into granular cleaning granulate in an integrated system and accelerated with compressed air before being blasted onto the surface to be cleaned. This enables a fully automated, uninterrupted cleaning process to be realized.

Acp will display its solutions at PaintExpo 2024 in hall 3, stand 3521.

For further information: www.acp-systems.com/en/

CONDOROIL CHEMICAL to Present its Low-Temperature Nanotechnology Solutions at PaintExpo

CONDOROIL CHEMICAL will exhibit its latest pre-treatment innovations at PaintExpo 2024 in Hall 1, Stand 1131.

CONDOROIL CHEMICAL, a company that has been specialising in the research, development, and production of chemicals for the surface treatment of metals for over fifty years, will present its nanotechnology pre-treatment solutions at PaintExpo 2024, including in particular Condorcoat EC 930. Condorcoat EC 930 is a nanotechnology passivating agent for the surface conversion of ferrous materials, galvanised iron, and aluminium. Free of phosphates, heavy metals such as zinc, manganese, and nickel, COD, and VOC, and therefore highly environmentally friendly, it creates a highly compact inorganic layer, although over 10 times thinner (approx. 40 nm) than iron phosphate phosphating, ensuring higher protection and lower operating costs.

This product can operate at room temperature, thus reducing the running costs of conversion baths, with less sludge production, which extends the service life of the baths themselves and guarantees further

savings and lower water consumption thanks to less frequent bath changes. It can also be used in a onestage surface degreasing/conversion process, as it is enriched with surfactants that allow for the perfect removal of oils and greases commonly found on iron and galvanised iron parts.

Condorcoat EC 930 is diluted preferably with demineralised water and can be used by either spraying or dipping in AISI 304 or 316 L stainless steel plants. The treatment of workpieces is followed by a rinse with demineralised water.

Pre-treatment with Condorcoat EC 930 is compatible with all coating processes. CONDOROIL’s technical assistance service is at the customers’ complete disposal for application tests that can be carried out in its technology laboratories located in Casale Litta (Varese, Italy).

For further information:

https://condoroil.com/EN/

© CONDOROIL

Curing Ovens with Step-by-step Movement

Approximately 7 years ago, when implementing a new e-coat and powder coating plant, we set a goal aimed at reducing energy consumption and optimizing the space allocated for paint curing ovens.

The most common type of curing ovens typically installed involves pieces entering and exiting at floor level. This configuration necessitates long pre-ovens equipped with air curtains that inevitably consume a certain amount of electricity. Despite the pre-ovens, however, this solution results in significant losses of hot air and consequently energy.

To mitigate this problem, we constructed the so-called “CANOPY ovens” with bottom entry and exit. This solution eliminates air curtains, but the entry/exit mouths are quite wide and, in turn, cause losses through convection and radiation.

Additionally, in both aforementioned solutions, the conveyor chain and the corresponding

piece support bars enter the oven, absorbing energy. We thus developed a new oven concept, and already in the initial study phase, significant results emerged. Our focus was on an approach involving efficient handling to reduce space and enable material entry and exit from the bottom with minimal openings to minimize heat loss to the hoods.

The first prototype we developed clearly showed markedly superior performance compared to conventional systems. The combination of optimized handling and an elevated oven proved to be a winning solution, highlighting tangible benefits in terms of energy efficiency and space utilization.

Furthermore, with this system, the overhead conveyor no longer passes through the oven, so it

does not heat/cool down with each cycle, allowing for significant energy savings and drastically reducing expansions, stresses, and wear.

As we progressed towards the realization of the second oven, we further refined our solution by defining and optimizing every aspect of the system, we ensured greater consistency in performance and maximized benefits.

The clear evidence of the high performance already observed in the first prototype was consolidated, confirming the validity and effectiveness of our innovative proposal. In conclusion, our steadfast commitment to achieving the set objectives has guided us in creating an advanced and efficient solution for paint curing.

Through the integration of an innovative handling system and the use of elevated ovens, we provide a solution distinguished by its high performance and effectiveness, fully in line with the style that characterizes us in our industry.

Trasmetal will exhibit at PaintExpo in hall 1, stand 1527.

For further information:

https://trasmetal.com/

© Trasmetal

Government Subsidized Heat Pump Drying

The Airgenex® drying technology by Harter GmbH will display at PaintExpo 2024 in Hall 3, Stand 3541.

Airgenex® paint drying with a heat pump makes possible to ameliorate energy balance, process and the quality of product as well. There is highly efficient drying technology behind Airgenex®, which combines manifold qualities, such a low temperature, low energy consumption and high process reliability, owing to its alternative physical approach. Harter’s dryers dehumidify within a defined temperature range of 20 °C to 75 °C, by using extremely dry process air and customized air routeing. Customers can thus achieve quality drying results. Painted surfaces dry from the inside out in a uniform manner, and cracking and cratering are a thing of the past. The heat pump technology integrated in each dryer makes the dehumidification process highly efficient.

Drying always takes place in a system that is closed in terms of air and energy, and is thus completely independent of the climate.

Harter dryers with integrated heat pump were classified as future fit technology in 2017, allowing customers to enjoy government subsidy. The same applies to pre-dewatered sludge which still contains some 60 to 70 percent of water after pressing. Low energy drying may save operators as much as 60 to 70 percent of energy and disposal cost, and it makes also recycling possible. There is much potential in heat pump drying in many respects.

For further information: www.harter-gmbh.de

Filtrazione per impianti di verniciatura

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

© Harter GmbH

The Global Requirements Placed on Surface Treatment by the ACE and Commercial Vehicle Sector: the Viewpoint of a Complete Coating System Supplier

From an interview with

Karla Roncevic, Coatings R&D Director at KANSAI HELIOS

Manufacturers from the ACE (agricultural, construction, and earthmoving machinery and equipment), truck, and trailer sector must find sustainable and energy-efficient solutions to minimise environmental impact while maximising performance. What role can a coating system supplier play in this context? What sustainable energy solutions are available for ACE coatings? And what do these projects look like in practice?

ipcm® asked Karla Roncevic, R&D Director at Kansai Helios, these and other questions.

ipcm®: As a manufacturer of complete coating systems, what requirements does the ACE and commercial vehicle industrial segment place on surface treatment technologies?

K. Roncevic: As with any protection system, the first element to consider is the substrate: the first requirement, therefore, is excellent corrosion protection. Mechanical, chemical and UV resistance are also of great importance. Customers are placing increasing attention on these paint characteristics. Streamlining operations is also very important for customers, as well as reducing energy costs, application times, and curing times. If we refer to the design requirements, we must conclude that the perfect match is only possible when all the components of the machine or vehicle are matching to perfect the look and functionality. When different surfaces and components, meaning paint systems, are used side by side, they must seamlessly match in terms of colour tone, surface finish and also the aging properties. This is precisely where the role of a reliable system supplier is crucial. Additionally, if using the whole system, from the primer (E-coat or sprayable primer), to the filler and the topcoat, performance of such system can be easily aligned and controlled. Finally, compliance with environmental and health and safety regulations is of the essence. Kansai Helios already stands by its customers with a focus on all these aspects, as demonstrated by the range of water-based and ultra-high solid coatings we offer to this industry segment: such state-of-the-art technology is also the main focus of our research and development activities.

ipcm®: From an R&D perspective, what responsibilities does Kansai Helios feel as a player in the chemical industry?

KR: Unfortunately, the chemical industry has a negative connotation as

© Kansai Helios

Karla Roncevic, R&D Director at Kansai Helios.

chemicals are considered unsafe and dangerous by their very nature. Innovation, therefore, is a big responsibility that we feel, inspiring us to develop products that help us build a better, more sustainable society. These are exciting times to live in, as far as research is concerned. Kansai Helios is embracing this important task and this great opportunity to create a more sustainable world, as coatings are an excellent example of how it is possible to reduce one’s environmental impact.

ipcm®: Can you give us some examples of these innovations?

KR: Continuing to refer to the ACE and commercial vehicle industrial segment, the first sustainable innovation to be mentioned is using raw materials of organic or biodegradable origin. However, sustainability goes far beyond this. Another aspect is undoubtedly reducing dependence on fossil fuels as much as possible, not only in terms of raw materials and paint formulations but also in other areas of the application process – for instance, eliminating the need for a curing step in a two-coat cycle, significantly decreasing energy requirements, or formulating paint products with greater durability to extend the service life of components. Other sustainable choices are improving paint application process, by for example lowering the curing temperature of powder coatings from 180 to 160 °C or less – this results in considerable energy savings, making it even more sustainable than using organic raw materials.

ipcm®: What are the current developments in the market of organic raw materials?

KR: Kansai Helios prides itself on having a fully integrated production flow that goes all the way back to raw materials, because this enables us to develop polymers that perfectly fit to our coating formulations. We have strived to increase our share of bio-based raw materials to replace fossil-based ones. We have achieved extraordinary developments in this area, although it also entails several challenges. Our engineers have been working hard to develop various product types for the ACE sector, which are containing bio-based raw materials. Of course, one cannot expect all raw materials to be replaced by elements of organic origin: it is not possible and would not even make sense to do so. Sustainable coatings aim to reduce the environmental impact by improving the overall lifecycle, and incorporating renewable recourses is just one of the ways to do so.

ipcm®: What are the pros and cons of raw materials of organic origin?

KR: The advantages, of course, include decreased dependence on fossil fuels and the great opportunity to collaborate with agriculture to promote the cultivation of certain plants useful to the chemical industry, without negatively affecting the food chain or biodiversity. The first disadvantage is that, as I mentioned earlier, some raw materials of organic origin require enormous amounts of energy and water for their

extraction and processing. This is something we have to keep in mind, without being fooled by the term “organic” and without over-using them. The second disadvantage is the higher difficulty in meeting the technical requirements of specific applications when using raw materials of organic origin. Bio-based raw materials certainly pose some challenges that require great attention.

ipcm®: What can a coating system do to save energy?

KR: It can do a lot process-wise. There are also functional paints that contribute to energy savings thanks to their intrinsic characteristics, such as products reflecting sunlight and preventing buildings from overheating, thus lowering the cooling requirements in buildings. The thermal barrier coatings can enhance the insulation properties of surfaces, reducing the need for heating or cooling.

When it comes to standard coatings for the ACE sector, Kansai Helios has successfully developed and implemented wet-on-wet liquid systems that eliminate the need for drying after the first coat. In the powder area, we have devised two-coat systems that do not require complete intermediate curing, thus dramatically reducing energy consumption, as powders cure at temperatures between 160 and 180 °C. We have also successfully developed liquid coatings that need less energy to dry, lowering the required temperature, for example, from 80 to 40 °C or

from 80 °C to room temperature for certain one-coat products. These all result in significant improvements for our customers, especially in an industrial sector like the ACE and commercial vehicle one, where one-coat paint products are widely used because they ensure the same degree of performance as conventional two-coat systems but with a faster and more streamlined production process.

ipcm®: What innovations will you present at PaintExpo 2024?

KR: Exactly those I mentioned. First of all, we will present a lowtemperature cure cataphoresis product. As for liquid paints, we will present a wet-on-wet two-coat system for the ACE sector. In addition, we will introduce a direct-to-metal product partly of organic origin and an epoxy primer also partly based on organic raw materials. Finally, we will present a two-coat powder system that does not require any intermediate curing phase and a super durable low-temperature powder coating. Last but not least, a “green” powder coating based on a recycled polyester resin will make its debut – indeed, recycled raw materials are another crucial area of research for our Group. These are all outstanding contributions of Kansai Helios to sustainability and we want to present to our customers!

Kansai Helios will be pleased to welcome you at PaintExpo 2024 in Karlsruhe (Germany) from 9 to 12 April at stand 1430, Hall 1.

Vermobil Chooses Mixed Infrared Technology for Dry-on-Fused Coating of its High-End Outdoor Furniture

Monica Fumagalli, ipcm®

Infragas’ integration of RHT burners and catalytic technology is the ideal solution for combining dry-on-fused powder coating performance, energy savings, and reduced environmental impact. Vermobil Style’s choice is proof of this. As a company that has been designing and manufacturing outdoor furniture and accessories since 1993, it searched for the most effective solution to raise the quality bar, speed up its coating process, and make its production even more sustainable.

Dry-on-dry powder coating, the most common powder application technology, calls for the intensive use of energy resources to cure the base coat and then the top coat. For several years now, an additional step called gelling has been added to the coating cycle to overcome this problem, which returns the base coat layer applied on the substrate to a molten state through

infrared heating; afterwards, the part enters the oven for final curing, initiating the process known as “dry-on-fused” precisely because the pre-cured coating is melted and not fully baked, thus avoiding a double curing step. Integrating the gelling phase also results in a coating layer that gives the substrate higher corrosion and UV-resistance properties, making it ideal for all products intended for outdoor use,

Vermobil Style Srl has been designing and manufacturing outdoor furniture and accessories for 30 years. Pictured here is the Quatris table, which finds its stability on any surface thanks to its special structure.

such as those manufactured by Vermobil Style Srl (Marsciano, Perugia, Italy). The company, celebrating its 30th anniversary this year, designs and manufactures outdoor furniture and accessories in line with contemporary trends to meet the most advanced design requirements. “What we do here,” says one of the founding partners, Mauro Baiocco, to present its business, “is making outdoor spaces more comfortable and liveable thanks to our furniture and accessories made in durable, premium materials, created with functionality and style in mind, and characterised by a refined combination of lines and colours. The attention we pay to green spaces and nature in general is also reflected in the standards we adopt to ensure fair, environmentally friendly production processes, also protecting the safety of our employees and geared towards providing durable, high-performance finishes.”

In fact, coating objects or structures intended for outdoors involves a more complex process than those intended for indoor use. “We have carefully improved each phase of our coating cycle because even though this is our final production step before assembly and packaging, it is responsible for the appreciation of our furniture nationally and internationally. Therefore, we started by perfecting the pre-treatment phase and then optimising the gelling phase before curing, which we have been carrying out for over 12 years with Infracat® catalytic panels, to which we have recently added a series of RHT gas radiant burners. Infragas Srl (Mappano, Turin, Italy) supplied us with both technologies.”

The history of Vermobil

The Umbria region, where Vermobil was established and developed, has

The pre-treatment tunnel using Chemtec’s multi-metal product Toran 3. The inside of the oven with the 22 Infracat® catalytic panels.

always been an important district for the furniture industry. “In 1993 there was the beginning of the adventure of our company, founded to offer a contract coating service for metal furniture, although it soon moved on to manufacture its own products thus meeting the needs of an increasingly demanding market. In 1995, the major players in the sector gathered, first, at the SPOGA fair in Cologne (Germany) and, then, at the Sun trade fair in Rimini (Italy), the most important outdoor furniture exhibitions in Europe at that time. Our presence at these events enabled us to make a breakthrough in the Swiss market and begin to distribute our products throughout the DACH market, as well as in Italy.”

The success of its furniture and accessories also enabled Vermobil to

grow in size. “Our original factory occupied an area of about 4,000 m2, to which another hall of 2,000 m2 was soon added. Both the facilities were addressed to the production department. "In recent times, an additional building spanning 7,000 m2 has been acquired for shipping warehouse and offices purposes. The three buildings currently house a total of 60 employees."

Today, the company’s main target market is Italy and its core business is outdoor furniture for the contract industry, especially for bars and restaurants. “We have established important partnerships with leading outdoor furniture companies. Our collaboration with them also raises the reputation of the products marketed under our own brand name, which can now be found in the high-end design segment.”

The gelling phase on some chairs.

The RHT burner section integrated in 2022. © ipcm © ipcm

Care at every production stage

From the purchase of raw material, consisting mainly of carbon steel and aluminium, to final shipment, the entire production process takes place in-house, except for cold galvanising, which is outsourced. When they go back to Vermobil’s factory, components have already undergone degreasing, perfected with a pre-treatment process, followed by drying, base coat application in a booth designed and installed by Siver (Corciano, Perugia, Italy), gelling in an Infragas IR oven, top coat application in a quick-colour change booth equipped with Nordson dense phase guns (of which Siver is the exclusive dealer for Italy), and final oven curing.

“For about a year now,” says Baiocco, “we have been using the one-stage product Toran 3 supplied by Chemtec (Corbetta, Milan, Italy) in our pretreatment process, after numerous tests carried out with an in-house large-sized salt spray test device capable of accommodating up to 3 chairs. This multi-metal product is suitable for both iron and aluminium, a valid alternative to phosphodegreasing or phosphating followed by passivation. As the product dries, it deposits a very thin, continuous, three-dimensional conversion film that promotes paint adhesion and increases the corrosion protection performance of the coating system. The organic polymer film obtained encapsulates the oily contaminants

on the workpieces, trapping them in the three-dimensional structure of the polymer formed on the metal, thus avoiding waste generation and converting the contaminants into an active part of the process. The result of the pre-treatment stage is functional to the aesthetic performance of the coating system, as well as to the environmental friendliness of our manufacturing operations: Toran 3 does not generate any emissions or waste to be disposed of.”

The oven installed in Vermobil’s paint shop is used for both drying after pre-treatment and curing. “To avoid any risk of contamination, we compartmentalised it. On one side, the burner feeds the oven for drying up to a temperature of 150 °C. On the other side, our Qualicoat class 1 and 2 polyester thermosetting powders are subjected to the final curing stage at 190 °C for 15/20 minutes.”

The infrared gelling system’s upgrade Vermobil has been using infrared technology for powder gelling since 2012. “Previously, we were forced to pass our parts through the curing oven twice, which meant a considerable waste of energy and time,” emphasises Baiocco. “The installation of the Infragas oven was such a turning point in our production flow that 10 years later, we decided to

upgrade its technology with the integration of RHT burners.”

