ipcm n. 86 | March - April 2024

The smart journal for surface treatments

ISSN 2280-6083

ipcm digital on

® Special issue

www.myipcm.com 2024

INTERNATIONAL PAINT&COATING MAGAZINE

ENVISION THE FUTURE OF COATINGS

Visit us in Hall 2, Stand 2140 to learn more

15th Year - Bimonthly N° 86 - MARCH/APRIL

A NEW FOCUS ON INNOVATION www.adaptacolor.com

Zaniolo CdA-01.24

d The strength of Europolveri products does not derive from the sole mixture 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.

EUROPOLVERI S.p.A. - Sandrigo (VI) Italy - Ph. +39.0444.750643 FILIALI/Branch Office: Cernusco sul Naviglio (MI) Ph.+39.02.92148001 - Erbusco (BS) Ph.+39.030.7704158 DEPOSITO/Depot: Iori Colori, Reggio Emilia Ph.+39.0522.327248

info@europolveri.it - www.europolveri.it

S I N C E 1 9 8 2

CONTENTS MARCH/APRIL 2024 © ipcm

26

FOCUS ON TECHNOLOGY

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

© Andreas Brücklmair

40

ADVANCEMENTS

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

© Gema Switzerland GmbH

54

ADVANCEMENTS

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

07 EDITOR’S LETTER 08 BRAND NEW OF THE MONTH 18 HIGHLIGHT New Sustainability and Automation Scenarios for the Dürr Group: Research, Innovation, and Investment to Seize the Opportunities of an Increasingly Informed Market

34 BRAND NEW

© TIGER Coatings

76

HIGHLIGHT OF THE MONTH

Thermoset: the Future of 3D-Printing

OF THE MONTH 44 HIGHLIGHT Mirodur Develops a New Direct-to-Metal Coatings Range with Excellent Adhesion on All Metals

ON TECHNOLOGY 48 FOCUS Optimising a Zero Liquid Discharge Waste Water Treatment Plant: the Virtuous Example of Arco

58 BRAND NEW 62 SUCCESS STORIES

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

TO 2050 64 ROAD Environmental Product Declaration to the VIVENDI SDS Collection by Adapta Color

STORIES 66 SUCCESS An Automatic Pre-Treatment Pilot Plant, Tailor-Made for Chemetall’s New Global Aluminum Competence Centre

ON TECHNOLOGY 70 FOCUS Innovation and Quality Research in the Powder Coating Sector: the Virtuous Technological Choices of Univer 2000

PRETREATMENT & WATER TREATMENT

OUR SKILLS INNOVATION PERFORMANCE NANO TECHNOLOGY R&D ESG TECHNICAL ASSISTANCE

Visit Us at

Hall 1 Stand 1542

a Dollmar Group Company

CONTENTS MARCH/APRIL 2024 © ipcm

82

FOCUS ON TECHNOLOGY

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

© Bialetti

108

SUCCESS STORIES

PPG's Partnership with Maker of Iconic Italian Coffee Pots

© AdobeStock

124

FOCUS ON TECHNOLOGY

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

OF THE MONTH 90 HIGHLIGHT A PVD Treatment Hub: Kenosistec’s Innovative Project

OF THE MONTH 94 HIGHLIGHT Very Good Signs for PaintExpo 2024: World Premieres as well as Advancements in Sustainability and Efficiency in the Spotlight

98 FOCUS ON TECHNOLOGY

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

© Vermobil

146

112 FOCUS ON TECHNOLOGY

FOCUS ON TECHNOLOGY

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

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

OF THE MONTH 118 HIGHLIGHT Hydro Italia Revolutionises Waste Water Treatment for ICA

OF THE MONTH 132 HIGHLIGHT New Horizons in Paint Curing Technology: Helios Italquartz Enlightens the Future of the Industry with Its IR and UV Lamps

138 BRAND NEW

OF THE MONTH 142 HIGHLIGHT The Global Requirements Placed on Surface Treatment by the ACE and Commercial Vehicle Sector: The Viewpoint of a Complete Coating System Supplier

ON TECHNOLOGY 154 FOCUS Achieving Excellence and Offering Impeccable Finishes: D.P.F. Srl’s New Coating Plant

162 ANALYSIS New Perspectives for Quality Control in Industrial Coatings

168 BRAND NEW

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CONTENTS MARCH/APRIL 2024 © D.B.M. Tecnologie