“The first equipment provided to Vermobil,” indicates Francesca Marabotti, Business Development & Marketing Manager at Infragas Srl, “included 20 catalytic panels from the Infracat® series, a name chosen by our team to emphasise the combination of infrared energy and catalytic technology. With a surface temperature that can be adjusted from 180 to 550 °C and a power output ranging from 1.5 kW (1290 kcal/h) to 17 kW (14617 kcal/h), these panels are designed to develop a power density of 20 kW/m2 at a medium to long wavelength (2 to 10 μm). This guarantees infrared radiation that is, first of all, safe thanks to the absence of flames and, secondly, effective because the prolonged permanence of the electromagnetic wave on the parts’ surfaces results in better absorption by the organic material, leaving the characteristics of the substrates unaltered. In this specific case, the panels supplied to Vermobil belong to our 18.60 Infracat series and have a power range of 7.2 to 12 kW.”

“In 2022, after 10 years of truly satisfactory use,” explains Baiocco, “we decided to test the Radiant High Temperature (RHT) technology. We visited Infragas’ test centre together with a team from Siver, our long-standing plant engineering partner, to assess the results we could

achieve by implementing a new RHT radiant burner section.” Following the tests, the company opted for adding a section of 3 RHT burners, 2 7C vertical ones and one 7L floor one, for a total installed power of 210 kW and manageable power up to 105 kW, in order to achieve a better powder curing performance.

“Infragas’ RHT gas radiant burners are infrared, pre-mixed gas systems that reach a surface temperature of 950 °C,” illustrates Marabotti. “They are a safe and reliable source of heat generated by burning natural gas or propane, transmitted through short-wavelength infrared rays. The structure of Radiant High Temperature burners is made of stainless steel for excellent robustness over time. Each burner has a control and pre-mixing unit for properly mixing air and gas. The micro-flame combustion on metal surfaces produces extremely low amounts of NOx, carbon monoxide, and unburnt emissions, an important factor from an environmental and safety point of view.”

The advantages of the new hybrid system

“With the parts dwelling in the oven for just 3 minutes and the double curing stage being eliminated, the advantages of catalytic technology were already obvious in terms of energy and time savings, but today,

The panels’ flexible installation allows them to be tilted horizontally, vertically, and obliquely as required to heat all surface areas.

The RHT burners’ control and pre-mixing unit for properly mixing air and gas.

FOCUS ON TECHNOLOGY

thanks to this hybrid system, we have further improved our coating quality,” confirms Baiocco. “The integrated RHT burners increase the effectiveness of radiation, enabling all-round heating of the entire surface of each component. This prevents the base coat layer from surfacing after the top coat has been applied. To avoid this problem, we were previously forced to apply dark top coats on dark base coats and light top coats on light base coats. Now, we can use only one monochrome base coat regardless of the colour of the top coat, with excellent results that are also highly appreciated by our customers in Northern Europe – who differ from the rest of the market in the strictness of their finishing specifications, as outdoor furniture is put to the test by the harsh weather conditions of those geographical areas. Saving energy and increasing the speed of the coating cycle also enables us to offer an even more sustainable production flow.”

Sustainable infrared catalytic technology

“Infrared radiant panels use catalytic gas oxidation technology to emit heat in the form of infrared rays,” adds Marabotti. “As a result, they can heat the material’s surface alone, improving the production process’ overall efficiency. They are equipped with a highly effective catalytic converter that allows achieving high temperatures with low electrical power consumption during the pre-heating phase, thus ensuring energy savings. In some cases, when treating parts such as cylinders or tanks that can turn on themselves 360°, our IR ovens can replace conventional hot-air ovens by reducing curing times by at least 3 times. In the case of Vermobil, we developed a system to speed up the coating cycle that was also endorsed by plant engineering company Siver.”

“Siver has been working with Vermobil since 1993, the year of its foundation,” says Marcella Baldoni, the owner of this Perugia-based company, “and has always affirmed the effectiveness of catalytic and RHT

Manual top coat application with a Nordson gun. Vermobil’s catalogue includes 6 standard colours, as well as special finishes made to customer specifications.

© Siver © ipcm

technologies, so much so that it immediately validated the hybrid system tested at Infragas. Since 2014, Siver has been the exclusive dealer for Nordson equipment in Italy, and this partnership has enabled us to provide our customers with an even more innovative range of products.”

“Siver supplied Vermobil with its first coating booth,” notes Baiocco. “Since then, mutual trust has been the basis of our 30-year collaboration. It was its owner, Luca Tomassoni, who suggested we contact Infragas to solve our coating problems. Its excellent consultancy service and the geographic proximity between our companies enable its team to intervene quickly for any critical issues. They provided us with advanced and flexible coating equipment, suitable for new future products.”

“As a company specialising in high-end outdoor furniture,” concludes Baiocco, “the natural environment is precious for us, and surrounding ourselves with reliable partners whose solutions enable us to minimise our impact is equally essential. From the choice of pretreatment chemicals to gelling and curing technologies, up to powder application equipment, Vermobil has further confirmed its focus on protecting the environment and greenery, without which our products would have no reason to exist.”

From left to right: Mauro Baiocco from Vermobil, Marcella Baldoni and Simone Tomassoni from Siver/Nordson, Francesca Marabotti from Infragas, and Alessia Venturi from ipcm®

Vermobil’s furniture and accessories must withstand harsh weather conditions like those in northern European areas. © ipcm

© Vermobil

Achieving Excellence and Offering Impeccable Finishes: D.P.F. Srl’s New Coating Plant

Ilaria Paolomelo, ipcm®

In order to meet the market’s growing demands and continue its journey towards excellence, D.P.F., specialising in contract coating for a wide range of sectors including furniture and design, has recently installed a new coating plant designed and built by Verona Impianti 2002. Developed to treat anything from small parts to large components, this new line has enabled the company to achieve excellent quality results while reducing energy consumption and increasing sustainability.

In the industrial coating sector, providing superior-quality products is the cornerstone for standing out in the market and maintaining a competitive advantage. The expertise and experience of the operators involved in the coating process, together with the careful selection of the paint products, technologies, and equipment used, are

critical elements in meeting the demanding requirements of customers. The coated components must not only guarantee excellent strength and durability but also impeccable aesthetics.

And if there is one sector where quality and aesthetics play a primary role, it is undoubtedly the design and furniture one. Here, every detail,

Overview of the system designed and installed by Verona Impianti 2002.

shade of colour, and surface finish contributes to the product’s added value. Therefore, for a coating contractor specialising in the indoor and outdoor furnishing sector, ensuring high-quality finishes is not just a duty but a real mission.

A tangible example of such dedication to quality is D.P.F. Srl (Trebaseleghe, Padua, Italy), a company specialising in contract powder coating for a wide range of industries, including furniture and design. To meet the growing needs of the market and continue on the path towards excellence, it recently inaugurated a new plant accommodating an innovative coating system from Verona Impianti 2002 (Colognola ai Colli, Verona, Italy), a supplier that has been designing and building industrial coating systems for over twenty years.

D.P.F.: a benchmark contractor for the furniture sector

D.P.F. Srl was founded in 1996 thanks to the entrepreneurial vision of Onofrio De Palma. With constant commitment, dedication, and experience, it has grown to become a well-established player in the industrial coating sector. “Although originally we were focussed on

liquid coating, we made a clear choice to shift our core business and devote our services exclusively to powder coating, because we believe that that when choosing the right products and processes, powder coating ensures superior resistance and durability performance,” states Paolo de Palma, the company’s owner and a member of the second generation at its helm.

“With a team of 12 people, we have been able to consolidate our market presence as a contractor operating with world-renowned companies from a wide range of sectors, including heating, plumbing, construction, and lighting, mainly from Italy’s Veneto and Friuli-Venezia Giulia regions. However, the sector that is of the utmost importance to us is that of indoor and outdoor furniture. In this industry, surface finishing is not only a matter of functionality but also of aesthetics. Indeed, our finishes are of the highest quality, and we are constantly searching for the best coating technologies to meet our customers’ needs. For us, excellent aesthetics are synonymous with quality and attention to detail.” That is why, when D.P.F. had to purchase a larger plant a few years ago to meet its customers’ growing requests, it chose

Components at the entrance to the pre-treatment tunnel.

The boiler and heat exchanger that feed the tunnel and heat water are separate from the tanks that make up the pre-treatment tunnel.

to install a new coating system that would allow it to achieve a higher degree of quality in line with the latest market demands.

The production requirements that led to the installation of the new system

“Our choice to expand our premises was motivated by various requirements and opportunities identified over time. Four years ago, we felt the need to expand our production department, since our old building was becoming too small to fulfil all the orders we had to process. We started looking for new, suitable premises, and at the same time, together with engineer Albino Tamellin, the owner of Verona Impianti 2002, and his sons Pietro and Stefano, we embarked on a journey to build a new coating plant, which turned out to be a success,” acknowledges D.P.F.’s owner.

The company’s main goal when designing the new line was to equip itself with a versatile system that could coat a wide range of parts

differing in size and weight and fill the previous plant’s gaps, especially in the pre-treatment cycle. “Verona Impianti 2002 provided us with valuable input based on its long-standing experience in the industry, suggesting we implement a system that would guarantee excellent surface finishes thanks to an optimised pre-treatment process and greater attention to the curing phase,” adds De Palma.

The coating cycle

“The plant is designed to treat both minute workpieces, such as small metal parts, and large components, such as metalwork fabrications. Its conveyor can handle up to 20,000 kg on the line and 150 kg per hook,” illustrates De Palma.

The process begins with the manual loading of the workpieces onto a monorail chain conveyor featuring rotating hooks, which are essential for parts requiring rotation during coating. Subsequently, the parts undergo a pre-treatment cycle consisting of four stages:

The parts’ dripping tank at the end of the pre-treatment tunnel.

The drying oven.

 phospho-degreasing;

 1st rinse with mains water to remove most impurities and the detergent used in the previous stage;

 2nd rinse with cleaner mains water to minimise residual impurities;

 final rinse with demineralised water.

“The special characteristic of this 22 m-long pre-treatment tunnel is that the boiler containing the heat exchanger that feeds the tunnel and heats the detergent solution is separate from the tunnel’s tanks. In most plants, these devices are located inside the tank, below the hot-stage spray bars. The solution adopted here, however, makes periodic cleaning of the heat exchanger much easier and safer for operators, and the heat exchanger itself tends to remain cleaner, increasing heat exchange efficiency and reducing energy consumption. Given its undoubted advantages, we offer this solution with a boiler separated from the tunnel as

Top view of the coating plant.

standard to all our customers,” says Albino Tamellin.

“Moreover, the spray bars are fed by a manifold at the top of the tunnel, which ensures more constant water supply pressure and prevents the formation of sludge due to water stagnation, since the bars empty automatically by force of gravity when the tunnel is turned off. Feeding often occurs from the bottom up, leading to much more frequent nozzle clogging issues and uneven pre-treatment results over time. Therefore, this has also long been the standard for our plants.”

After pre-treatment, the components are taken to the drying oven, where they dwell for 13 minutes at 120 °C, and then to the paint application booth, where D.P.F. performs completely tailor-made cycles with a varying number of layers depending on customer requirements. D.P.F. has only one booth for both primer and top coat application.

“We already used it in our previous line. As we are fully satisfied with its efficiency and reliability, we asked Verona Impianti 2002 to integrate it into the new line’s layout. The powders are applied manually with Zeus Electrostatic System’s Gen 01 electrostatic guns, ensuring greater

flexibility and the possibility to also treat complex parts, especially when it comes to furniture components requiring meticulous finishes,” notes De Palma.

“Thanks to dedicated software, the air-convection drying and curing ovens record temperature trends and display diagrams that help ensure curing uniformity and consistency while maintaining low energy consumption. After powder curing at 180 °C, the parts are conveyed to the cooling area, manually unloaded by the operator, and subjected to rigorous quality controls,” explains Pietro Tamellin.

Sustainability measures

One of the main difficulties D.P.F. encountered with the previous plant concerned pre-treatment. For this reason, Verona Impianti 2002 devised a series of measures – the heating boiler separated from the tunnel body and the spray nozzle’s feeding from above – creating an optimal cycle that would guarantee excellent paint adhesion and durability over time.

Manual coating application inside the booth.

Coated components entering the curing oven.

© ipcm

© ipcm

D.P.F. also aimed to optimise energy consumption. Several measures were implemented to this end, as confirmed by Tamellin: “The cleaning tunnel’s pumps are equipped with inverters to adjust rotation speeds and optimise energy consumption.” The tunnel also features electric heaters to heat water using the photovoltaic panels installed last year, enabling the company to be completely autonomous during the summer months. The drying and curing ovens are also energy efficient: both are equipped with air curtains designed to retain all the heat inside their chambers and avoid dispersion, assisted by a system for reintroducing the hot air escaping from the part inlet and outlet openings called “economiser”. The ovens’ heat consumption is also minimised through excellent mineral wool insulation. Accurate temperature management is essential to ensure the quality and efficiency of the coating process. “We regularly check the temperatures inside the ovens and pretreatment baths. In the former, we constantly monitor the temperatures to ensure they are optimal and stable. Similarly, we perform regular checks on the temperatures and substances contained in the pre-treatment baths,” says De Palma.

Maintenance and full process traceability for higher quality

“The plant was developed in compliance with the Industry 4.0 principles, which means we

have integrated advanced technologies to ensure analytical management and highquality production. One of its main features is the PLC control system, enabling us to manage the plant from the terminal. We can monitor and control all key parameters, including speed values and oven and bath temperatures, thus ensuring optimal operation and maximum precision in the coating process,” indicates Stefano Tamellin.

In addition, the plant has a remote service and control system that allows for quick intervention in case of production anomalies or defects. “Thanks to full process traceability, we can identify and correct any issues promptly. In the event of anomalies, the system emits an alarm enabling the operators to intervene quickly to solve the problem,” says De Palma. “Computerised production management has revolutionised our

The coating system is managed by the PLC.

approach to coating, enabling us to optimise the part’s feeding speed and monitor the production flow in real time.”

The importance of finishing Quality is a non-negotiable for D.P.F., but its range of finishes also plays a key role in its success. This coating contractor offers a wide choice of finishes, including epoxy, polyester, epoxy-polyester, and polyurethane coatings in their gloss, semi-gloss, matte, and super-matte versions and with different effects, from textured to wrinkled. “We coat 90% of parts with polyester powders purchased from some of the most important paint suppliers. We chose to mainly use this type of coating due to the variety of intended uses of the components we treat, which could also be exposed to marine environments. Polyester powders guarantee high mechanical, weathering, and corrosion resistance properties, ensuring reliable performance in any context,” the owner of D.P.F. continues.

Reduced consumption and improved quality: the main advantages of the new line

“From the energy consumption point of view, we recorded a significant

40% saving on methane gas, which is a major achievement that fits into a broader strategy aimed at energy efficiency and using alternative sources,” states De Palma.

Another advantage of the new system is the increase in quality, which was an essential requirement for the success of D.P.F. “Attention to detail is a hallmark of our work, especially in the furniture and design sector. To achieve better results in terms of durability and quality of finishes, we have improved our pre-treatment cycle by adding a rinse with demineralised water, which was implemented just after the plant was commissioned precisely to further improve paint adhesion and durability,” says De Palma.

“In addition, again to optimise the coating cycle, we have installed an oil seal channel on the conveyor to prevent chain lubrication oils from dripping on the parts’ surfaces,” adds Pietro Tamellin.

“We are pleased to confirm that we have achieved our initial objectives. Our collaboration with Verona Impianti 2002 was crucial to the success of this project. We have found a reliable and competent partner in this company, which has allowed us to establish great cooperation from the beginning,” says De Palma.

From left to right: Albino, Pietro, and Stefano Tamellin from Verona Impianti 2002 with Paolo De Palma, and two employees from D.P.F. Verniciatura.

ipcm

CHEMICAL MAKING SOLUTIONS

TRATTAMENTO ACQUE WATER TREATMENTS ←

PREVERNICIATURA E NANOTECNOLOGIE

COATING PRETREATMENT AND NANOTECHNOLOGIES

SGRASSANTI INDUSTRIALI DEGREASERS

SVERNICIANTI PAINT STRIPPERS

New Perspectives for Quality Control in Industrial Coatings

Carola Konitzer

PhoenixTM GmbH, Bad Oeynhausen - Germany carola.konitzer@phoenixtm.de

Precise knowledge of the various oven parameters is essential to optimise the product quality, productivity and efficiency of the coating plants. This is a very important criterion, especially in the current situation, as it helps to reduce costs, increase productivity and thus be able to act more economically.

Production without well-functioning quality control is not possible. The demands are constantly increasing. Customer specifications must be met and verified, as well as the specifications of the paint manufacturers. Especially in the coating industry, there are also more and more standards and certifications, compliance to them is essential. But how can all these specifications and decrees be integrated into the operating processes as effectively, economically and simply as possible?

PhoenixTM has been very successfully with the design and development of temperature measuring systems for 10 years now. In addition to the well-known systems, there are always new products that are added to the product range and further developments. PhoenixTM has been very active in this area over the last two years. In addition to the new and innovative optical systems, there is the Epsilon system, which has been approved for ATEX zones and can be used safely in the hazardous areas of the paint shop, thus contributing to a legally compliant working

environment. In addition, there is a completely revised user software that has been specially optimised for the paint shop area. The TS04 Finishing System is a complete solution for monitoring temperature data, especially in coating processes. The system is easy to operate and records the temperature data of the product during the oven cycle. By attaching the thermocouples directly to the product, such as a car test body, it is possible to bring it into the coating line at any time. There, the actual product temperatures are recorded. The pyrometers permanently installed in the oven can only measure the ambient or external surface temperatures. They therefore do not provide any information about what is happening in the more difficultto-reach areas of the product, for example in flanged sheet metal parts. Before the measurement, a test product (e.g. the aforementioned car body) is fitted with thermocouples at all relevant points in order to obtain a comprehensive picture of the heat distribution over the entire

The standard FIS04 temperature measuring system.