174

HIGHLIGHT OF THE MONTH

D.B.M. Tecnologie: 40 Years of Excellence in Industrial Automation and Surface Finishing

© Evonik Coating Additives

200

ADVANCEMENTS

Simplify Coating Formulations with AEROSIL® Easy-to-Disperse Fumed Silica

© Marcin Szczepanski, Michigan Engineering

210

RESEARCH BREAKTHROUGH

Researchers to Study Biological Molecules for Producing Ice-Shedding Coatings

OF THE MONTH 178 HIGHLIGHT Coatings That Go a Long Way

182 HIGHLIGHT OF THE MONTH

Adapting to the Evolving Market while Maintaining One’s Peculiarities: Stardust Powder Coatings Changes but Remains True to its Mission

186 HIGHLIGHT OF THE MONTH

Spanesi to Present its Wide Range of Coating Technologies for the General Industry at PaintExpo

190 BRAND NEW JOE POWDER 196 ASK The "Ask an Expert" Column

© Clint Strydom

214

198 UCIF INFORMS

S.M.A.R.T. 3: the Finishing of the Future Between Innovation and Sustainability

TO 2050 204 ROAD BASF Launched the GLASS Tool to Calculate CO2 and Cost Simulations for Automotive OEM

STORIES 206 SUCCESS New Preservation Line Placed into Existing Building Containing an Overhead Crane

216 BRAND NEW 218 WHERE WE HAVE BEEN

ART WITHIN SURFACES

Retrospective of Pioneering South African Artist Esther Mahlangu with her BMW Art Car on View

220 COLOUR STUDY

Axalta Presented Starry Night as its 2024 Automotive Colour of the Year

222 COLOUR STUDY

Black, the Non-Colour with Eternal Charm

BREAKTHROUGH 226 RESEARCH Bacteria Found in Desert Pave the Way for Paint That Produces Oxygen Whilst Capturing Carbon

228 MEETING THE INDUSTRY

EDITOR’S LETTER

Richiedi la versione in italiano a info@ipcm.it

T

he 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.

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.

Alessia Venturi Editor-in-chief Direttore Responsabile

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.

international PAINT&COATING magazine - MARCH/APRIL 2024 - N. 86

07

BRAND-NEW

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.

T

he international paints and coatings manufacturer AkzoNobel has

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

recently announced that it has completed the expansion of its

and Middle East Africa (MEA).

Italian powder coatings manufacturing plant in Como (Italy). The

The new installation at the Como site is located in a refurbished building

investment will allow the company to enhance its offering to customers

dating back to 1992, originally dedicated to the production of powder

in Europe, the Middle East and Africa (EMEA region).

coatings. The new lines use recycled energy and are geared to meet the

The €21 million project resulted in four new production lines, two of

highest standards of sustainable production – supporting the company’s

which are dedicated to automotive primers and two to architectural

ambition to reduce its carbon footprint by 50% by 2030.

coatings. In addition, new bonding equipment lines were implemented

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

to ensure that products meet and exceed industry standards.

It supplies products for seven main market segments: white goods,

“Increasing our capabilities in Como is a significant milestone which

architecture, automotive, agriculture and construction machinery,

supports our ambition to create safety of supply for our customers.

commercial coatings, furniture and general industry.

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

For further information: www.akzonobel.com

© AkzoNobel

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N. 86 - MARCH/APRIL 2024 - international PAINT&COATING magazine

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. © AMPP

T

he Association for Materials Protection and Performance - AMPP -

has 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

BRAND-NEW

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.

W

B Coatings – which is a brand belonging to the Mipa Group

however, it must be light enough so that the gigantic ELT does not

since 1st January 2023 – has recently announced that its

collapse under its own weight.

paints have been employed to coat the steel structure of the

The project required the deepest possible black dull matt surface,

Extremely Large Telescope - ELT of the European Southern Observatory

in order to minimise scattered light and prevent disruption during

– ESO. The ELT, that is currently being assembled in Chile, is considered

operation. WB Coatings then developed a combination of a robust

to be groundbreaking for space exploration: due to go into operation

epoxy primer, a polyurethane topcoat and the matching clearcoat.

in around five years, it will become the largest telescope for visible

Since the construction was carried out by an international consortium,

and infrared light. When planning the steel structure, the focus was on

the products were supplied to two participating companies in Spain and

keeping the telescope stable under all conditions, including strong winds

Italy – where the individual steel components were coated before being

or earthquakes.

delivered to Chile for assembly.