© PhoenixTM GmbH

process. The data obtained in this way are stored in the data logger. This is protected from the temperatures prevailing in the oven by a thermal barrier. At the end of the process, the data logger is removed and read out. With the help of the ThermalView finishing software, the raw data is converted into meaningful process data. With this information, quick and well-founded decisions can be made to solve baking problems. The measurement results are available as a complete temperature profile at a glance and can be used, for example, for process or product optimisation, customer audits, reduction of operating costs, saving of resources and much more.

ThermalView Finishing Software

This software has been specially developed for the coating industry and is an easy-to-use tool. The entire oven process is displayed using detailed graphical data. For example, the heat source and fan positions can be stored so that problem areas can be located quickly. The possibility to store cure chart and their factorisation on the basis of user-defined specifications shows at a glance whether all measuring points are within the specifications. Profile comparisons with other measurements are also possible. A standard report shows all relevant information and a graph. Subsequently, various detailed evaluation reports can be created.

Phoenix Factor

The Phoenix Factor as a curing index is the exact calculation of the paint or powder coating process by means of temperature profiles including the cross-linking temperature with the aim of presenting the result easily

understandable and comparable as a numerical factor. The curing of the coating is dependent on both time and temperature. For this reason, paint and powder manufacturers specify recipes or curing charts according to which the paint should be baked in order to achieve a good quality result. This recipe is stored in the software as a ‘time at a certain temperature’ curve.

If we look at these curves taking into account separate firing windows, we find that the time at 180 °C is identical for both curves, although the curves are in fact very different. If we take these curves and analyse them as they are against the specifications, we must conclude that undercuring has occurred here. Time at 180 °C for only 7 minutes, instead of the specified 12 min (Table 1).

But how to analyse the holistic nature of the results? The application of mathematics allows the exact calculation of the curing of lacquers or powders including all curves in the temperature profile. The Arrhenius equation, named after its inventor Svante Arrhenius, describes approximately a quantitative temperature dependence in physical and chemical processes in which an activation energy (here the transition to cross-linking) must be overcome at the molecular level. For coating, it is assumed that the frequency factor (k) refers to the reaction temperature at which A and E both constantly cause cross-linking.

In relation to the temperature curve, this means that a reference curve is created using three temperature points specified by the coating manufacturer in order to determine the values between the points by interpolation (Table 2). In this way, the required curing time at any temperature is calculated for each measuring point. Then, taking into account the total curing time, the total equivalent of the curve at a given

Screenshot from the new ThermalView finishing software.

temperature (here 180 °C) is determined (Table 3). The ThermalView software compares these values and determines the curing index, the so-called Phoenix Factor. This is clearly and simply displayed in a graph and provides an immediate overview of the measurement taken and its result.

Despite the supposedly measured underbake that the component was de facto overcured. The evaluation shows an actual time at 180 °C of 21:50 min. instead of the manufacturer›s optimum specification of 12 min. This is almost a doubling of the baking time. A precise and holistic observation of the curing process, with the possibility of direct comparison of the parameters specified by the manufacturer, is thus the more accurate alternative to ‘time @ temperature analysis’.

Advantages at a glance

 Determining whether there is an under- or overcuring with just one glance;

 Precise setting of process parameters guarantees quality and efficiency;

 Recording the Phoenix Factor over a longer period of time enables preventive correction of errors for upcoming processes;

 Simple comparability of different coatings.

From top to bottom:

Table 1: Simple setpoint/actual temperature curve.

Table 2: Constant curve - reference curve of three points.

Table 3: Calculation of the Phoenix Factor.

Dual expertise for the perfect surface

Profile splitting for more flexibility

For example, a car body passes through four ovens to finish the paint. With the PhoenixTM FIS04 system, all ovens can be recorded in one run and with one measurement. This means that the test car body is prepared once and automatically passes through all areas. This makes the measurement effort much easier and more accurate, as measurements are truer to the process. If the ovens are measured individually, there is undesired cooling on the body each time, which can affect the final result. Afterwards, the measurements can be split to make detailed statements and add separate process parameters.

Current zone temperatures

The ability to include target and actual temperatures in the analysis means that deviations from these can be quickly identified and rectified. By including these in the evaluations, the auditor can be provided with a comprehensive picture of the drying process and its parameters.

New coating and process library

In addition to the proven features, the default variants for the evaluation as well as the Phoenix Factor and the curing charts have been added. The process library makes it possible to archive the various firing processes with the respective furnace settings.

Cold junction temperature

As an additional safety feature for the proper operation of the data logger, it is now possible to display the temperature curve for the cold junction sensor. This shows the internal operating temperature of the data logger in a separate graph. In this way, the user can see at a glance whether the data logger has been used reliably.

Focus on operational safety

The focus of the considerations was to create a device that meets the strict requirements of explosion protection at the workplace according to the latest EU standards. The basis for further development here is the proven PTM1-200 data

logger. The resulting Epsilon series is intended to meet the requirements of the ATEX regulations (ATmosphere EXplosive = Explosive Atmospheres). Since the last amendment in 2015, these have been transferred from the BetrSichV (Ordinance on Industrial Safety and Health) to the GefStoffV (Ordinance on Hazardous Substances)

In the course of this transition, various new requirements were added to the regulations, which must now be taken into account. In order to be able to offer legal certainty to those responsible in the company, PhoenixTM has further developed the data logger and the associated components so that they comply with the valid ATEX approvals according to Directive 99/92/EC (or ATEX 137). It has been certified accordingly and is approved for Ex zone 2. This is particularly important for wet painting systems, as the paints are outgassed during the curing process and, depending on the recipe, explosive gases can be produced.

The Optic System

With the optical system, PhoenixTM has added another effective tool to optimise process control to the product family. Optical checks usually take place after the drying process. Defective products are then sorted out or reworked at great expense. PhoenixTM has now expanded its existing portfolio for inprocess temperature monitoring in paint dryers with the new optical monitoring system. This is used by the technician to view the interior of the oven as well as the product under production conditions. Like the temperature measurement system, the system travels directly through the process and videotapes the entire process as it passes through the oven, providing a complete picture of the paint drying process.

In paint drying processes, so-called paint noses, drops or similar can occur from time to time, which represent a quality defect. The causes are known, for example, fans or burners generate air currents that can push up the still moist paint or the melted powder. But it is not always easy to find out where and when these arise in the dryer. The new optical system now makes this possible directly in the process, in which a camera travels through the oven

Hall 2

Booth 2410

and records what happens to the paint at the relevant points. In this way, problems can be detected and rectified without having to interrupt production. Oven revisions can also be better controlled in this way. The recorded videos also provide information on whether there is any wear or tear, for example, on the oven cladding, the insulation material or the racks. Defective fans or heating elements can also be detected, as well as deposits and dirt. In this way, the user knows at any time what condition the dryer is in and whether maintenance or repairs are necessary. The special features in the development of the system are in the challenge of maintaining the heat protection and at the same time maintaining a view for the camera and the light source. The heat-resistant glass used to close these openings for the optics and light source is designed to withstand the prevailing temperatures on the one hand, and on the other hand to allow illumination and adjustment of the camera angle as required. Likewise, due to the optical implementation, attention had to be paid to the lowest possible interior heating. With a powerful 4K HD video camera and a 1000 lumen illuminant, detailed videos are recorded so that even the smallest problems and errors can be detected. The Optic System is available in different versions. It is possible to use both an independent system and a combined system that combines temperature and optical recording.

The ATEX-compliant Epsilon system.

The optical system with data logger.

© PhoenixTM GmbH

© PhoenixTM GmbH

Eurosider Presents POLIFLUID ® , a Patented System for Powder Coating

Visibly better finishing, powder reaching the most difficult areas, colour uniformity and savings of coating materials are only some of the many advantages which allow end users of POLIFLUID® to apply powder coatings with excellent results, without the need to make expensive modifications or replacement of existing coating equipment.

When installed on powder coating lines with cyclone system, even with 99% of powder recovery, POLIFLUID® guarantees a significant increase of transfer efficiency and higher performance, expressed in m2/kg of powder used. The Return on Investment (ROI) is calculated to be from 6 to 8 months averagely. POLIFLUID® concentrates the nitrogen contained in compressed air through the principle of selective permeation and uses it as a fluid carrier during all stages of powder application. The temperature control of the fluid carrier and the positive or negative ionization

further enhance the inherent performance advantages of the system. POLIFLUID® produces inert, anhydrous and clean fluid carrier and enables constant humidity and temperature values: two previously uncontrolled variables.

The application conditions can therefore be controlled and consistent all day long and through all seasons. POLIFLUID® is installed between the air compressor and the powder coating application point.

It does not replace users’ existing equipment but operates with it for the application cycles, feeding:

 electro-static application (so called “Corona”);

 tribe static application;

 fluidizer bed. Various kinds of powder coatings can be used with POLIFLUID®:

 effect powders;

 metallic powders;

 pearled powders.

The advantages of POLIFLUID®

 Economic aspect

- 20-30% overage savings of coating materials;

- Improved transfer efficiency of powder coating;

- Improved yield;

- Optimization of all application technical parameters.

 Productivity

- Higher fluidity of powder during the application, leading to better reach of difficult areas (as corners or edges);

- Excellent coverage and powder performance with less micron even on problematic areas as weld joints;

- Improved control of electro-static charge with reduction of the Faraday Cage effect;

- Quicker colour switch;

- Increase of production line speed from 10 to 20%.

 Quality

- Uniform thickness and colour with excellent appearance;

- Improved finish due to better lay down of coating material;

- Less finishing defects, such as orange peel, blistering, blushing;

- Lower speed and powder volume at the gun output.

 Environment and safety

- Improvement of working environment conditions with cleaner booths;

- Less stress for workers due to constant and repeatable conditions of application;

- Increase of safety level in terms of fire prevention.

Eurosider will exhibit at PaintExpo, hall 2, stand no. 2528.

For further information:

https://eurosider.com/en/

© Eurosider

ALIT Technologies S.p.A will Attend PaintExpo 2024

ALIT Technologies is thrilled to announce its participation in PaintExpo, the main European trade fair dedicated to the world of industrial coating technologies.

ALIT Technologies, a company specialising in the manufacturing of machines and products for the chemical paint stripping of metals, will attend as an exhibitor the 2024 edition of PaintExpo, which will be held in Karlsruhe, Germany, from 9th to 12th April.

ALIT Technologies, in a spirit of continuous growth, will make PaintExpo the perfect opportunity to present many new features and some innovative projects that will leave stand visitors pleasantly surprised.

For the 2024 edition of PaintExpo and with this in mind, ALIT Technologies decided to go big by setting up the company’s largest stand ever.

The trade fair will represent an excellent opportunity to meet several stakeholders operating in the world of industrial coating as well as to exchange views and ideas on the present and future of this sector.

ALIT Technologies thus awaits you at PaintExpo, stand 2446, hall 2.

For further information: www.alit-tech.com

electrostatic systems for liquid painting

2 in 1 Smart Solution for an Affordable Anodizing in Minimum Space

Alsan Alvarez Schaer, a Spanish company specialised in the chemical and mechanical engineering for the surface treatment of aluminium and other metals, presented ANODIKIT® Zone, a new compact anodizing line that was developed as an affordable solution to all those companies reluctant to install a traditional anodizing line in their factories while meeting all Qualanod quality requirements.

ANODIKIT® Zone is a new compact anodizing line that was developed by Alsan as an affordable solution to all those companies reluctant to install a traditional anodizing line in their factories while also meeting all Qualanod quality requirements.

This installation only requires 200-250 m2 of space because of its revolutionary concept and is completely made of plastic and glass fibre. With just 4 tanks, for natural version, it is designed to provide high service quality and cope with production rhythms that are not

very high, such as order changes, small colour runs, or overnight orders. The key element that differentiates this line from traditional ones is that surface finishing is achieved by means of a spraying system. In fact, this is what makes it possible to “compact” the process and reduce the space required for the line, that is, the number of tanks required as well as their volume. This means that ANODIKIT® Zone concept saves a minimum of six tanks for pretreatment stages which are all done in just one tank. Another key difference with traditional lines, and also one of Alsan’s

patented elements, is the rotative frame used that, with its movement, allows that all profile faces can receive a homogenous application throughout the different treatment stages. The loading system is completely different from that of a traditional anodising system, because the finishing product is sprayed during almost the entire process in order to achieve the same finishing quality as a standard plant.

Line automation is controlled by AluZone software, which continuously and automatically collects more than 200 variables, controlling all required parameters. The concept for this compact anodising plant, unique in the world and patented in 2020 by Alsan, is available in three versions:

 Natural anodized finish (with just four tanks).

 Coloured finish (with an electrocolouring tank).

 Qualanod-certified finish (including an ageing bath).

Alsan Alvarez Schaer will exhibit at PaintExpo 2024 in hall 2, stand 2630.

For further information:

https://www.alsan.es/en/

Carlisle Fluid Technologies Offers Training and Webinars at its UK Facilities

The United Kingdom facilities can offer you training in different areas such as refinishing, sealant and Adhesive, fast Set, powder, liquid.

At Carlisle Fluid Technologies the team is always supporting customers through products and services. The laboratory in Bournemouth, United Kingdom offers the latest technology for training courses, from programmed robots to a conference room that can host up to 50 attendees and is equipped with video cameras, 8 speakers and screens that can present duplication.

The refinishing area of the company counts with Manual and Automatic finishing and curing area, in which you can find brands like BGK, DeVilbiss, Trisk-DeVilbiss, Binks.

Carlisle Fluid Technologies also offers a Sealant and Adhesive laboratory where you can find our 3D guns and dosers in action.

The Powder laboratory counts with a display of MS products, from MS M5 manual guns, MS Topcoater, where customers can experience for themselves the technology.

The Fast Set laboratory displays the IntelliSpray IS40 along with the QuickHeat Hose and ST1-gun.

Carlisle will display its solutions at PaintExpo 2024 in hall 3, stand 3526.

For further information: www.carlisleft.com

Chemtec to Participate at PaintExpo 2024

Chemtec will showcase its innovative technologies for the surface pre-treatment and industrial wastewater treatment at PaintExpo, hall 2, stand n. 2623.

Chemtec, an Italian company specializing in the formulation, production and commercialization of technologies for the industrial finishing sector, ranging from surface treatment to industrial wastewater treatment, will participate in the 2024 edition of PaintExpo, the world’s leading trade fair for industrial coating technologies that will be held in Karlsruhe (Germany) from 9 to 12 April 2024. On this occasion, Chemtec will showcase a wide range of innovative chemicals with a low environmental impact developed specifically for the pre-treatment of surfaces; solutions which allow to replace the traditional phospho-degreasing and zinc phosphating with the latest cutting-edge processes. These products include TORAN 3®, a single-stage, room temperature pre-treatment technology suitable for a wide range of metals, and PRONORTEC, a nanotechnology based on the use of organic phosphorous compounds designed to provide an innovative chemical process. Chemtec’s chemicals and systems for the treatment of wastewater generated by painting booths using water curtains for overspray separation grant an enhanced purity of the water, reducing disposal costs and ensuring the high quality of the painting process. At Chemtec’s booth, visitors will have the opportunity to deepen their knowledge of the company and, thanks to the presence of highly qualified and specialized sales technicians, to understand how these chemicals and systems can fully meet their needs. Thanks to the advanced R&D laboratory, which allows to conduct cutting-edge analytical tests, it is possible to perform comprehensive paint quality and corrosion resistance tests, in order to develop innovative solutions to improve finishing cycle performance.

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

D.B.M. Tecnologie: 40 Years of Excellence in Industrial Automation and Surface Finishing

From an interview with D.B.M. Tecnologie Technical Sales Specialist Alessandro Mattiuzzo and Operations Planning Manager Nicoletta Mattiuzzo

40 years is an important milestone for a company. However, significant goals can only be achieved through experience and adaptation to challenges and opportunities. In 2024, D.B.M. Tecnologie celebrates its 40th anniversary. A long-established Italian company specialising in the production of surface treatment equipment, it has achieved the perfect synergy between quality and innovation in recent years. This article outlines its history and future goals.

For a company, its 40th anniversary is an opportunity to be grateful and recognise the path taken and the challenges overcome, reflecting on the importance of consistency, innovation, and commitment to achieving lasting results on the market. Celebrating this milestone also strengthens the bond among the company, its employees, and its customers, reaffirming the value of its presence in the industry and its commitment to the future.

In 1984, a small business was founded in the province of Treviso (Italy), destined to become a benchmark supplier in the industrial automation and surface treatment sectors: D.B.M. Tecnologie.

© D.B.M. Tecnologie

D.B.M. Tecnologie specialises in designing, constructing, and installing industrial cleaning and coating equipment.

The first 40 years of activity and the D.B.M. Group

Founded by four partners, D.B.M. Tecnologie soon specialised in designing, constructing, and installing industrial cleaning and coating equipment, especially for the eyewear sector. Through constant commitment to research and development, it has designed several state-of-the-art systems and earned the trust of many major global market players. This has enabled D.B.M. Tecnologie to expand into several sectors, including home appliances, automotive, fashion, electronics, aerospace, and medical, and conquer important markets in Europe, South America, and Asia-Pacific. “In order to meet the needs of the surface treatment industry, D.B.M. Tecnologie has gathered a pool of companies that work in synergy to provide a comprehensive, reliable, and accurate service from a single source,” explains Alessandro Mattiuzzo, Technical Sales Specialist.

The D.B.M. Group is composed of the following divisions:

 D.B.M. Tecnologie S.r.l., specialising in the design and construction of industrial plants;

 E-CHEM S.r.l., the chemical division involved in the formulation and supply of chemicals, equipped with a laboratory and a test room. “Our company, which now employs over 60 people, manages every process in-house, guaranteeing a complete service from sales to after-sales assistance. This enables us to monitor each process phase and guarantee high quality standards and reliable customer service,” indicates Nicoletta Mattiuzzo, Operations Planning Manager.

Overview of industrial coating solutions

The D.B.M. Tecnologie division offers a wide range of standard and custom-designed advanced surface treatment technologies to meet any requirement. The solutions that D.B.M. offers to the industrial coating sector include as follows:

Spray booths

The coating booths produced by D.B.M. are the result of years of experience in the surface treatment industry. “Thanks to this consolidated experience, we are able to offer booths that stand out for their high degree of efficiency and reliability. Designed to meet the needs of small and medium productions, the booths are equipped with advanced technical features that make them essential for a modern paint-spraying department.

One of the main strengths of our product is the innovative four-stage coating removal system. It not only ensures high efficiency in the painting process but also ensures strict compliance with emission limits. Furthermore, all components used are ATEX certified, ensuring maximum safety in potentially explosive environments”, emphasizes Alessandro Mattiuzzo.

Automatic painting systems

“Our painting systems are engineered maintaining all the innovative features of our paint-spray booths and are integrated with automatisms that allow to obtain the ideal painting even on extremely difficult pieces”, affirms Mattiuzzo.

The DAV/1 series systems feature:

 top loading of the frames;

 automatic protection system of the frame holding points;

 limited overall space required;

 automatic painting system.

The VAA series system feature:

 front loading of the frames;

 automatic protection system of the frame holding points;

 automatic painting system.

Both systems are managed by a PLC that allows the operator to select the most suitable painting cycle for the specific needs, as well as to set the translation speed of the painting unit and the number of turns of the pieceholder frame (through electronic governor with agent display on inverter).

Dip-coating e flow-coating systems

Designed to meet the requirements of coating processes that demand high quality and productivity, D.B.M.’s systems are tailored based on the customer’s needs, from pretreatment to the curing phase.

For the pre-treatment, the solutions offered by the company include degreasing and phospho-degreasing, rinsing and demineralized rinsing with dedicated treatment, as well as chemical surface conversion applications such as phosphatizing, etching, and passivation. As regards the coating application phase, the systems allow different processes to be carried out including:

 immersion painting or lacquering (Dipcoating) with tank movement with controlled speed and guaranteed stability;

D.B.M. Tecnologie’s headquarters in Casale sul Sile, Treviso (Italy).

© D.B.M. Tecnologie

 flow coating painting or lacquering with single or multiple nozzles applied to one or more robotic arms with flow control and total programming flexibility;  paint treatment systems with temperature regulation and automatic mixing. The cycle concludes with the curing phase, for which D.B.M. provides flashing and curing zones with automatically regulated temperature and controlled humidity.

“The movement systems are customized based on the production needs of the project and can develop on one or more transport lines with centering and translation devices especially studied for a better positioning of the pieces, improving the high quality of the result”, concludes Mattiuzzo.

Drying and curing ovens

As a corollary to the coating systems, DBM offers a series of static and automatic ovens designed to meet the demands for flash-off, distension, drying and curing options.

“Alongside standard products such as the flash-off stations of the SAR 16/12 series, designed to rotate 12 piece-holder frames, and the static ovens of the FS series (for drying pieces inserted using trolleys) and the P series (equipped with grid trays), we have developed automatic lines both for the drying of pieces on a rotating frame and for applications that reach actual heat treatment, with controlled temperature, ramps and thermally differentiated zones”.

The advantages of turning to an all-round technology partner D.B.M. Tecnologie stands out in the market as a hi-tech partner that can support its customers from the design to the after-sales phase. “Thanks to our

The automatic oven FAM 180.

© D.B.M. Tecnologie

Magnify your efficiency with our automation solutions

HUBO Automation has always focused the attention to the market needs and to the technological evolution. This allowed the company to establish itself as a leader for the industrial automation and painting. Thanks to the experience of the technical staff and to the continuous investment in new technologies, HUBO is able to satisfy dynamically the requests of a wide range of industries.

HUBO core business is the painting division. The wide range of automation solutions fully meets any need of automatic painting; in addition, the combination of special systems can satisfy particular requests and can guarantee a flexible and reliable painting system from all points of view.

ROBOTISED PAINTING SYSTEMS

STANDARD AND CUSTOMISED RECIPROCATORS

AUTOMATIC FEEDING SYSTEMS FOR PAINTING PLANTS

Coatings That Go a Long Way

Brought to you by Rajesh Wadhwani, Honeywell Advanced Materials Charlotte, United States of America

Honeywell presents its innovative additive solutions, specifically developed to improve the performances of paints, coatings, inks, adhesives and colour master batches.

Honeywell is a trusted name in the specialty additives industry, providing innovative solutions for over sixty years. Its experts are dedicated to creating performance-driven solutions that seamlessly integrate into the workflow and offerings of the customers.

Whether it is paints, coatings, inks, adhesives or colour master batches, its additives offer performance benefits that are unmatched. Its synthetic waxes have been formulated to provide a deeper matte

finish, improve abrasion resistance and offer better slip control. Its low molecular weight and micronised polyethylene polymer and copolymer additives are perfect for achieving the desired performance in formulations.

The company takes pride in being pioneers of innovative additive solutions for the paints and coatings industry. Its team of experts and R&D scientists are committed to helping improve the performance of

© AdobeStock

formulations with its vast range of offerings, including A-C®, AClyn®, Acumist®, NduroMatt™ and Cohesa® performance additives. Its synthetic waxes are designed to influence many critical surface properties, including mar resistance, abrasion resistance, improving slip, matting, adhesion and surface feel/hand. Whether for water or solvent-based thin film applications, its additives come in a variety of sizes, including in a small-particle micronised powder form.

Live demo at American Coatings Show 2024 – Experience

the NduroMatt™ difference

Come over for a first-hand experience of NduroMatt™ at BOOTH 2454 to understand how our additives enhance surface properties. Meet with the expert team behind our high-performance additives portfolio and talk to us about your unique paints/coatings and additives needs.

Explore a range of customizable solutions. Try to scuff our walls at ACS 2024 and enter an exciting lucky-draw! We are waiting for you at booth 2454 at ACS 2024 which will be held from April 30 to May 2, 2024 at the Indiana Convention Center, Indianapolis, USA.

The NduroMatt micronised multi-functional additives –Outstanding surface protection

Honeywell’s NduroMatt™ micronised multi-functional additives provide outstanding surface protection for matte paints and coatings. Traditional matting agents can leave coatings vulnerable to surface defects such as burnish mar, and scratches, which can compromise the longevity and durability of the surface.

The NduroMatt™ multi-functional additives are a game-changer in this regard, as they can fully replace conventional alternatives like extender

Honeywell Energy & Sustainability Solutions

As a global technology leader, Honeywell Energy & Sustainability Solutions (ESS) enables the energy evolution, provides solutions that reduce emissions, and delivers innovative sustainable materials to our customers across industries. We are solving the worlds toughest sustainability and energy transition challengers across our end markets while seizing new opportunities to deliver outstanding value to our clients and shareholders.

As part of the ESS business group, Honeywell Advanced Materials is an industry leading solutions provider, playing a crucial role in advancing industries worldwide through diverse applications, revolutionary inventions, and pioneering technologies focused on high growth mega-trends. Our science and technology experts create solutions that enable our customers to overcome their challenges today and into the future.

About Honeywell Specialty Additives

For over 60 years, Honeywell has been producing and formulating multifunctional waxes. Create deeper matte finishes, improve abrasion resistance, and get better slip control with our low molecular weight and micronized polyethylene polymer and copolymer additives.

Low molecular weight polyolefin-based additives for adhesives, paints, coatings, asphalt, PVC and plastics:

• Broad range of low-molecular weight polymers

• Customized lubricants for PVC applications

• Formulation oriented

• Delivers high-impact on process and product performance at low-use levels

• Improved cost performance

• Minimally intrusive on current processes and product.

pigments and silica or be used in conjunction with them to boost the surface properties of matte coatings. Compared to conventional and synthetic silicabased matting agents, NduroMatt™ offers superior performances. With a product line consisting of nine separate products designed for architectural, wood, industrial and functional coatings, NduroMatt™ provides a 2-3-fold improvement in:

 Matting efficiency;

 Burnish resistance;

 Rub resistance;

 Scuff and stain resistance.

In addition, NduroMatt™ has minimal impact on viscosity and boasts excellent shelf stability.

Emulsion additives for water-based formulations Honeywell Cohesa® for adhesives, inks and coatings

Cohesa® additives are innovative high-solids copolymer-in-water emulsions, formulated with low or zero surfactant content. They may be used in a broad range of water-based formulations to improve technical characteristics. Enhance the performance of water-based adhesives, inks, and coatings, and help bridge the gap towards solvent-based formulation performance with Cohesa®. They have been developed for use in water-based pressure sensitive adhesives, but also provide benefits in water-based inks and coatings. The additives are also ideal for several other applications. Key benefits from their use include an improved adhesion, especially to low surface energy substrates, and resistance to shear.

The ranges of solutions from Honeywell are designed to enhance performance, improve processing and increase the value of formulations. Each offering in its product line is backed by the consistent quality, the customer service and the reliable global supply network of the company. As one of the world’s leading manufacturers of low molecular weight polyethylene additives, the technical support of the company is prepared to help the customer to identify the most suitable additives for its own specific application and assist with a hassle-free incorporation.

Scan or click the QR Code to book an appointment at American Coatings Show 2024!

HIGHLIGHT OF THE MONTH

Adapting to the Evolving Market while Maintaining One’s Peculiarities: Stardust Powder Coatings Changes but

Remains True to its Mission

From an interview with

Guido Pozzoli CEO of Stardust Powder Coatings

Staying abreast of the times and following the changes of a constantly evolving market is essential for any company that wishes to continue to be a benchmark within its industry. At the same time, staying true to its mission and maintaining the characteristics that have made its name great is equally crucial. This is why Stardust Powder Coatings has decided to adapt to the evolutions in the market without giving up its distinguishing peculiarities, and today is happy to recount how, in recent years, it has succeeded in integrating its long-standing core business – the management of small batches, a sort of “haute couture” of powder coatings – with the production of large volumes –which we could define as “ready-to-wear” product lines.

Stardust Powder Coatings is a company specialising in producing and distributing powder coatings, founded in 2007 in L’Aquila (Italy). In just a few years, it has developed such a know-how and expertise that it has become an established player on the national and international scene. By focusing on the relentless pursuit of ever-higher standards of excellence, this company has grown more and more, and now it provides its customers with the highest level of coating aesthetics, resistance, durability, and efficiency.

Customisation and small batches: the hallmark of Stardust Powder Coatings

Since the beginning, the company has chosen to work on order, offering tailor-made solutions according to customer requirements. This strategy has always proved effective because, especially in an era when customers prefer to order smaller batches due to the economic situation, being able to supply volumes from 25 kg upwards means responding to this precise need to limit large orders.

“Over the years, we have structured our business to work only on order, apart from the rare exceptions when customers order certain products repetitively and we thus keep stocks accordingly,” says Guido Pozzoli, the CEO of Stardust Powder Coatings. In other words, this company has always offered hypercustomised services, enabling customers to rely on it even to produce batches of paint intended to “test the waters”: if the product takes off, they can then manufacture larger amounts, whereas in all other cases, the small quantities produced remain only colour proofs that are never marketed in large volumes. “For Stardust, this flexibility has always been a strength, a way to distinguish itself as a partner capable of meeting the unique demands of every customer. Even at a time that we can consider “of crisis”, this ability of ours to handle small-volume orders promptly has been our trump card, as well as an opportunity, since such flexibility enables us to offer something difficult to find on the market: speed, customisation, and the production of small batches,” notes Guido Pozzoli. “Stardust’s adaptability also counteracts a phenomenon that is occurring increasingly in this sector: very often, customers are forced to purchase huge quantities of product that far exceed their actual needs and end up being disposed of, causing environmental and economic damage.”

The challenge of handling large batches won by Stardust Powder Coatings

Stardust Powder Coatings finds itself on a path of continuous development, so much so that from January 2024 to date, it has grown by 20% compared to last year. This has enabled it to become more and more structured and, therefore, also able to meet the needs of companies requiring larger product batches. “High production volumes, which are much more economically viable for a powder coating manufacturer, are nothing new in our industry. In this case, the actual advantage Stardust offers is production to order, in ultra-fast times,” says the company’s CEO. Guido Pozzoli tells us that a couple of years ago, when the market was going through some less than rosy developments due to the difficulties in sourcing materials, Stardust could still support customers needing to receive large quantities of paint in a short time. “At that point and seeing such a rise in demand, we were certainly tempted to focus our energies on producing large batches alone, since working with high volumes has a much lower cost. However, when analysing Stardust’s identity as a supplier that has always been committed to tailor-made production and meeting customer needs from the very beginning of its activity, we realised how important it was to maintain this distinctive trait,” states the company’s CEO. From an economic point of view, Stardust presents itself as a supplier that can provide small batches of powder coatings at

affordable prices despite the high production costs, machines tooling expenses, and the high costs of controlling coating’s stability and finish. In addition to these costs, higher logistic fees must also be added, with an increase of 4 times compared to the pallet costs. Precisely to absorb these costs, Stardust has developed in recent years a series of complex management systems, as well as advanced computerized automation and process control tools, through which it has succeeded in the challenge of not only containing the high costs of small batches, but also positioning itself as a valid alternative in the production of medium and large batches.

Guido Pozzoli, CEO of Stardust

Investment and growth for continued expansion

In short, this company has reached maturity and set up a hybrid strategy to achieve excellent performance with both small and medium-large batches. “This growth, which results from huge investments and the hard work done every day with commitment and dedication, means that we are now a credible and trustworthy partner that all companies can rely on for orders of any size.

In such a highly fragmented market, Stardust is still known as a small company, specialised in the production of small batches. However, we believe that the time has come to make our true potential known to the market, confidently asserting that we are one of the few companies capable of handling even very large orders with the same skills, meticulousness, and speed devoted to small volumes,” says Pozzoli. As mentioned, this growth has only been possible thanks to the investments made over the past five years. Stardust has invested considerable economic resources in acquiring and renovating its premises, purchasing new technology and lab devices – not only machinery but also automation and process control systems and software to govern this complexity – and hiring new employees. “Although we are still planning more, we have already made many investments that have affected the company’s entire operation. For

example, we purchased a new process line that will allow us to produce large batches even faster and thus be even more competitive. In addition, the number of employees has grown significantly to 20 within a two-years period,” illustrates Pozzoli. In this regard, he explains that the reorganisation of human resources has played a central role in the company’s development: “In the last few years, Stardust has invested not only in equipment and tangible assets but also in everything that contributes to its actual functioning, making it come alive. All departments, from logistics to production and administration, must be perfectly synchronised to ensure efficiency and speed. To offer an excellent service even with large stocks, we therefore had to analyse the difficulties of some departments that were understaffed and take action by hiring new employees and training them: it was a long and complex process that, however, is ensuring and will ensure excellent results.” Stardust, therefore, has decided to evolve in two specific directions, ensuring the well-known craftsmanship of its “haute couture” products on both small and medium-large batches. In any case, be it with massive volumes or smaller quantities, today Stardust is well positioned in the market, responding to many customers’ need to rely not on a mere powder coating manufacturer but on an all-round reliable partner with which to work consistently, synergically, and understandingly.

Spanesi to Present its Wide Range of Coating Technologies for the General Industry at PaintExpo

Edited by Spanesi S.p.A

Spanesi (San Giorgio delle Pertiche, Padua, Italy) designs, develops, and manufactures coating systems for a variety of industries, including automotive, transport, aerospace, and marine. Present worldwide with numerous subsidiaries and an extensive distribution network, the company will be exhibiting its technologies at PaintExpo, the leading trade fair for industrial coating technologies, to be held in Karlsruhe (Germany) from 9 to 12 April 2024.

Spanesi is the ideal partner for the design and production of coating systems for various sectors, from general industry to aerospace, shipbuilding, and transport. One of its distinguishing features is the ability to produce tailor-made plants by addressing and solving problems in all application areas to consistently deliver customised, high-performance products.

Listening carefully to its customers’ needs, implementing the latest technologies in terms of sustainability with the utmost attention to consumption and environmental impact, and providing its workforce with a clean and ergonomic environment are the keys to the success of this company and its customers as well. Both its in-house processes and its products are all proudly Italian-made, and this is one of

Spanesi designs, develops, and manufactures coating systems for a variety of industries.

the cornerstones that distinguishes its brand. Quality, innovation, meticulous attention to detail, refined design, and turnkey projects are the hallmarks of Spanesi’s offer, making it unique and recognisable worldwide.

History and identity

Spanesi S.p.A.’s current identity is rooted in the past, shaped by experience in the automotive field since its founder started out as a small independent body shop mechanic in the province of Padua. Driven by curiosity and by the awareness that the market was not meeting the needs of automobile repair shops and, above all, was not in step with the times and with the technological evolutions occurring in the sector, he decided to start the industrial processes required for producing Spanesi-branded equipment, with the extraordinary peculiarity of being its first user himself.

Keeping his own garage operational, Orazio Spanesi then began to collect feedback, listen more and more to other body shops, and participate in international trade fairs explaining his philosophy, and he soon gained worldwide recognition as a technical leader in the automotive after-sales sector. Thanks to his company’s success and the quality of its products, which prompted a wide distribution network to

request that Spanesi be the sole interlocutor and equipment supplier, the 2000s were characterised by the introduction of coating booths and preparation areas in its equipment range. This entailed opening an entire dedicated production department and an engineering department set up to design these systems since, from the outset, Spanesi’s approach has been based on supplying totally customised plants that fully meet its customers’ requirements and needs. This combination of product customisation and system reliability gradually attracted the attention of players specialising in sectors outside the automotive field. That is why the company began to produce equipment for the wood industry, the coating industry in general, the marine and aerospace sectors, and even the transport sector with coating booths for trucks, trains, and buses of all kinds. Today, Spanesi is present with its products in every corner of the globe, thanks to its subsidiaries both in Europe and in America and Asia and an extensive distribution network, meticulously developed to provide advice and assistance and meet the needs of each individual user.