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

For further information: www.mipa-paints.com

© ESO/L. Calçada

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N. 86 - MARCH/APRIL 2024 - international PAINT&COATING magazine

BRAND-NEW

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.

T

he European Chemicals Agency – ECHA – has recently added

Lastly, importers and manufacturers must notify ECHA within six

five new chemicals to the Candidate List:

months if their article contains a listed substance. EU and EEA suppliers

 One is toxic for reproduction;

of substances on the Candidate List must update the safety data sheet

 Three are very persistent and bio-accumulative;

they provide to their customers.

 The last one is persistent, bio-accumulative and toxic.

These chemicals can be found in adhesives as well as sealants

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

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 – SVHC now contains 240 entries for chemicals that may harm people or the environment. Companies responsible for managing the risks

ll

ha

information on their safe use.

2

4 20 o 20 xp s! 23 tE t u h in Visi oot b

Pa

of these substances must provide customers and consumers with

are as follows:

SOLUTIONS FOR THE

 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-4-

|

The entries added to the list of candidates, updated January 2024,

SURFACE

TECHNOLOGY est.

1987

yl) 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;

.com www.emptmeyer

 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

HOOKS & S HANGING SYSTEM

RACKS

MASKING

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

ACCESSORIES

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.

international PAINT&COATING magazine - MARCH/APRIL 2024 - N. 86

11

BRAND-NEW © Beckers

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.

B

eckers and ArcelorMittal have announced a partnership to

application and curing technology were developed by ArcelorMittal to

develop a radiation curing technology for pre-painted steels to

meet high-speed strip coating requirements.

be used in the coil coating industry.

The long-term partnership between ArcelorMittal and Beckers has been

The main objective of this innovative technology is to replace

crucial to overcoming challenges with scaling up the technology from

solvent-based paints with solvent-free solutions, in order to produce

laboratory to industrial production in a very short timeframe. The first

pre-painted steels for building envelopes. The regular thermal

coils produced were processed to make sandwich panels that have

polymerisation is replaced by EB polymerisation to achieve the following

already been installed on a pilot building. The new paint technology is

results:

expected to be used together with a high-speed galvanizing process in

 Reduce CO2 and VOC emissions;

the future.

 Lower energy consumption - thus avoiding natural gas and the use of

Furthermore, this collaboration was fundamental in overcoming the

cooling water, given that the process takes place at room temperature;

challenges related to the transition of technology from the laboratory to

 Limit waste treatment;

industrial production in a short time. The first coils produced have been

 Improves productivity.

transformed to make sandwich panels and, in the future, a new painting

The Coil Coating line n. 3 at ArcelorMittal Construction in Contrisson

technology is also planned to be used in combination with the high-

(France), was converted in early 2023 as part of a major project. The

speed galvanizing process.

paint formulation for this project was developed by Beckers to match the performance and applicability of solvent-based products. Proprietary

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N. 86 - MARCH/APRIL 2024 - international PAINT&COATING magazine

For further information: www.beckers-group.com

BRAND-NEW

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

I

GM 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.

© IGM Resins

For further information: www.igmresins.com

CONVEYORS and spare parts

BRAND-NEW

I

©

AL

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no

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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.

T

he Italian manufacturer of machines and products for the metal

of the highest quality, designed with precision and made with advanced

surface treatment ALIT Technologies has introduced MAS-KING,

materials. The brand aims to set a new standard in industrial masking and

its new brand specialising in industrial masking. In an increasingly

represents the commitment signed by ALIT Technologies to excellence in

dynamic industrial world, it is essential for a company to innovate but also

the protection of parts during all stages of surface treatment.

to renew itself to offer increasingly comprehensive services to the market.

The new brand has a strongly international vision made possible by the

Strong on this approach, ALIT Technologies decided to expand its reach

ALIT Technologies’ global network of agents. To Italian customers, MAS-

by creating MAS-KING, a new brand specialising in industrial masking

KING offers an innovative service based on speed of delivery, supplier-

based on innovation, progress and responsiveness to the demands of an

customer trust, problem-solving ability as well as on good price-quality

increasingly demanding market.

ratio: a dedicated van, loaded with solutions for protecting parts during

The San Bonifacio (Verona) based-company is pleased to announce the

coating, will be available to customers directly at the workplace, thus

transition from dealers to owners of a new line of business operating in

guaranteeing immediate and customised supply.

the field of masking for coating and other surface treatments. MAS-KING, the brand chosen for this new business, presents a range of products

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N. 86 - MARCH/APRIL 2024 - international PAINT&COATING magazine

For further information: www.alit-tech.com

BRAND-NEW

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.

T

he international paints and coatings

Furthermore, it is environmentally tolerant of

manufacturer Sherwin-Williams, through its

application conditions, provides excellent gloss hold

Aerospace Coatings Division, has launched a

out and can boast superior low-film wetting, levelling

new chrome-free epoxy primer, which consists of a

and dry-film profile. It also allows superior topcoat

two-component, corrosion-inhibitive technology able

wetting for easy collapse, flow and levelling for a

to provide good performance with several substrates

smoother finish. Lastly, it will be offered as individual

and pretreatments as well as working with all exterior

kits and can be used with all spray equipment,

topcoat systems of the company.

including conventional air spray HVLP, electrostatic

The new primer is ready to spray with no additional

air spray and air assisted airless. The primer meets

reduction required for true ease of use. It offers a

the U.S. VOC regulations, which require 335 g/L and

broad application range using a single activator, it

will be available for sale in all Americas region.

flows out to a nice smooth surface and its wet edge is ideal for both large surface application areas and

For further information:

different environmental conditions.

https://industrial.sherwin-williams.com

© Adobe Stock

BRAND-NEW

SPECIAL ISSUE - PaintExpo

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.

T

he Italian liquid paints manufacturer Lechler has recently

also possible to produce paints with binders compliant to CAM criteria,

introduced EvoEffects: a new colour collection with over five

in order to offer products in compliance with the strictest international

hundred special effects finishes, including pearlescent and

environmental protocols.

metallic paints, created with an innovative approach – combining the

The collection has been produced only with the YD943 Hydroplast

needs of product appearance and industrial design with a commitment

Semi Glossy WS enamel, which guarantees high levels of durability and

to sustainability. The range of colours is produced with high-durability

quality. All the products feature very low solvent content, thus resulting

lead-free pigments, which satisfy the highest quality requirements and

in a marked reduction in the emissions of Volatile Organic Compounds.

specifications of the industrial world.

EvoEffects also complies with all the requirements of the ISO 9001:2015

With the colour cards included in the box, the clients can easily choose

and ISO 14001:2015 quality management systems, guaranteeing

a colour and create the desired paint in the needed quantities with

complete reliability and safety of use.

the Lechsys Hydro Tintometer or take advantage of the innovative and unique Intinta service, that allows customers to order any colour in the

©

Le ch

ler

collection – even in small quantities, starting from a single 4-litre tin. It is

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N. 86 - MARCH/APRIL 2024 - international PAINT&COATING magazine

For further information: www.lechler.eu

HIGHLIGHT OF THE MONTH

SPECIAL ISSUE - PaintExpo

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

2

018 report of the UN Intergovernmental

market itself has become more aware of

and now rethought to enable collaboration

Panel on Climate Change (IPCC)

both environmental and social sustainability

between machines and human operators in

affirmed the urgent need to limit

issues, and it now demands technologies

what is shaping up to be Industry 5.0.

global warming to 1.5 °C by 2030. In recent

combining low environmental impact and high

As a result, the market increasingly values

years, it has become clear that, for this to

automation. It is precisely automation that

those suppliers who invest in sustainability,

materialise, we must not only transform

has been the second industrial mega-trend

social responsibility, and automation. In the

our energy system but also rethink how we

of recent years, pushed to the extreme by

coating and surface treatment industry, one

live, travel, and manufacture our goods. The

the digitalisation processes of Industry 4.0

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.