The motto of the company’s founder, Orazio Spanesi, is: “It does not matter where you start. To go far, you need a dream to fight for with all your might.” And Spanesi S.p.A. fully reflects this.

General view of the production site.

© Spanesi S.p.A

How Spanesi operates

Every project is a story in itself. Plant dimensions, customer requirements, regulations, and production needs can be the most diverse. Therefore, collecting information is always the first step, with onsite visits and the assessment of regulations and environmental factors. Once the analysis process has been completed, the designers’ team reproduces in 3D the factory hall accommodating the new coating plant, with two different approaches.

The first concerns the project’s details: every internal and external dimension of each element is included to the millimetre in the 3D layout, thus ensuring extreme precision both in the initial phase and in the subsequent installation phase. The second approach is creating a 3D virtual tour, in which the customers can “immerse” themselves in the new plant to realistically visualise the expected final result and make any adjustments according to their organisational needs and, why not, their tastes. Once full customer satisfaction, high energy efficiency, and low environmental impact have been achieved, the plant’s production can begin.

The production plant

The technical office carrying out the design operations and the factory devoted to the machines’ production are adjoining and cover a total area of 3000 m2. This allows for maximum cooperation and control between the design and manufacturing phases, as well as a significant reduction in lead times. This area is equipped with state-of-theart software and machinery. The production process is, therefore, characterised by a high degree of automation, which makes the daily work for Spanesi’s employees light and fast and significantly reduces the time required to complete each project.

The quality of the products and of the pre-delivery stages is enhanced by this combination of technology and human expertise and subsequently reflected in the installation stages, where maximum precision is guaranteed – an essential factor, especially in particularly narrow locations or with uniquely complex projects. All these processes make Spanesi’s products and services of excellent quality, reliability, and durability.

Spanesi awaits you at Stand 3345, Hall 3, at PaintExpo, Europe’s most important event for industrial coating technologies, to be held from 9 to 12 April 2024 in Karlsruhe (Germany).

A detail of a processing phase taking place within Spanesi’s production department. © Spanesi

It’s time for METALSTRIP

Line of products for the chemical paint stripping of metals

The METALSTRIP range is suitable for the paint stripping of many metals and alloys. It offers the best technology on the market, it has a low environmental impact and its products can be filtered and reused. All the paint strippers are developed in our chemical laboratory, in order to guarantee the best possible result, always.

Henkel Developed a Solvent-Free and UV-Curable Coating

The newly-developed coating of Henkel can protect the industrial electronic components subjected to extreme environmental conditions.

The multinational Henkel has launched Loctite Stycast CC 8555, a coating designed to protect electronic components in extreme environments.

As a matter of fact, the new solution can safeguard the printed circuit boards (PCBs) and sensitive components in demanding, high-power applications, such as motor drives, PLCs, electric vehicle charging infrastructure, AC/DC power supplies and other high-voltage electronic devices.

“High-power electronics are integral to industrial manufacturing, human mobility and comfort, and global energy production.

These systems must adhere to the highest reliability and safety standards; protecting electronics is vital to their dependable function and longevity. Conformal coatings are the go-to protective material for nearly all PCBs used in power electronics, and Henkel’s latest formulation rises above. It delivers on the reliability requirements foremost, but is also easy to use, cost-effective, and lower-impact material. Loctite Stycast CC 8555 covers all the bases and then some,” has stated Justin Kolbe Director of Market Strategy for Power and Industrial Automation at Henkel.

Loctite Stycast CC 8555 offers good resistance to adverse weather conditions, such as humidity, gas mixtures and various chemicals. In addition, it has a relative temperature rating of 130°C per UL 746E standard, a UL 94 V0 flammability rating and meets IPC-CC-830 requirements. This solution is essential for protecting industrial equipment, power conversion systems and alternative energy infrastructures, which need to be reliable and durable.

“Loctite Stycast CC 8555’s VOC- and solvent-free formulation answers the call for environmental concerns and provides significantly lower cost from a surface area perspective. With solvent-borne conformal coatings, three to four times the weight must be deposited to achieve the same thickness as non-solvent-based materials. This means Loctite Stycast CC 8555 can provide exceptional protection with one-third to one-half of the sprayed volume of a solventbased system. Users get lower total cost, environmental volatiles reduction, energysaving curing, and superior performance. That’s a hard combination to beat!” has added Kolbe.

Lastly, Loctite Stycast CC 8555 is cost competitive with solvent-based formulations and provides wetting, flow and levelling performance – thus ensuring rapid and complete coverage of PCBs and components sensitive without voids or visible defects. Curing is achieved quickly, with primary UV curing occurring within seconds, followed by moisture curing for shaded areas.

For further information: www.henkel.com

© Henkel

Marcel Krohnen Will Guide the Global Paint Additives Business Of BYK

Marcel Krohnen will further consolidate the position of BYK in the paints and coatings market.

The specialty chemicals supplier BYK has announced that Marcel Krohnen will lead the global Paint Additives business. The new director joined BYK in 2007 and held several management positions for the company, such as Global Head of Wood and Furniture Coatings and Head of the Architectural Coatings businesses.

“The market and customer environment, which has become increasingly dynamic and complex in recent years, will continue to present us with growing challenges. The key to the company’s future success lies in focusing our activities to offer the greatest holistic customer benefit. I am looking forward to playing an active and responsible role in this important task at BYK,” has stated Marcel Krohnen.

For further information: www.byk.com/en

Dedication leads to innovation. Quality creates value

IFS Coatings Launched the New Powder Coating IFS Puroplaz PE16

The polyethylene thermoplastic powder coating of IFS offers good adhesion properties for metal structures and the automotive sector.

The powder coatings supplier IFS Coatings has recently launched IFS Puroplaz PE16, a durable thermoplastic modified polyolefin powder coating, which offers flexibility and good adhesion properties. In addition, this new technology offers a Shore D hardness of 60 and excellent gravimetric performance as well as exceptional resistance to impacts and abrasion.

“This PE16 formula has a rare combination of hardness and flexibility. These attributes are normally codependent with a trade off in one for gains in the other. The brand-new formulation overcomes this which makes it ideal for products that will be post formed after coating, such

as fence wire weaving, that also require excellent abrasion resistance. It can be used to replace nylon coatings in certain applications,” has stated Tim Brinner, Vice-President of Thermoplastics at IFS Coatings. Puroplaz PE16 can be used for several applications, including woven wire fences, fence posts, waste bins, agricultural tools, automotive components and pipelines. It is also available in both spray and dip formulations and is made without the use of PVC and BPA.

For further information: www.ifscoatings.com

ALTANA Acquired Silberline Group

The acquisition of Silberline will allow ALTANA to expand the production capabilities of its Eckart division in the chemicals and coatings markets across North-America and Asia.

ALTANA AG has recently signed an agreement to acquire Silberline Group, an American company specialised in the development and production of effect pigments used in automotive and protective coatings – thus adding new research and manufacturing facilities in North America and Asia.

“The acquisition is further proof that we are sustainably implementing our strategy of generating value-creating growth through targeted acquisitions. With the move, ALTANA is strategically expanding its ECKART division and strengthening its regional presence, particularly in North America and Asia,” has stated Martin Babilas, CEO of ALTANA AG. “The acquisition of Silberline by ECKART creates new potential. Together, we can more intensively drive the development of sustainable product innovations, benefiting both customers and employees,” has added Gary Karnish, CEO of Silberline.

For further information:

www.altana.com/divisions/eckart.html

Brenntag to Acquire the Glycols and Solvents Distributor Solventis Group

The acquisition of Solventis Group will allow Brenntag to expand its presence in the European chemicals market.

The international chemicals and ingredients distributor Brenntag has recently announced it will acquire Solventis Group, a glycols and solvents distribution company. This acquisition will provide Brenntag access to the Port of Antwerp (Belgium), a major chemical hub in the EMEA region – thus strengthening its presence in the European chemicals market.

“Brenntag Essentials combines a cost-efficient network of last mile service operations with regional sourcing and supply chain services, and global sourcing. Solventis Group is a highly compatible fit to our strategy, adding tollgate capabilities and volume optionality via their Antwerp state-of-the-art site to our regional capacities, while opening interregional optimisation potential. The acquisition will support our integration with increasingly global supply markets while strengthening our regional market position and customer proximity in EMEA,” has stated Ewout van Jarwaarde, CEO of Brenntag Essentials.

“Our global network of suppliers and customers stands to gain significant advantages from Brenntag’s extensive global reach and diverse product and service portfolio. We eagerly look forward to becoming part of the expanding Brenntag Essentials platform, offering our extensive product range encompassing glycols, solvents and automotive products, including coolants, antifreeze, brake fluids and de-icing fluids, to a broader customer base worldwide,” has added David Lubbock, Owner and CEO of Solventis Group.

IMCD Group Acquired ResChem

The acquisition of ResChem will allow IMCD to strengthen its market position in the paints and coatings market in Oceania.

The speciality chemicals supplier IMCD Group has announced the acquisition of ResChem, a Sydney-based (Australia) company specialising in resins, additives and pigments for coatings. “We see steady growth in the coatings industry in Australia and New Zealand with the advancement of innovative and sustainable solutions. With the joining of ResChem, we can leverage their complementary portfolio and technical capabilities to further develop our footprint in the local markets,” has stated Frank Schneider, Global Business Group Director for Coatings & Construction at IMCD. “This is a wonderful opportunity for our employees to join a leading multinational company and the opportunities for advancement it provides. We will continue to provide and improve the high level of service they are used to from ResChem for our customers and suppliers,” has added Bruce Forder, Managing Director of ResChem Technologies.

For further information: www.imcdgroup.com

For further information: https://corporate.brenntag.com

© IMCD Group

Our 70 years experience in Surface Treatment is ready for the E-Mobility market.

Research, innovation, development.

In 70 years, our vision towards the future has never stopped. Today, Tecnofirma provides quality to the electric market which is the most evolving technology in the automotive industry. Our impregnation, cleaning and painting plants are the result of the constant commitment to offer cutting-edge solutions and products anytime, anywhere.

ASK JOE POWDER

The “Ask an Expert” Column

Kevin Biller kbiller@chemquest.com

Joe,

I don’t know if you have covered this before. We notice that the cured powder does not stick readily to edges that have been cut by a laser. What are the causes of this and what can be done to overcome the adhesion issues?

Thank you,

Brian Gurney

Sidney, New South Wales

Hi Brian,

Indeed, we have not covered this one yet. Cutting steel with a laser offers many advantages, including precision, speed, less rejects, and low labour costs. However, one of the problems inherent to laser cutting is the blue oxide edge it leaves on carbon steel. Powder coatings don’t like to adhere to this oxidised surface. Conventional iron or zinc phosphate does not adequately penetrate the oxide to provide adhesion of the cured powder, resulting in a loss of adhesion and the potential for serious corrosion problems.

There are a few paths to compensate for this shortcoming. One is to employ a more aggressive pretreatment process. Using a strong acid etch prior to the phosphate stage can attack the oxide layer enough to allow the phosphate to do its thing.

Another option is to avoid creating the oxidation by using nitrogen in the laser cutting process. It is more expensive than using oxygen, but it minimises oxidation from the laser and therefore allows a conventional

iron or zinc phosphate process to provide a surface more amenable to adhesion of a cured powder. A third option is physically abrading the edges. This can be accomplished either automatically (blasting or wheel abrading) or manually. If you opt for a blasting process, it is imperative to keep your media clean; otherwise, you can contaminate the surface you are attempting to clean. ScotchBrite® pads or wheels work well but require additional labour. Keep in mind that these extra steps can be cost-prohibitive. I hope this helps.

All the best,

Joe

Hey Joe,

We powder coat formed wire products made from 1008/1010 grade steel. The powders are epoxy and polyester hybrid/ TGIC types. How long must we wait after cure to: [a] test for crosshatch adhesion and [b] before we do the MEK rub tests?

If we recoat over a thin coat, will that affect the cure time, affecting the same tests?

Thank you in advance,

Norm Gajewski Angola, Indiana

Hey Norm,

First, let’s talk about the powder material types. It sounds like you may be using two powders – a hybrid (epoxy-polyester) and a polyester-

TGIC product. Regardless of powder type, the manner in which you conduct the after-cure testing is the same.

Crosshatch adhesion testing and MEK solvent resistance can be evaluated as soon as the parts have reached ambient temperature because, with powder coating technology, the entirety of cure occurs in the oven. The polymers and curing agents react and harden while they are in a molten state, as long as they are above a certain threshold temperature specified by the powder manufacturer. Unlike most liquid coatings, no post-cure occurs after the parts exit the baking process.

Recoating over a thin coat will not affect the cure time. It is important to note that recoats may not have the same adhesion as a single thicker coat. Sometimes inter-coat adhesion is affected by oven conditions and bake time (overbaking can impair adhesion).

A follow-up question from Norm:

Thanks again, now your response raises another question from our sales engineering department. Is there a minimum time to wait to do the crosshatch test after salt spray tests are performed? We test for a few parameters, for different customers, namely 96-192 hours to failure, sometimes over a primer and sometimes over a double-pass topcoat.

Norm,

A scribe into the coating should be done before the test panels/ parts are put on salt spray testing. We normally check for scribe creep and blistering about fifteen minutes after we pull the panels out of the cabinet – basically enough time for the panels to dry. We use a wooden tongue depressor and vigorously rub across the scribe. ASTM D 1654 and D 714 are used to rate and report the evaluations. Please refer to ISO 9227.

Best regards,

Joe

Engineering specialized in the supply of systems for surface treatment, painting and coating

E-COAT SYSTEMS

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S.M.A.R.T. 3: the Finishing of the Future Between Innovation and Sustainability

Manuela Casali, UCIF – Italian Surface Treatment Equipment Manufacturers’ Association, Milan, Italy info@ucif.net

22 May marks the return of S.M.A.R.T. (Surface. Manufacturing. Advanced. Research. Trends.), the conference organised by UCIF (the Italian Surface Treatment Equipment Manufacturers’ Association), which has reached its third edition under the prestigious patronage of the City of Milan, the Poliefun association, and the MADE Competence Centre Industria 4.0.

This year, the theme “The finishing of the future between innovation and sustainability” will be the focus of the eleven presentations given by participating companies, exploring new technologies, interactions between machines and humans, and the importance of sustainability in manufacturing.

With its third edition of S.M.A.R.T., UCIF continues to be an important point of reference in the surface treatment industry, offering a stage for all companies that are driving innovation and sustainability – already with an eye to Industry 5.0, highlighting the importance of a humancentred approach and technological progress.

The surface treatment sector has a considerable footprint on the environment and working conditions, making it a focal point for environmental regulations. Thanks to new technologies and sustainable

practices, it is now reducing its environmental impact, improving energy efficiency, and limiting polluting emissions. Innovation plays a crucial role in pursuing such sustainability goals, reducing the investment and operating costs of surface treatment plants. i4.0 solutions are making these systems more flexible, efficient, and safe, leading the industry towards a more sustainable future.

The S.M.A.R.T. conference not only provides a platform for sharing experiences and innovative ideas but is also an opportunity to celebrate the excellence of the Italian surface treatment industry globally. UCIF, through its membership in ANIMA Confindustria Meccanica, is a point of reference for companies in this sector, with impressive figures confirming Italy’s leading role on the international scene.

S.M.A.R.T. 3 promises to be a unique opportunity to explore the new frontiers of innovation and sustainability in the surface finishing industry while joining forces to create a more sustainable and efficient world.

Further information on the conference is available at www.smart-ucif.it and the e-mail address info@ucif.net.

ADVANCEMENTS

Simplify Coating Formulations with AEROSIL ® Easy-to-Disperse Fumed Silica

Fabian Schwane

Evonik Coating Additives – Essen, Germany fabian.schwane@evonik.com

Evonik Coating Additives’ AEROSIL® Easy-to-Disperse product range sets new standards in the coatings manufacturing process, allowing customers to disperse fumed silica in a single milling step, and thus saving time, money, and energy.

In the dynamic world of coatings, the continuous search for innovative solutions that streamline manufacturing processes and improve product performance is crucial. Evonik Coating Additives has responded to this industry demand with its AEROSIL® Easy-to-Disperse (E2D) product range: this advanced product line composed by four fumed silica-based additives is designed to significantly reduce the energy, time and costs associated with the dispersion process in coating formulations.

Fumed silica is a popular choice among coatings formulators for rheology control. However, a persistent challenge has been the

dispersion of aggregates and agglomerates, making optimal dispersion of fumed silica one of the most technically challenging and timeconsuming steps in manufacturing coatings. Traditionally, a two-step process is used: a pre-dispersion step using a dissolver to wet-in the powder and to break up large aggregates and agglomerates, followed by bead milling to achieve the desired dispersion quality. This process is not only technically challenging, but also time and energy consuming. To address this, raw material manufacturers offer dispersions, preparations and pastes that have been optimised to disperse insoluble solids (such as silica, pigments and fillers). However, these goods may

contain undefined amounts of solvents, water, binders or additives that can significantly affect the finished coating system and are beyond the control of the formulator.

Eliminating one production step

“Our AEROSIL® E2D is designed to be incorporated directly into coating systems without the need for extensive milling or high shear forces,” stated Maximilian Cornelius, Head of Particle Design in the Research, Development & Innovation department at Evonik Coating Additives.

“Thanks to this globally unique technology, our customers can now perform wetting and dispersion processes in a single high-speed dispersion step.”

This ease of incorporation is a game changer for coatings manufacturers, as it not only speeds up the production process, but also minimises equipment wear and energy consumption. The result is a more sustainable and cost-effective operation that does not compromise the quality or performance of the final coating product.