© ipcm

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N. 86 - MARCH/APRIL 2024 - international PAINT&COATING magazine

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

HIGHLIGHT OF THE MONTH

© Dürr

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.

ipcm®: What is Olpidürr’s market strategy in light of the changes

and after-sales support. Finally, the fourth pillar relates to sustainability

that occurred in its management and corporate structure in

and responsibility, not only in the production facilities we build, but also

2022?

within Dürr itself. It is an ongoing commitment to environmental and

P. Pedruzzi: First, a brief summary of the changes: At the end of 2022,

social sustainability to reduce the environmental impact of our activities

the Italian partner of Olpidürr left the company, which means that

and promote a culture of social responsibility. Thanks to this strategy,

Olpidürr is now 100% owned by the Dürr Group. At that time, I was head

Olpidürr has maintained a leading position in the automotive industry,

of the two divisions, Paint and Final Assembly and Clean Technology

even though in recent years the Italian market has focused more on the

Systems, and was then offered the position of Managing Director,

modernization of existing plants than on new brownfield or greenfield

which I have now held for two years. At the end of 2024, Olpidürr’s

plants.

headquarters will move to a new facility in the northeast of Milan.

Our market strategy is closely aligned with the headquarters and

ipcm®: Will Olpidürr remain the Global Competence Centre for

focuses on technological innovation, efficiency and excellent customer

wheel finishing?

service. Our goal in Italy is to consolidate our long-standing leadership

P.Pedruzzi: Yes, definitely. Olpidürr continues to have a team dedicated

position in the coating equipment sector. This is based on four main

to this sector to follow up on any opportunities in both the Italian

pillars: the first can be summarized under the name “Paint Shop of

and international wheel market. At the same time, it also has many

the Future”, i.e. we offer more advanced coating technologies that

customers outside the automotive market. We are seeing a trend

reduce operating costs, improve energy efficiency and reduce pollutant

towards a greater openness to investment in the wheel sector, where

emissions. The second pillar is Industry 4.0-oriented digitalization, i.e.

greater market stability is required to make major new investments.

the implementation of digital and automation solutions that increase efficiency and productivity and optimize production processes. The third

ipcm®: What is the strategy and vision of the Dürr Group in

pillar is Service, which is the provision of excellent and comprehensive

general Business and in the Industrial market?

customer service, including consulting, design, installation, maintenance

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

international PAINT&COATING magazine - MARCH/APRIL 2024 - N. 86

19

SPECIAL ISSUE - PaintExpo

important topics of the future: sustainability, electromobility, and

producing non-polluting energy (photovoltaic panels, for example) for

automation. Over the past few years, it has invested substantially in the

one’s own needs, buying green energy from third-parties if self-supply is

first two areas, and now it is investing in automation, also by acquiring

not sufficient, electrification of the company car fleet, and encouraging

external companies. Above all, the trend towards sustainability and

employees to suggest and implement projects to reduce global pollution

decarbonisation offers many opportunities, as our company is a market

in the Group. The ultimate goal of this strategy, and the next key target,

leader in energy-efficient solutions in the relevant markets. We will

is to become carbon-neutral by 2050.

leverage this technological advantage for profitable growth. At the same

In terms of market demand, Dürr sees two trends in the field of

time, we will continue to invest in climate protection at our sites in order

industrial painting technology that we are pursuing: the desire for

to contribute to the 1.5-degree target1 set out in the Paris Agreement.

greater sustainability and for more automated painting processes.

Dürr is pursuing a clear climate strategy for 2030 that includes

When it comes to sustainability, our customers are particularly

ambitious, science-based climate targets in line with the global

interested in reducing paint consumption and saving solvents. This is

1.5-degree target and validated by the Science Based Targets (SBTi)

why we always ensure that our new developments make a significant

initiative, an independent initiative that reviews a company’s reduction

contribution to conserving resources, such as overspray-free painting

targets based on the latest findings in climate science. In this case, the

with the EcoPaintJet and the EcoSupply P Core pigging technology.

goal is to reduce the emissions of the Dürr Group’s individual companies

In combination with our standardised paint supply, the pigging

worldwide by 70% by 2030, compared to their levels in 2019. This can

components can be used to recover the paint in the hose line and

be achieved through a variety of processes and virtuous behaviors:

significantly reduce the consumption of rinsing agents. In the field of

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.

1

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

© Dürr

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.

20

N. 86 - MARCH/APRIL 2024 - international PAINT&COATING magazine

N E E GR S I S OA

L LY A T N E NM O R I V N E LE B A N I A S* G SUST N I T A CO R E D W PO

Come visit us at PaintExpo 9 -12 April 2024 in Karlsruhe.

Grimm Pulverlack GmbH - Hall 3, Booth 3430

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

*The Green Oasis powder coatings available today are based on one or more raw materials containing recycled PET. The PET content depends on the type of finish and can reach up to 20% by weight of the powder.

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HIGHLIGHT OF THE MONTH

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 © Dürr

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

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

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

international PAINT&COATING magazine - MARCH/APRIL 2024 - N. 86

21

SPECIAL ISSUE - PaintExpo

© Dürr

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

paint and rinsing agent waste during the painting process. Here, the

unit, encompassing the most common 1C and 2C processes across

new EcoSupply P Core comes to the rescue. Current paint supply

low and high-pressure ranges, and it supplies the EcoBell2 atomiser

systems clean the hoses using solvent and compressed air to remove

or the EcoGun spray gun with paint and rinsing agents. This makes

all paint and rinsing residues before preparing for the next color run.

the product ideal for tasks in industrial painting applications, such as

This process is laborious and time-consuming. The EcoSupply P Core

the woodworking, construction and automotive. The EcoMCC3 colour

pigging system uses a fitting body tailored to the internal diameter of

changer is located on the Fluid Board and can supply up to ten colours.

the hoses – the so-called “pig” – to make the process more efficient and

The Fluid Board significantly reduces engineering and assembly effort.

reduce paint and rinsing agent consumption. Paint flowing through the

For years, Dürr has pursued its ready2integrate concept, aiming to

pigging hose, pushes the pig from the source to the destination module.

seamlessly align individual products to swiftly assemble a high-quality

In the process, the paint remaining in the hose is returned into the paint

solution comprising a controller, dosing technology, and applicator. The

container.

Fluid Board is another piece of this puzzle allowingintegrators to quickly install application technology at the end customer’s site via plug-and-

Fluid Board

play.

It is a compact and modular colour dosing and colour changing system

The Fluid Board is Dürr’s first industrial painting product to come

developed by Dürr to provide a link between the control unit and the

with digital, technical documentation. The EcoDocu streamlines the

applicator for the industrial painting industry. The fully assembled

commissioning, operation, and maintenance of the paint dosing and

colour dosing and colour changing system is unique on the market. The

colour changing system.

Fluid Board is designed to be fully controlled by the EcoAUC control

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HIGHLIGHT OF THE MONTH

©D

ürr

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

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.

EcoGun AS MAN DC/EC

in just a few seconds, without the need for solvents,

Dürr expands its range of manual spray guns with

to make colour changes much faster and easier.

an electrostatic air spray gun (ESTA gun) . The new

Dürr and HSM Lackiersysteme partnered to develop

EcoGun AS MAN DC/EC is a more sustainable way

a new technology: a rapid-change system for the

of painting, reducing overspray by about 40%. The

colour channel, including the nozzle and the cup,

spray gun is available in two versions, with direct

which allows the spray gun to be ready for use

or external charging. It is equally suitable for both

within seconds after a color change without solvents.

solvent and water-based paints, and its ergonomic

This feature is ideal for the car repair sector, where

handle and light weight make it comfortable to use,

small-batch painting is standard.

HOOKS & CE HOOKS

even for longer periods. The new spray gun is ideal for applications where workpieces, such as tubes,

ipcm®: Let us now talk about Verind, the Italian

rims, and two-wheeler or train parts, are coated

company in the Group that specialises in

manually. Benefits include electrostatic charging

application technology for both the automotive

of paint and components and increased transfer

and general industry sectors. What is its most

efficiency.

recent investment?

M. Minelli: Verind has carried out an investment

EcoGun ACE

campaign that has lasted a decade. First, we

A new low-pressure spray gun for colour changes

renovated our site in Aquino, in the province of

COMPLETE SOLUTIONS FOR HANGING AND MASKING

www.rostirolla.it

SPECIAL ISSUE - PaintExpo

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 © ipcm

the industrial sector, on the other hand, we are pursuing different

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

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.

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N. 86 - MARCH/APRIL 2024 - international PAINT&COATING magazine

CUSTOM SOLUTIONS WITH INFRARED AND UV TECHNOLOGY COME AND VISIT US AT PAINTEXPO 2024, BOOTH 3245 HALL 3 Helios Quartz Group SA Via Roncaglia 20 6883 Novazzano - Switzerland Tel. +41 (0) 919233555/6 Fax +41 (0) 919233557 swiss@heliosquartz.com

www.heliosquartz.com

Helios Italquartz S.r.l.