The AEROSIL® E2D range is versatile, suitable for rheology control in both pigmented and clear coating formulations, and can be used in a

wide range of coatings, including wood, plastic, automotive and general industrial coatings. AEROSIL® E 972 is recommended for rheology adjustment in a wide variety of formulations, while other silicas are tailored for specific applications – for example, AEROSIL® E 812 and AEROSIL® E 805 are especially suitable for automotive OEM and wood clearcoats, and AEROSIL® E 9200 is primarily used to improve durability, such as scratch resistance.

No need for formulation adjustments

“The viscosity curves at high and low shear rates are identical in the key area of increasing viscosity, compared to the standard AEROSIL® R grades” continued Cornelius. “This demonstrates another key advantage of our AEROSIL® E2D products: it achieves the same level of efficiency and optical characteristics, so manufacturers do not need to adjust existing formulations, and new formulations can be created using the same principles as previous coatings.”

In addition, the AEROSIL® E2D versions of fumed silica are chemically identical to the corresponding standard AEROSIL® products offered by Evonik Coating Additives. Using AEROSIL® E2D fumed silica reduces

processing time, cleaning time, and production downtime, while eliminating the bead milling step reduces investment and maintenance costs, especially in coatings production. Pigment manufacturers also offer products that can be dispersed using dissolvers, opening the possibility of formulating colored coatings without the need for a bead mill.

Individual cost savings calculator

In line with Evonik’s approach to sustainability, AEROSIL® E2D products enable lower energy consumption and less waste in the production process. This environmental benefit can be quantified using the Cost Savings Calculator on COATINO®, the Dynamic Formulation Network. “The Cost Savings Calculator is an example of our customer-centric approach at Coating Additives,” explained Matthias Kremser, EMEA Marketing Industrial & Transportation Market Segment. “Customers can independently calculate their individual savings by using our AEROSIL® Easy-to-Disperse with low-shear dissolver milling, allowing them to make datadriven decisions that optimize their production processes and maximize profitability.”

Commitment to quality and innovation

Coatings manufacturers have long sought ways to simplify the fumed silica dispersion process. With the innovation of AEROSIL® 2 E2D technology, Evonik has met this demand by reducing the number of production steps and the required batch cycle time to achieve optimal dispersion. These efficiencies ultimately reduce production costs and energy consumption while maintaining performance. The technical performance of the AEROSIL® E2D range demonstrates Evonik Coating Additives’ commitment to quality and innovation. Developed in state-of-theart production facilities, these additives not only meet but exceed industry standards for performance and ease of use.

Comparison of high shear milling and dissolver milling regarding time effort.

Milling processes for incorporation of fumed silica with high shear milling (left) and innovative dissolver milling (right).

Comparison between bead mill and use dissolver for 1% AEROSIL® for 1000 kg clear coating.

industrial coating plants impianti di verniciatura industriale

spray booths for car body shop cabine di spruzzatura per carrozzeria

sandblasting booths cabine di sabbiatura

industrial coating booths cabine di verniciatura

BASF Launched the GLASS Tool to Calculate CO 2 and Cost Simulations for Automotive OEM

The new GLASS tool developed by BASF will allow paint shops in automotive manufacturing plants to optimise costs, performances and sustainability.

BASF has recently presented GLASS, an innovative tool that can provide a comprehensive life cycle analysis of the ecological footprint of the paint shops in automotive manufacturing plants by calculating CO2 emissions and cost simulations.

Reducing the ecological footprint towards CO2 neutrality is a significant goal for many industries and value chains, including the coating and

pre-treatment processes of the automotive industry – which accounts for more than 60% of all the energy employed in vehicle production at automotive factory. Through its new tool, the Coatings division of BASF will offer an analysis approach that enables transparency and support customers in making informed decisions for sustainable surface solutions.

The GLASS (Global Life-cycle Assessment of Automotive Surface Solutions) tool analysis follows the cradle-to-grave approach, covering the entire value chain from raw material extraction via pre-treatment to clearcoat as the final step of the coating process. From this transparency, the customers can then derive optimisations of costs, performances and ecological footprint.

“A coating with its various layers of paint contributes approximately 30 kilogrammes of CO2 per manufactured vehicle. However, the actual application process has a much larger impact, accounting for at least 150 kg of CO2 per vehicle, which makes approximately one third of the vehicle manufacturing process,” has explained Sabrina Platzek, the vice-president of Global Marketing Automotive OEM Coatings for BASF. “Therefore, in addition to the product carbon footprint of the coating, it is important to make the footprint of the coating process in the paint shop transparent – as well as the energy consumption and related cost. Only with comprehensive data and simulation, it is possible to derive impactful measures. That is precisely what we can achieve for our customers with GLASS – and this provides an exceptional insight for the industry.”

Transparency, CO2 reduction and costs simulations

The GLASS tool is based on an adapted lifecycle analysis model that does not only considers individual aspects of the paint application process – such as specific ovens or coating systems –but also allows to analyse the environmental impacts of all essential components throughout the application process and across all layers in a modular approach. As a matter of fact, regional and site-specific factors such as local climate conditions, energy use and customer-specific application processes or production structures are also considered.

“Once transparency is established, we can provide targeted advice to our customers and develop solutions together. These can be CO2-reduced technologies at the beginning of the value chain or solutions that have a CO2-reducing effect

when applied,” has added Tim Banik, a lifecycle assessment expert for BASF Coatings and developer of GLASS.

All information on products assessed with the footprint calculation method of BASF is available and usable in the GLASS tool. TÜV Rheinland has certified that the CO2 calculation method of the company and reporting of the cradle-to-gate Product Carbon Footprints fully comply with the requirements of the Greenhouse Gas Protocol, the DIN EN ISO 14040 and 14044 standards as well as Together for Sustainability (TfS).

“We aim to lead the way in sustainability in our industry. Therefore, it is at the centre of all our actions. The positive feedback from the market proves that this is the right way. That is why in the long term we are looking forward to offering GLASS not only to the automotive OEM coatings industry, but also to other application areas,” has concluded Markus Piepenbrink, the director of sustainability for BASF Coatings.

For further information: www.basf-coatings.com

New Preservation Line Placed into Existing Building Containing an Overhead Crane

In order to meet customer demands faster and more efficiently, Carl Spaeter Hamburg expanded its range of manufacturing equipment with KON 34/6-HD: the preservation line from Rösler combining shot blasting and painting in one single system. Designed to handle large-size steel components, the line is also equipped with two paint systems and has been perfectly integrated into an already existing building containing an overhead crane.

Founded in 1905 in the city of Hamburg (Germany) as hardware store, Carl Spaeter Hamburg became one of the leading steel suppliers for retailers, mechanical contractors and industrial manufacturers in Northern Germany and beyond. The success of the company is based on a broad line of steel products, an inventory of more than 25,000 tons, short delivery times, high operational flexibility and numerous processing and refinement services.

“Since our existing shot blast and painting line had reached the end of its usable life, and because we wanted to improve our customer support, we purchased the KON 34/6-HD from Rösler. Within a very

short time period, they developed a viable equipment concept that was perfectly adapted to our existing building and our technical requirements,” has explained Mike Barz, the general manager of Carl Spaeter Hamburg.

The equipment supplier from Untermerzbach won this substantial purchase order against two competitors for the following reasons: Rösler adapted its equipment concept to the requirements of the customers and, at the same time, the customer was impressed by the quality and sturdy equipment design. In addition, Rösler could show several reference plants in the field.

The KON 34/6-HD preservation line developed by Rösler, adapted to an existing building containing an overhead crane.

SUCCESS STORIES

Fully automatic and energy-saving shot blasting

A critical customer demand was that the line should have handled steel components up to 3,200 mm wide, 400 mm high and 21.2 meters long. Moreover, Rösler had to make sure that steel plates with a thickness of 4 mm could be shot blasted with the same high-quality cleaning results as plates with a thickness of 100 mm. An additional requirement was that all surface areas and edges of steel beams had to be perfectly blasted and receive optimal paint coverage. Since the steel components have a maximum weight of twelve tons, the design of the roller conveyors and cross transport systems had to be extra sturdy. The special sensors placed on the inlet roller conveyor of the preservation measure the height of the steel components and, in the case of steel plates, also their width. The PLC then automatically determines how many turbines must be turned on to clean the respective components. Other parameters like travel speed, paint type and thickness are also part of the processing programmes, which are stored in the PLC and can be called up from the operating panel. In the first step, the steel components are passing through a pre-heater that prevents moisture from being carried into the shot blast machine. The exhaust air from the pre-heater is guided to the paint drier, which helps to reduce the drying time of the applied paint.

From the pre-heater, the work pieces are

transferred to the shot blast machine. The machine housing is made from manganese steel. In addition, the blast chamber is lined with overlapping liners made from manganese steel. Eight high-performance Gamma 400G turbines, each with a drive power of 22 kW, ensure that the specified cleanliness of SA 2,5 is consistently and safely achieved at a travel speed of up to 4 meters/minute. Compared to conventional blast wheels, the Gamma turbines with curved throwing blades in ‘Y’ design achieve an up to 20% higher blast

KNOW-HOW, EXPERIENCE, AND RELIABILITY

performance and, at the same time, reduce the energy consumption. Residual blast media and dust on the shot blasted components is removed with a combined brush-off/blow-off system at the exit of the blast chamber.

Low paint usage and minimal overspray

To meet individual customer requirements for the coating operation using a water-based primer, the integrated automated spraying equipment is equipped with two independent

For decades, Radial has been designing, building and installing tailor-made coating plants for metals, plastics and wood. Our systems are the ideal choice for those who desire a cutting-edge turnkey solution.

The preservation line can handle large-size steel components up to 3.2 m wide, 0.4 m high and 21.2 m long.

paint application systems. Prior to the paint process, special sensors precisely measure the work piece dimensions. The gantry holding the spray guns is then programmed for these measurements, ensuring that the primer is only applied onto the surface of the respective steel components. The result is minimum overspray and the prevention of unnecessary waste of the valuable resource paint. The paint filter with air extraction points on both sides of the transport system collects any residual paint overspray, leaving only 0.2 mg/m3 of residual dust load in the clean air – considerably below the official standard specifying a maximum of 1 to 2 mg/m3. The residual dust in the clean air coming from the dust collector of the shot blast machine amounts to 1 mg/ m3, well below the legal limit of max. 3 mg/m3. Heating the paint drier with exhaust air from the pre-heating system is a further contribution towards resource-saving operations. “With the new Rösler preservation line, we can run our surface treatment operations for steel plates, beams, pipes and tubes and steel bars not only with an excellent finishing quality but also in a highly eco-friendly manner,” has clarified Reyk Hagelberg, the plant manager of Carl Spaeter Hamburg.

Optimised manufacturing processes and material flow

The work piece transport system of the new preservation line was integrated into a building with an already-existing overhead crane. The roller conveyors with forward and reverse transport direction cover all four bays of the building with an area of over 42,000 m2. The arrangement guarantees a highly flexible material handling operation. For example, it allows the transport of steel components from anywhere in the building to the preservation line, to other areas in the building or to the truck load station. The cross-transport systems, placed to the left and right of the roller conveyor, offer plenty of capacity for the intermediate storage of steel components.

“With the new preservation line and the resulting further steel processing and refinement possibilities, we can fulfil customer requests faster and more efficiently. This helps to reduce our lead times. In addition, the new line, in combination with the roller conveyors and cross-transport systems, improves our logistical setup with shorter walking distances for our employees and streamlines our entire workflow,” has concluded Barz.

For further information: www.rosler.com

At the entrance of the automated painting system, special sensors measure the dimensions of the workpieces.

The Gamma 400G high-performance turbines with ‘Y’ shaped throwing blade.

© Rösler Oberflächentechnik GmbH © Rösler Oberflächentechnik GmbH

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Researchers to Study Biological Molecules for Producing Ice-Shedding Coatings

Derek Smith

Michigan Engineering - University of Michigan, Michigan - United States smitdere@umich.edu

Taking inspiration from nature could allow researchers to create ice-shedding coatings protecting solar panels and airplane wings.

New non-toxic materials could one day keep solar panels and airplane wings ice-free or protect first responders from frostbite and more thanks to a new University of Michigan-led project funded by the Defense Advanced Research Projects Agency. The research team will study biological molecules used by other living things to survive freezing temperatures.

The project includes researchers from Raytheon Technologies, North Dakota State University and the University of Minnesota. Existing materials used to accomplish these feats come with serious downsides. For instance, road salts prevent pavements and streets from freezing but also corrode concrete and enter natural freshwaters through runoff, to the detriment of aquatic life.

Spraying planes with de-icing fluids ensures that winter flights stay safe, but the chemicals in such fluids are toxic and can also pollute waterways. And some of what the researchers aim to make with the up to $11.5 million project has no current analogue, like a lotion that protects from frostbite without heavy winter layers. “For the past seven or eight years now, my group has been making surfaces that have very low adhesion to ice. Such ice-shedding coatings can be very useful for a number of applications such as wind turbines, power lines or airplane wings,” has stated Anish Tuteja, the principal investigator of the project and a professor of materials science and engineering at the University of Michigan. “However, for many other applications, it would be beneficial to completely eliminate ice formation. Preventing ice formation for hours on end in freezing conditions has thus far been very challenging to achieve.”

Taking inspiration from nature

The project aims to find molecules that can be used to manipulate ice

and snow in several ways, including changing the temperature at which water freezes, increasing and decreasing how strongly ice adheres to surfaces, changing the structure of the formed ice and inhibiting or encouraging ice crystals to grow on surfaces.

To meet their goals, the research team is looking to plants, animals and microbes for inspiration. Many organisms produce molecules that allow them to survive freezing solid or stop their bodies from freezing. Wood frogs, for example, produce antifreeze lipids that prevent ice from damaging their cell membranes when they freeze over the winter. Other organisms produce ‘ice-nucleating’ molecules that stimulate ice to form at warmer than usual temperatures. The bacterium Pseudomonas syringae produces ice-nucleating proteins to freeze plant leaves. The ice helps break apart plant cells so that the bacterium can access the nutrients inside.

By creating and mixing these natural molecules in the lab, the researchers hope to find less toxic and biodegradable alternatives to the current de-icing chemicals as well as molecular cocktails that could

Sudeep Sharma, a postdoctoral researcher in materials science and engineering who works in Anish Tuteja’s laboratory, adding droplets of water to a cooling unit.

© Marcin Szczepanski, Michigan Engineering

enable brand new technologies. “If you combine the molecules in the right ratios, the freezing point can decline more than what would be achievable by each molecule individually,” has added Tuteja.

Testing all the options

When starting from even a small subset of known molecules, the number of possible combinations and ratios can become unwieldy. The research team must measure the effectiveness of over 5,000 different ice-forming and antifreeze molecules within the first year of the project. That number could double or triple as the project progresses.

To quickly study these molecular combos, the team plans to build an automated platform to determine the freezing temperatures of as

many as 1,500 samples a day. The team hopes to narrow its search down to the 30 most promising candidate molecules for further study by the end of their first year. In the second year of the project, the team will test each candidate molecule’s safety and toxicity as well as its effectiveness at larger scales and in several forms, such as liquids, creams and coatings. These experiments will not only help the researchers find the best antifreeze and ice-forming mixtures: the large dataset will also help reveal how different ice-forming and ice-inhibiting molecules do their jobs. “Once we start to gather a lot of data on how these molecules work, we will work with machine-learning experts who will be able to determine which parts of the molecule might be modified to further improve their performance,” has concluded Tuteja.

© Marcin Szczepanski, Michigan Engineering

Droplets of water added to a cooling unit designed to measure the freezing temperature of water. The plate has 96 wells, each of which can house a droplet of a unique chemical cocktail that causes water to freeze at warmer- or colder-than-usual temperatures.

ART WITHIN SURFACES

Retrospective of Pioneering

South African Artist Esther Mahlangu with her BMW Art Car on View

Thomas Girst

BMW Group Cultural Engagement – Munich, Germany thomas.girst@bmwgroup.com

The iconic BMW 525i Art Car, painted by Esther Mahlangu by blending African art with contemporary automotive design, will come back to South Africa for the first time in over thirty years.

The Iziko Museums of South Africa and BMW are pleased to announce ‘Then I Knew I Was Good at Painting’: Esther Mahlangu. A Retrospective. The exhibition, curated by Nontobeko Ntombela, highlights Esther Mahlangu’s over 50-year long career and her meteoric rise as a contemporary artist, earning her global acclaim. The retrospective will be on view at Iziko Museums of South Africa from 18th February until 11th August 2024. From there, it will begin its global tour, stopping first at the Wits Art Museum in Johannesburg (South Africa) before moving to the United States in early 2026.

BMW is proud to support this landmark exhibition which honours the talent of Esther Mahlangu and celebrates a shared history of collaboration. Included in this exhibition will be Mahlangu’s BMW 525i Art Car, returning to South Africa for the first time in over 30 years. Mahlangu

became the first African and woman to paint a BMW Art Car in 1991. This collaboration marked a significant moment in the art world, blending African art with contemporary automotive design.

“Painting has always been a part of me. I cannot separate it from myself, and neither would I want to. I look forward to sharing my practice and long and colourful story with you on my upcoming Retrospective Exhibition”, stated Mahlangu.

Through the language of colour and form, the exhibition charts Mahlangu’s contribution to contemporary art close to seven decades. More than 100 artworks have been gathered from global collections. They have been placed alongside historic photographs and a short film. This diverse collection from Mahlangu’s expansive oeuvre which features in ‘Then I Knew I Was Good at Painting’: Esther Mahlangu. A Retrospective,

© Clint Strydom

ART WITHIN SURFACES

will offer a comprehensive yet intimate insight into her vast and vibrant career.

“Mahlangu’s journey is a testament to passion, innovation, and resilience”, Curator Nontobeko Ntombela remarks. Continuing, “The retrospective pays homage to Esther Mahlangu’s unique approach to art, which intersects African cultures with modernity and the contemporary. The exhibition celebrates Mahlangu’s voice, agency, and pioneering spirit, symbolizing her self-enunciation, selfdetermination and creativity.”