Via delle Industrie 103/A 20040 Cambiago - Milano - Italy Tel. +39 02 95 34 93 18 Fax +39 02 95 34 50 85 italy@heliosquartz.com

www.heliosquartz.com

© ipcm

FOCUS ON TECHNOLOGY

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.

T

he 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.

FOCUS ON TECHNOLOGY

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

© ipcm

© ipcm

© ipcm

© ipcm

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.

international PAINT&COATING magazine - MARCH/APRIL 2024 - N. 86

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© ipcm

business. At the same time, we consider ourselves pure coating

cycle that can include alkaline degreasing, pickling or phosphating,

contractors because we can meet any customer need, from treating

multiple rinsing stages, passivation, no-rinse nanotechnology

small volumes of small parts to liquid-coating large-sized and complex-

conversion, and drying. Afterwards, the components are taken to

shaped components,” states Andrea Bellotto, the managing director of

our various coating lines, which differ from each other in the type

VP Verniciatura. “Over the past five years, our growth has progressed

and size of the parts they can treat,” explains Bellotto. “We wanted to

at a dizzying pace: we were among the first in Europe to obtain the

experiment with a higher performance pre-treatment cycle to achieve

QualiSteelCoat certification for coated steel, and we have since doubled

greater paint adhesion and corrosion protection properties up to the

our workforce. This is the result of our degree of production flexibility

C5-H corrosion class for all metal substrates, from steels (carbon, hot-

and our substantial investments in new 4.0 technologies, such as the

dip galvanised, Senzdimir) to aluminium. At the same time, we needed

plant recently supplied by Imel.

a system that would allow us to speed up the cycle time for those

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

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.

finishing grade, and chemical pre-treatment with a nanoceramic

The new powder coating plant

conversion process. “The shot blasting plant can process components

“The coating plant has a production capacity of 20 load bars/hour and

with a maximum size of 10,000 x 3,000 x 3,000 millimetres and a weight

can process workpieces with a maximum size of 2,200h x 3,500l x

of 5,000 kg. We also perform a customisable chemical pre-treatment

1,000w mm and a maximum weight of 500 kg. Since VP Verniciatura’s

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FOCUS ON TECHNOLOGY

GLOBAL SOLUTIONS FOR WATER TREATMENT

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

© VP Verniciatura

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,

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

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

srl

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

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

SPECIAL ISSUE - PaintExpo

© ipcm

© ipcm

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

water, nanotechnology no-rinse conversion, and drying at 110 °C. The

The i4paintshop management system

parts are then led through a cooling area and, subsequently, to a Gema

To ensure greater flexibility and control of process parameters, Imel

MagicCylinder EquiFlow booth for the application of the galvanising

integrated VP Verniciatura’s line with its i4paintshop 4.0 management

epoxy primer, which is gelled in the subsequent curing oven if a two-

system, consisting of a series of digital modules that guarantee

coat system is required. In this case, a bypass device specially designed

complete part traceability and processing of consumption data. Upon

by Futura Convogliatori Aerei leads the parts back into the electrostatic

matching each load bar with a specific programme, the automation

application booth for finishing with a low-temperature cure, Qualicoat

system allows the user to select the pre-treatment process to be

class 1 or 2 polyester paint, depending on the specifications.

carried out independently: the tunnel is structured to offer the

Following curing and cooling to room temperature, the load bars finally

possibility of choosing between different types of phosphating stages

reach the unloading area, where the coated products are checked by

(phospho-degreasing or phospho-pickling), setting the required

the QC operators and then labelled with a VP sticker that confirms their

number of rinses, and including or excluding surface conversion. The

suitability and indicates the operator who carried out the checks, in

management system also allows adjusting bath concentrations through

order to guarantee total compliance with customer requirements as

metering pumps and pH and conductivity meters.

well as traceability. “Our factory is equipped with photovoltaic panels

“Complete monitoring of the coating process is crucial to guarantee

that generate 400 kW, almost enough to power this entire coating

the traceability of our material’s quality. Our customers have access

plant,” adds Bellotto.

to a portal where they can check the progress of their orders and

®

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N. 86 - MARCH/APRIL 2024 - international PAINT&COATING magazine