The retrospective is a landmark achievement for South African art. It recognises Mahlangu as one of the few South African artists who have had the opportunity to present a Retrospective Exhibition in worldrenowned museums. Of the exhibition, Dr Bongani Ndhlovu, Acting CEO, Iziko Museums of South Africa, commented: “Iziko Museums is honoured to celebrate the living legend, Esther Mahlangu, and to host this colossal showcase where creativity, culture, and aesthetics are fused. Mahlangu is a living symbol of triumph against adversity. Her approach to art has inspired generations and is a re-affirmation of calls for Africa-centred innovations.”

“The BMW Group’s commitment to this exhibition is a testament to our respect and admiration for Esther Mahlangu’s pioneering spirit and remarkable contribution to the world of art. This exhibition not only celebrates the incredible journey and legacy of Mam’ Esther but also symbolises a cherished collaboration that dates back over three decades. We are especially excited about the return of the BMW Art Car to South African soil – a significant symbol of our shared history and appreciation for art that transcends boundaries”, concluded Peter van Binsbergen, CEO of BMW Group South Africa.

HangOn Launches New Sustainability Concept at PaintExpo to Improve CO 2 Footprint

At the next PaintExpo edition HangOn will present its new solutions to improve the CO2 footprint of the coating lines.

HangOn will demonstrate at PaintExpo how to calculate the amount of CO2 emitted from a coating line and to improve those numbers in hall 2, stand 2110. What is it that affects the CO2 emissions in a coating line? The type of oven and how electricity is produced are of course important factors, and perhaps the first things that come to mind when this question is asked. The type of powder used is also significant. Factors such as its application process and the amount wasted during production can significantly impact emissions, making it a crucial aspect to consider.

The solution: dense hanging

Hanging densely and really filling the line, will result in both reduced power waste and lower energy usage – which will have a direct effect

on CO2 emissions. A theory that HangOn is planning to provide multiple clear examples of during the exhibition in April. HangOn is also going to be giving a number of lectures in two different languages.

Product release 2024

The new product HQW S, the latest dense hanging HangOn innovation will also be presented during the exhibition: it is a close relative to HQW D, which the company displayed during PaintExpo last time. Compared to its double-sided and flexible precursor, the new product aims even more towards simplicity. Easy to understand and easy to use.

For further information: www.hangon.com

Plasmatreat Presents Openair-Plasma Surface Treatment at PaintExpo 2024

Perfect paint results while reducing the carbon footprint and dry and primer-free surface treatment with Openair-Plasma will be the focus of Plasmatreat GmbH at PaintExpo 2024.

From 9th to 12th April 2024, the leading developer and manufacturer of atmospheric plasma systems and equipment Plasmatreat GmbH will be demonstrating the activation, cleaning and coating of various materials such as plastics, glass and metal (hall 1, stand 1210). Visitors can also learn how to significantly reduce the carbon footprint of their manufacturing processes.

If parts are difficult or impossible to paint, the cause is usually a low surface energy or a contaminated surface and the associated poor adhesion properties of the material. Only when the surface energy of the material to be painted is higher than that of the paint to be applied will uniform wettability and therefore optimum adhesion be ensured. It is also important that the surface is clean and free of release agent residue, grease or dust. Various pretreatment methods have been used in the industry to improve adhesion properties, such as grinding, sandblasting, etching, flame and plasma treatment. Plasma technology has significant advantages over many conventional processes: it is in-line, selective and can be applied to the entire surface.

“The dry Openair-Plasma process completely eliminates the need for environmentally harmful wet chemical primers. In this way, we also reduce the release of VOCs (volatile organic compounds) into the atmosphere,” explains Joachim Schüßler, Head of Sales Germany at Plasmatreat GmbH.

In addition to reducing VOCs, manufacturers can also reduce their carbon footprint by using plasma surface treatment: the reactive plasma species are generated by a combination of

compressed air and electricity, eliminating the need for solvents or huge amounts of gas for flame treatment. Using fast-drying UV coatings in combination with Openair-Plasma eliminates the need for costly and spaceconsuming ovens to dry painted components during pretreatment. Plasma pretreatment is ideal as an environmentally friendly solution that provides optimum adhesion properties for a perfect paint finish.

Visitors to the Plasmatreat booth at PaintExpo will be able to see for themselves the effectiveness and functionality of plasma surface treatment. Several plasma systems will be available for live demonstrations with different materials. In addition to the activation of a plastic automotive component in a PTU1212 (Plasma Treatment Unit), visitors will see how a Scara robot is used to precision clean various metal battery cells as a pretreatment for painting with 100% UV paint.

Thanks to this Openair-Plasma application, the foiling of the battery cell can be completely and reliably replaced by painting, resulting in cost and time savings and a higher quality of the final products.

At the booth, the plasma experts will clearly activate and clean the surfaces of various materials, such as PP and PE or aluminum, and verify the plasma treatment with various test methods. The plasma effect can be detected and the surface energy determined by measuring the contact angle of a water drop, water spray tests or Plasmatreat’s test inks.

For further information:

www.plasmatreat.com

© Plasmatreat

WHERE WE HAVE BEEN

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myFAIR is a free web app that can be accessed from both desktop and mobile devices, which allows you to stay up-to-date with the leading events of the surface treatment sector.

© Adobe Stock

Axalta Presented Starry Night as its 2024 Automotive Colour of the Year

To celebrate the 10th anniversary of its colours of the year, Axalta introduced the dynamic black shade Starry Night.

The international paints and coatings manufacturer Axalta Coating Systems has recently presented Starry Night, its automotive colour of the year 2024 – marking the 10th anniversary. The colour is a dynamic black shade evoking depths of our universe and space exploration. “Black is the second most popular automotive colour globally, so we are excited to feature a black shade as our 2024 Global Automotive Color of the Year. Starry Night is a hue where black is bright and dark is distinguished. The colour of this year is part cosmic and part classic, but all Axalta,” has stated Dan Benton, Senior Manager, Global Color at Axalta.

Starry Night is a strong and contemporary colour with light blue and silver flakes that evokes the depths of our universe and space exploration, representing bold imaginations and driving to reach new heights. As a dynamic hue, Starry Night transcends classic and modern design styles and harmonises with other colours, finishes, patterns and textures. The company first introduced its Global Automotive Color of the Year in 2015 with Radiant Red. Since then, its global team of colour experts collaborated annually to introduce a trending and up-in-coming shade for the automotive industry.

For further information: www.axalta.com

© Axalta Coating Systems

ART WITHIN SURFACES

Black, the Non-Colour with Eternal Charm

Monica Fumagalli, ipcm®

Why dedicate this column to the non-colour par excellence? Because, despite its negative reputation, black is much more present in our daily lives than other hues. Because it is one of the most ambiguous and, for this very reason, most fascinating shades. And because it is one of the tints most required from coaters, as well as one of the most challenging colours to apply with satisfactory results.

According to colour studies, black and white are not colours. White is obtained by combining all colours, whereas black is obtained by subtracting them – that is, it is the result of the subtractive synthesis of all the colours of the visible spectrum. As often mentioned in this column, colours are determined by light and differ according to its wavelengths. We can identify the colours of objects because the

materials in which they are made receive beams of light that they partly reflect and partly absorb. Black does not reflect light and, therefore, has no colour. It is thus considered a non-colour. Yet, it is one of the most widely used tints in the most diverse applications, from fashion to interior design, from architecture to electronics, from art to literature, from music to sport and comics, to name but a few, perhaps also thanks

to its ability to match and bring out all the other colours in the spectrum. This shade is characterised by a dual nature, perhaps much more than the others, although its negative associations have been prevalent throughout history. While, on the one hand, it is a symbol of elegance, charm, mystery, and courage, on the other hand, it represents mourning, darkness, death, and fear. Of course, there are some geographical differences: black is the colour of mourning in the West, whereas, in some African countries, white is; in Japanese culture, black symbolises experience, whereas white symbolises naivety, so much so that in the martial art of karate, for example, the black belt is awarded to those who have demonstrated dedication and commitment to the discipline, while beginners are assigned the white one. This choice is also linked to the Yin and Yang philosophy: sun and moon, day and night, beginning (white) and ending (black).

Black represents contrasting ideas: authority and humility, rebellion and conformity, wealth and poverty. It also means modernity, power, professionalism, traditionalism, evil, pain, subjugation... and absence: today, there exists a black pigment that is so black that it feels like staring into the void, capable of absorbing up to 99.965% of the visible spectrum radiation (see below).

The origin of the word “black”

The etymology of “black”1 (in Italian nero, in French noir, in Spanish negro, in Portuguese preto, and in German Schwarz) is directly related to the Latin nigrum, the accusative of niger, i.e. “black”, “dark”, and, in a broader sense, “gloomy”, “sombre”, “foreboding”, “mournful”. In fact, it is assumed that this term was connected to the Greek root nekrós, “death”, which in turn can probably be traced back to the Proto-IndoEuropean nekw-t, “night”.

Black in ancient history

Carl Gustav Jung wrote that black is “the colour of the sunrises, of the principles, of the occlusions in their germinal phase, preceding the luminous and the hopeful explosion of birth”. Indeed, in the Bible, it is the primordial colour from which light springs forth. The same concept is found in Egyptian mythology, according to which the cosmos was created from the Nun, the primordial chaos, akin to the Te Bo Ma (“darkness”) of Micronesia and the Dreamtime of Aboriginal culture. Black, therefore, emanates a generating and fertile power, an original chaos from which light and life can erupt. In ancient Egypt, it was associated with the fertile land left by the Nile after the floods, whereas among the Maasai of Kenya, it recalled the puffy clouds heralding rain, becoming a symbol of life and prosperity. From darkness comes the light: this concept was also evoked by Homer, who described the sea’s depths as black and containing latent life, the great reservoir of all things, and even by Aztec mythology, in which the god of medicine,

1 www.linkedin.com/feed/update/urn:li:activity:7001092899694129152

Ixtlilton (“the little black one”), used magical tlital (“black water”) as a remedy for ailments2

Made from black charcoal and iron ore, black was the first pigment used in history: the bison drawn in the prehistoric caves of Altamira (Spain) and Lascaux (France) bear witness to this. In Greece, black silhouettes on a red background were painted on clay pottery using a sophisticated technique. Black was obtained by Roman painters with graphite-based powders and pigments made by burning resins or tar, although the use of soot (carbon black) to produce inks was even cheaper. Pliny wrote that some painters, to obtain good-quality black pigments, robbed graves to collect charred remains, but this practice was obviously forbidden. The black tint for dyeing textiles was obtained from the vegetal waste of the wine industry, consisting of copper tannates (fouling on vats). The name of Nero, the Roman emperor who ruled Rome from 54 AD to 68 AD and is (perhaps erroneously) blamed for the great fire that destroyed the city, derives from the Roman cognomen “Nero” (connected to the Latin nigrum, “black”), probably of Sabine origin and

2 https://www.mentinfuga.com/lartificio-del-colore-nero/

Caravaggio’s “Narcissus”, oil on canvas, 1598-99 - Galleria Nazionale di Arte Antica, Rome (Italy). ©

meaning “strong” and “valiant”, further confirming that, even in ancient times, black did not have an entirely negative connotation.

Black in the Middle Ages

At the height of the Middle Ages, black became the colour of Hell, where darkness reigns, and the symbol of the devil. Black animals, such as the raven, were penalised for this. However, according to colour historian Michel Pastoureau, something good was still seen in black since, in the same period, it also became the colour of humility, temperance, and dignity. Benedictine monks wore a black tunic, which became the subject of a religious dispute with Cistercian monks, accused of excessive pride, as evidenced by their white robes: the Cistercians replied that the black worn by the Benedictines was the colour of the devil, death, and sin, whereas their white symbolised purity and innocence.

A little later, black became the preferred colour for courtiers’ clothes and a symbol of luxury, as clearly shown in many portraits of the time. It retained the reputation of “fashionable colour” until the 16th century. Although it remained associated with witchcraft and mourning practices, its position evolved: now respectable and luxurious, it became a royal colour until the mid-17th century. And, with the invention of printing, which used black ink on white paper, it became a part of everyday life, in the same way the smartphones’ black screens are today.

In the 19th century, black became the symbol of the smoke of the first factories and automobiles – a world difficult to imagine in colour, which we are in fact more inclined to visualise in black and white. It then became a symbol of political extremism in the 20th century, linked to a grim historical period: suffice it to recall the black swastika of the Nazi flag, the colour worn by the paramilitary corps of the Italian National Fascist Party, and the black flag symbol of anarchy.

Black in the world of art

Here, it would not be possible to mention the countless works of art in which black was preferred to white to bring out the other tints of the palette or the shapes of sculptures, from Flemish painters Jan Vermeer and Rembrandt to Caravaggio, who used it with masterly skill to create the backgrounds of his indescribable paintings, up to Édouard Manet, who, in his 1863 oil painting “Olympia”, was able to make the black of the cat on the right and the face of the servant girl stand out against the black background of the canvas by creating a unique “black on black” effect. In contemporary art, we cannot fail to mention Anish Kapoor, one of the most important sculptors today, who has been at the centre of much controversy for having acquired Vantablack®, the blackest black pigment ever made, produced by British company Surrey NanoSystems and composed of carbon nanotubes. It absorbs up to 99.965% of the visible spectrum radiation and it was developed originally for military purposes, as it was intended to coat stealth aircraft, built with technologies that make them “invisible” to radar. Kapoor described it in these words: “It is so black that you almost cannot see it, and it is so dark that you lose awareness of space, so much so that you are driven to rely on something you do not know in your inner reality.” BMW coated the body of one of its car models, the BMW VBX6, with Vantablack® for the first time in 20193

When the soul is dark Black clothing has made history, not only in fashion – Coco Chanel is credited with the invention in 1929 of the “little black dress” that Audrey Hepburn made timeless – but also in sport, music, and comics, sometimes with surprising implications. For example, the black jersey awarded to the last rider to cross the finish line of the Giro d’Italia

3 https://www.ipcm.it/en/open/ipcm/2019/59/146-147.aspx

BMW VBX6 is the first BMW model coated with Vantablack® . Audrey Hepburn in the movie “Breakfast at Tiffany’s”.

© Surrey NanoSystems

does not have the negative meaning one might expect. It originated, as is often the case, from a particular sports story: Giuseppe Ticozzelli was a fairly well-known footballer with an immense passion for cycling who, in 1926, decided to race some stages of the Giro d’Italia as an independent. Since he did not have a team with official colours, he chose to compete with the black jersey with a white star on the chest of his then-football team, Casale. The jersey worn by “Tico” served as an inspiration when the Giro d’Italia resumed after the Second World War in 1946 and it was decided to establish a prize for the last classified, which was then abolished in 1952.

The black colour chosen for the jersey of the All Blacks, as the athletes of the New Zealand national rugby team are nicknamed, makes one of the world’s strongest teams, also known for its pre-match Haka dance, all the more fearless – and probably its opponents all the more worried. The origin of this choice institutionalised in 1893 is unclear4: according to the most suggestive version, black was chosen to make the silver fern on the athletes’ chests stand out; according to the more practical version, it was selected to differentiate from the colours of other national teams or to prevent the jerseys from becoming excessively dirty during matches.

Black clothes such as leather jackets, tight jeans, and boots have also marked the history of music: from punk to heavy metal, they have become the symbols of transgression par excellence. And from Batman, who became the Dark Knight in Christopher Nolan’s movies, whose costume is reminiscent of the black of the bats he was inspired by and of the darkness of Gotham City on whose rooftops he moves, to Black Panther and Black Widow, black is also the colour of the costumes of many heroes (and villains) of comic books.

Has black really redeemed itself?

Although, nowadays, black also evokes positive aspects, we unconsciously continue to feel uneasy about it. Positive associations include Black Friday, the day after Thanksgiving in the US, since 1952 traditionally considered the beginning of the Christmas shopping season and sales. The reason for using the adjective “black” associated with this day is unknown. According to some, it originated in Philadelphia and would refer to the traffic created on that particular day, whereas according to others, it referred to the entries in merchants’ ledgers that moved from red (losses) to black (gains). From (black) magic to economics (black market, black Monday) and from literature (noir as a subgenre of crime fiction) to endless other fields, this shade remains linked to negative feelings and, perhaps, to archaic superstitions (black cat and wolfs), or simply to what is different and unknown.

Without wishing to delve into socio-historical issues related to the perception of blackness – this is not the appropriate place – I would instead like to mention a personal anecdote, which proves to what

4 https://www.rugbymuseum.co.nz/stories/history-of-nz-rugby/black-black-black

extent the negative connotations of black still affect our everyday life, even at an unconscious level. I was walking two large dogs, one black and one brown. Although the former is more docile and friendly, the people I met only paid attention and cuddled the brown dog, completely ignoring the black one.

Perhaps, although black is now largely legitimised, it still unsettles us deep down... and this, too, is part of the intriguing, eternal fascination of this non-colour.

The New Zealand national rugby team wears a black jersey.

Bacteria Found in Desert Pave the Way for Paint That Produces Oxygen Whilst Capturing Carbon

Edited by University of Surrey Guildford (United Kingdom)

An innovative paint that contains oxygen-producing bacteria capable of capturing carbon dioxide (CO2) has been created by scientists from the University of Surrey. Researchers suggest this paint, known as ‘biocoating’ could be used in extreme environments, such as space stations.

Scientists from the University of Surrey in Guildford (United Kingdom) have recently presented Green Living Paint, an innovative biocoating containing oxygenproducing bacteria capable of capturing carbon dioxide (CO2) that could be used in extreme environments such as space stations. “With the increase in greenhouse gases in the atmosphere, particularly CO2, and concerns about water shortages due to rising global temperatures, we need innovative environmentally-friendly and sustainable materials. Mechanically robust ready-touse biocoatings, or ‘living paints’, could help meet these challenges by reducing water consumption in typically water-intensive bioreactor-based processes” has stated Suzie Hingley-Wilson, a senior lecturer in bacteriology at the University of Surrey. Biocoatings are a type of water-based paint that encase live bacteria within layers. Besides capturing carbon, they can also serve as bioreactors or as biosensors. The creation from scientists at the University of Surrey – named ‘Green Living Paint’– features Chroococcidiopsis cubana, a bacterium that undergoes photosynthesis to produce oxygen while capturing carbon dioxide (CO2). This species is usually found in the desert and requires little water for survival. Classified as an extremophile, it can survive these extreme conditions.

To investigate the suitability of

Chroococcidiopsis cubana as a biocoating, researchers immobilised the bacteria in a mechanically robust biocoating made from polymer particles in water, which was fully dried before rehydrating. They observed that the bacteria within the biocoating produced up to 0.4 g of oxygen per gram of biomass per day and captured CO2. Continuous measurements of oxygen showed no signs of decreasing activity over a month. In contrast, researchers conducted similar experiments with the bacterium Synechocystis sp., another cyanobacterium usually found in freshwater. Unlike its desert counterpart, it was unable to produce oxygen within the biocoating.

“The photosynthetic Chroococcidiopsis have an extraordinary ability to survive in

extreme environments, like droughts and after high levels of UV radiation exposure. This makes them potential candidates for Mars colonisation,” has added Simone Krings, the lead author and a former postgraduate researcher in the Department of Microbial Sciences at the University of Surrey.

“Our research grant from the Leverhulme Trust enabled this interdisciplinary project. We envision our biocoatings contributing to a more sustainable future, aligning perfectly with the vision of our Institute for Sustainability, where both Dr Hingley-Wilson and I are fellows,” has concluded Joseph Keddie, a professor of soft matter physics in the School of Mathematics and Physics at the University of Surrey.

Image of Cyanobacteria in a biocoating.

© University of Surrey

Where the Industry Meets

Surfex is the UK’s event for the paints, inks, coatings and surface technology industry featuring a large exhibition running alongside a comprehensive programme of scientific, technical and topical industry content. With extensive access to a whole spectrum of suppliers, scientists and industry experts, Surfex delivers the ideal meeting place to develop new ideas, source solutions to technical challenges, find inspiration, enhance knowledge and address key issues.

Visit www.surfex.co.uk to find out more and investigate exactly what you can achieve at Surfex.

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Organised by:

Chemetall Inaugurated the New Global Aluminum Competence Center

The new Global Aluminum Competence Center will strengthen the position of Chemetall in the aluminium surface treatment sector.

The Surface Treatment global business unit of BASF’s Coatings division, operating under the Chemetall brand, celebrated the opening of its new Global Aluminum Competence Center in Giussano (Italy). The state-of-the-art facility will strengthen the position of Chemetall as a global supplier of solutions for the surface treatment of aluminium substrates.

The Aluminum Competence Center was established to bundle the comprehensive competences of Chemetall in the area of surface treatment of aluminium in one place. After the intensive analyses of existing capacities, development priorities as well as customer and market requirements, the existing Chemetall site in Giussano was identified as the best option. With the centralisation of the research and development

activities for aluminium, Chemetall is positioned to develop technologies faster and more efficiently resulting in transformative innovations in the field of anodising and pretreatment of this special substrate.

“The new global Aluminum Competence Center will allow us to bring new surface treatment solutions to the market faster. The centralisation of our research and development activities for aluminium will result in pioneering technologies that solve the challenges of our global customers, provide solutions for their needs and most of all deliver long-lasting sustainable value,” has stated Frank Naber, Senior Vice President of Chemetall.

“The Aluminum Competence Center at our Giussano site is a strategically important step towards further expanding our technological leadership.

© Chemetall

The ribbon-cutting ceremony during the inauguration: from the left Lorenzo Bottinelli, CEO of BASF Italia Spa, Marco Citterio, Mayor of Giussano, Daniela Polzot, Managing Director of Chemetall Italia, Guido Guidesi, Regional Councillor, and Frank Naber, Senior Vice President of Chemetall.

As a lightweight metal with high availability, aluminium plays an important role in architectural, aerospace and automotive construction. Aluminium is normally used in alloys because pure aluminium has different mechanical properties compared to materials like steel. Depending on the specific alloy, not only do the mechanical properties change, but also the chemical and corrosion characteristics of aluminium. This presents chemical challenges for pretreatment solutions. Our new technology centre will enable us to better manage the complexity of this material and empower our team to set new standards in the industry,” has added Arjan Termaten, Director & Head of Global Technology at Chemetall. “We are very proud to play a key role in the research and development for our global aluminium business in Giussano. Our team has great expertise in development and application technologies and has achieved remarkable success in areas such as neutral cleaners and plastic recycling. In close collaboration with our global technology teams and through partnerships with universities and research communities we will provide new, innovative technologies for the aluminium market,” has explained Daniela Polzot, Managing Director of Chemetall Italy. The Grand Opening of the Aluminum Competence Centre took place last February during a two-days event dedicated to technology, innovation, and research. On February 13, after the ribbon cutting ceremony, the guests, the press and the local authorities were guided through the new Competence Centre to discover its full potential of research, analysis and testing. After the visit, guests were taken to the Museum of Science and Technology in Milan for a private tour of the Museum and for a gala dinner in the wonderful frame of the Sala del Cenacolo (the room of the Cenacle) inside the Museum itself. On February 14 guests moved to BASF Italy headquarters in Cesano Maderno for a technical conference and round table moderated by Alessia Venturi, Editor-in-Chief of ipcm®. After a series of technical presentations that explored the areas of sustainability and market trends, the round table analysed all the facets of a hot topic in the aluminium industry, namely the use of secondary alloys.

Chemetall is a global provider of surface treatment solutions with a comprehensive product range of advanced pretreatment solutions like the chrome-free thin-film Oxsilan® AL0510 and anodising technologies like nickel-free medium temperature sealing Gardoseal® 1999 for the aluminium industry. In Italy, more than seventy Chemetall employees, including fifteen technology experts, contribute to providing surface treatment solutions for a broad range of industries to the market. The new Global Aluminum Competence Center meets the strict quality requirements QUALICOAT, GSB and QUALANOD of the aluminium finishing industry.

For further information: www.chemetall.com

© Chemetall

Alessia Venturi, ipcm® Editor-in-Chief, moderating the technical conference on future megatrends of the aluminium industry.

© Chemetall

Aerial view of the new Chemetall Global Aluminum Competence Center in Giussano (Italy).

The gala dinner in the wonderful frame of the Sala del Cenacolo.

AI at HANNOVER MESSE: the Key to a Competitive and Sustainable Industry

Boosting competitiveness, protecting the climate, promoting prosperity – these are the major tasks facing industry today. Innovative technologies are the key to mastering these challenges. But how can companies make efficient use of automation, artificial intelligence, renewable energies, and hydrogen? And what steps can be taken to counteract the impending de-industrialization of Europe? HANNOVER MESSE 2024 will provide answers: the next edition runs from 22 to 26 April 2024 in Hannover, Germany.

Hannover. “Geopolitical tensions, climate change, stagnating growth, high prices for energy and a shortage of skilled workers mean that cost discipline and efficiency are currently the dominant themes in companies. At the same time, artificial intelligence is leading to profound changes in the worlds of work in industry. In addition, business leaders and trade associations are warning of a deindustrialization of Europe,” says Dr. Jochen Köckler, CEO of Deutsche Messe AG, describing the environment in which this year’s HANNOVER MESSE takes place.

“HANNOVER MESSE is more important than ever this year, because the economic environment has rarely been so volatile. In Hannover, technologies and solutions will be presented to enable industry to produce on a competitive and sustainable basis. The trade fair will be all about intelligent and carbon-neutral production, AI, hydrogen, and

cross-sector energy solutions. For European companies in particular, HANNOVER MESSE will thus create a bulwark against the impending de-industrialization of Europe,” says Köckler. “Our exhibitors will show that competitive industrial production is possible in Europe. However, this will require a regulatory framework that promotes innovation and entrepreneurship.”

The solution lies in the interplay of automation, digitalization and electrification, broad cross-industry and cross-border cooperation, and a clear political course. Köckler: “With the lead theme ‘Energizing a Sustainable Industry’, 4,000 exhibitors, high-caliber representatives from politics and industry, and with Norway as the partner country, HANNOVER MESSE 2024 is the ideal platform for this.”

More than 300 economic delegations are expected to attend the trade fair, first and foremost the Chancellor of Germany, Olaf Scholz,

© Deutsche Messe

MEETING THE INDUSTRY

who will open HANNOVER MESSE together with the Prime Minister of Norway, Jonas Gahr Støre. In addition, the President of the European Commission, Ursula von der Leyen, and the German Minister of Economics, Robert Habeck, will use the world’s leading trade fair for industry to exchange ideas with representatives of the industrial sector.

“If Europe is to retain substantial and sustainable production and investment, then the amount of red tape must be urgently reduced, for example through faster planning and authorization procedures,” Köckler appeals.

“Visitors to HANNOVER MESSE are looking for guidance on how they can use automation, artificial intelligence, renewable energies or hydrogen in a meaningful way. This is precisely the expertise that the exhibitors at HANNOVER MESSE can provide,” says Köckler.

The exhibiting companies include global tech giants such as Accenture, AWS, Bosch, DELL Technologies, Google, Microsoft, SAP, ServiceNow, Schneider Electric and Siemens as well as SME technology leaders such as Beckhoff, GP Joule, ebm-papst, Ericsson, Festo, Turck, Harting, ifm, igus, LAPP, Pepperl+Fuchs, Phoenix Contact, Rittal, Schunk, SEWEurodrive, Wago, WIBU and Ziehl-Abegg plus renowned research organizations such as the Fraunhofer-Gesellschaft and the Karlsruhe Institute of Technology (KIT) and more than 300 industrial startups.

Artificial intelligence: the next level of industrial digitalization

For more than a decade now, HANNOVER MESSE has been the most important trade fair for the digitalization of industry. Artificial intelligence is now taking industrial digitalization to the next level by revolutionizing industry, making processes more efficient and adding value. By using AI, companies will be able to shorten development times while saving resources and energy.

“The speed at which AI solutions are finding their way into industry is breathtaking. Companies need to invest now and, above all, introduce their employees to the opportunities offered by AI, otherwise they will get left behind by the competition,” emphasizes Köckler. “AI is the key to competitiveness and sustainability in industry.”

Specific applications will be on show at HANNOVER MESSE: robots that can be controlled by voice, machines that automatically recognize defects; or systems that cut downtimes through predictive maintenance.

Köckler: “In the near future, generative AI will be able to design machines. This will lead to fundamental changes in engineers’ job profiles – a subject that will also be discussed at HANNOVER MESSE.”

When will the hydrogen economy arrive?

With the increasing use of unpredictable renewable energy sources, hydrogen is increasingly coming to the fore as a suitable energy carrier for an emission-free economy. Around 500 exhibitors from the

hydrogen and fuel cell industry will be showcasing their solutions in Hannover. This makes HANNOVER MESSE the world’s largest and most important trade fair for the topic of hydrogen.

Köckler: “Hydrogen offers enormous opportunities as the green energy carrier. However, the current pace of roll-out and scaling up is too slow.” Developing a hydrogen economy now requires bold political decisions to be taken in the regulatory area, intensive research and development for rapid implementation, and the development of the necessary infrastructure for scaling up. This is the only way that viable business models will be able to become established. “At HANNOVER MESSE, we will be demonstrating what is technologically feasible, and creating the framework for discussions between representatives of politics and industry, hopefully allowing decisions to be taken on a specific road map towards a functioning hydrogen economy,” says Köckler.

Partner Country Norway: a powerhouse for energy and digitalization

Norway is using the global stage offered by HANNOVER MESSE to present itself as an innovative and reliable energy partner, among other things. The motto of the partner country is “Norway 2024: Pioneering the Green Industrial Transition”. This underscores Norway’s ambition to play a key role in the development of solutions in the fields of renewable energies, carbon-neutral production, carbon capture and the digitalization of industry.

At the “North Sea Energy Hub” conference on 23 April, politicians and experts from Norway and Germany will discuss the transition in energy policy, with a focus on general political conditions as well as technological developments and applications. Köckler: “In Europe, Norway is a powerhouse for energy and digitalization. Which means it fits in perfectly with HANNOVER MESSE.”

European Union: strong economic alliance

Two months before the European elections, the European Union will be presenting itself as a strong economic alliance at HANNOVER MESSE. Ursula von der Leyen, President of the European Commission, will get the program started with a speech at the opening ceremony on 21 April. The EU program during the trade fair includes the “Investing in European Industry” conference on 22 April, at which representatives of industry will be able to discuss with EU politicians topics such as the Green Deal.

For further information: www.hannovermesse.de/en

Lechler Opens its First Color Design Lab

Lechler’s new Color Design Lab is a multifunctional space that allows the company to communicate directly with colour experts and customers and work with them to identify and develop the most suitable special-effect finishes for their projects.

Coatings have been a valuable ally for centuries in enhancing the technical and functional characteristics of substrates, improving their aesthetics and making them attractive through a variety of special-effect finishes. However, the technical requirement to faithfully reproduce an exact colour point or effect regardless of the type of surface to be coated is often not easy to fulfil. For example, light refraction changes the visual perception of tints on products made of different materials and with different shapes: this must always be considered and thoroughly addressed when selecting and designing coatings. However, Lechler has succeeded in making the repeatability of colours and finishes on any substrate, be it plastic, plaster, wood or metal, one of its strengths. The company offers a wide range of technical and colour solutions with dedicated water- and solvent-based systems for all sectors, including decorative, industry, habitat, refinish, and yachting.

On Thursday, 8 March, at the Stangalini Point of Lechler Trade S.r.l. (located in Via Pier Lombardo 230 in Novara, Italy), this paint manufacturer inaugurated its first Color Design Lab to be even closer to its customers and streamline its analysis and design processes, as this innovative platform is designed to enable the company’s team, colour experts, and customers from multiple industries to connect and work together to identify and develop the most suitable finishes for even the most ambitious projects. The event also provided a unique opportunity to explore design and colour perception topics.

“Opening our Color Design Lab in Novara is a turning point for Lechler, an excellent opportunity to explore the depths of colour design. This state-of-the-art space not only enables us to encapsulate our vast selection of resources and customised consultancy services for specific projects in one place, but also allows our customers to engage with

our finishing experts and directly access samples and mock-ups, thus making their decision-making process faster and more effective,” explains Claudia Salomoni, Marketing Manager Industry at Lechler. During the visit, Lechler’s experts and highly qualified staff were open to explaining in detail the many functions of the new space, highlighting how it can be a valuable ally in creating distinctive and successful projects.

Following the welcome speech and the presentation of the space, the event continued with the participation of a few experts, including renowned colour psychologist Dr Lia Luzzato, who gave a speech entitled “Finishing, colour, and effect”. Through interesting case studies and an overview of the evolution of the discipline, Luzzato analysed the perception of colour from a synaesthetic point of view. Luzzato went into details of the importance to design a finishing since colours, textures and effects, in order to define the language of finishing, that is used by the designer to communicate the characteristics of an object, modelling it according to his vision.

Afterwards, architect Stefano Maestri shared valuable insights with his presentation entitled “Colour in architecture and interiors”, explaining how to collaborate with customers to create more productive and welcoming working environments, combining the users’ needs and aspirations with the areas’ functional requirements. With numerous successful examples, Maestri, too, demonstrated the crucial importance of colours and finishes in creating spaces that reflect the mission and

values of companies. The day ended with a convivial aperitif, during which participants had the opportunity to exchange thoughts and ideas, further consolidating the importance and value of Lechler’s new Color Design Lab.

“The inauguration of the first Colour Design Lab is a milestone in colour and finish design for Lechler, as it offers experts and customers an unprecedented tool to explore, create, and realise projects that reflect their vision and identity in a unique and surprising way. In the near future, we plan to open more in the most relevant areas of Italy to expand these opportunities even further,” states Salomoni.

For further information: www.lechler.eu

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Stuttgart Surface Technology Prize 2024

This year, the Fraunhofer IPA is once again awarding the Stuttgart Surface Technology prize “DIE OBERFLÄCHE”. The award honours innovative applications and technologies within all disciplines of surface technology. The application phase began on January 19, the award ceremony will take place June 4 at the Surface Technology Germany trade fair.

From January 19 up to and including April 8, 2024, it is once again possible to apply for the Stuttgart surface technology prize DIE OBERFLÄCHE. Participation individuals and organizations that have played an innovative role in shaping the surface technology industry, whether in in electroplating, painting technology, thermal spraying or other industrial areas related to surface areas related to surface technology are invited to take part in the competition.

In addition to sustainability, the three-member jury also evaluates the degree of innovation of the technology or application as an enabling technology and the industrial feasibility.

“Every component inevitably interacts with its surface. This is why surface technology plays a key role in the degree of innovation and progress in numerous industries. We want to promote and recognize this,” says juror Martin Metzner, Head of the Electroplating Department at the Fraunhofer Institute for Manufacturing Engineering and Automation IPA. First place in the Surface Technology Award at THE SURFACE 2022 went to Dürr Systems AG.

The paint devices manufacturer from Bietigheim-Bissingen, together with partners from the paint and automotive industry, had developed a completely overspray-free wet painting system.

Award ceremony at the Surface Technology Germany trade fair

In addition to Metzner, the interdisciplinary and independent expert jury also includes Martin Riester (VDMA Surface Technology) and Michael Hilt (Research Association for Pigments and Coatings e.V.). The Stuttgart surface technology prize DIE OBERFLÄCHE is awarded every two years and will be presented for the ninth time in 2024. The award ceremony will take place on June 4, 2024 at the specialist forum of the international trade fair Surface Technology Germany trade fair in Stuttgart. All necessary documents for the application as well as further information are available at: www.ipa.fraunhofer.de

For further information:

www.surface-technology-germany.de/en/

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