FOCUS ON TECHNOLOGY

better organise their own activities. This is why

technologies. Its new plant features a MagicCylinder®

we expressly requested that the cycle be entirely

EquiFlow booth equipped with twelve OptiGun GA03

controlled by a 4.0 management system to monitor

automatic dispensing guns (six on each side) and

the plant’s operation and set process parameters,”

two manual guns for the pre- and post-finishing

notes Greta Dal Col, quality control manager

stations, OptiSpray AP01 dense phase pumps with

at VP Verniciatura. “Thanks to the i4paintshop

Smart Inline Technology, a MagicControl 4.0 plant

system, we can obtain data on water and electricity

control unit with the GemaConnect application

consumption, schedules, and production volumes

for remote data readout on devices such as PCs,

for each load bar. We can also manage the

tablets, and even smartphones, and an OC07

preventive maintenance of individual devices

OptiCenter powder centre for fast colour changes.

through a smart calendar based on the operating

The non-conductive plastic structure of the booth,

hours of the different system components, create

in combination with EquiFlow extraction technology,

daily, weekly, and monthly routine maintenance

prevents powder from accumulating on the bottom

schedules, and manage the system’s self-learning

and adhering to the walls, while its “H”-shaped floor

functions.”

ensures excellent air distribution and balanced

The ongoing collaboration with Gema for all things paint application

suction, as the three slits in the bottom guarantee optimal powder containment and ventilation in the application area. This creates a uniform airflow that

VP Verniciatura had already been cooperating

ensures easy control of the application process and

with Gema for many years and chose to extend

outstanding coating results. The booth is designed

the collaboration because it was happy with

for 7-minute quick colour changes – VP Verniciatura

the performance of this supplier’s application

performs about 50 per day – and automatic cleaning

© ipcm

COMPLETE SOLUTIONS FOR HANGING AND MASKING The touch-screen panel of the MagicControl 4.0 control unit.

www.rostirolla.it

SPECIAL ISSUE - PaintExpo

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

© ipcm

we need spare parts or specialised technical assistance. Gema’s service Some coated components.

partner Tecnospray Srl, located in Pasiano di Pordenone, provides truly efficient technical assistance,” Edoardo Bellotto states.

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N. 86 - MARCH/APRIL 2024 - international PAINT&COATING magazine

Discover more than

1.700 stunning finishes With more than 1,700 powder coating products in stock, the TIGER Drylac® standard range is the largest in the industry. Explore a color palette rich in nuances and effects, featuring various gloss levels and impressive effects – just one click away and available 24/7.

Visit us at PaintExpo 2024!

Karlsruhe | April 9 to 12 | Hall 1 | Booth 1641

www.tiger-coatings.com

BRAND-NEW

SPECIAL ISSUE - PaintExpo

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).

A

t the PaintExpo Walther Trowal

An important application for the Rotamat

has a capacity of 160 liters, respectively

introduces its new Rotamat R

systems is the coating of O-rings and flat

100 kg. In one single batch it can handle about

100 system for coating elastomer

gaskets, for example, for sealing individual

300 sealing rings with diameters of up to

sealing components with anti-friction and

cells in battery packs, but also in fuel cells,

350 mm or batches of up to 50,000 O-rings.

decorative lacquers. The new coater can

engines, and transmissions.

Compared to its predecessor model R 85,

handle work piece batches, which are three

At numerous job shop companies the demand

the new Walther machine can handle batch

times bigger than the batches processed in

for coating of large volumes of big sealing

sizes that are three times bigger. Of course,

its largest predecessor model. One reason

components, used in cooling systems and

the cycle times have remained the same, and

for developing this new machine was that

control panels for electric vehicles, has rapidly

the space and energy requirements have only

numerous customer coating companies

grown. This created the need for higher-

increased marginally.

requested a system that can handle large

capacity coating systems. The new Rotamat R

Frank Siegel, sales manager for coating

batches of big, flat sealing components.

100 is in full compliance with such demands: It

technology at Walther Trowal explains: “Until now our customers used the Rotamat

© Patrick Temme Photographie

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

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BRAND-NEW

SPECIAL ISSUE - PaintExpo

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.

A

t 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. © Venjakob Maschinenbau GmbH

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

The focus of PaintExpo is not on the ‘just

processes, since it is the process that becomes

join the dialog and play a part in shaping the

one’ solution. Instead, the company will

the solution. Visitors will also learn how they

future of manufacturing. The company will

showcase its expertise in meeting a wide

can use IoT, AR and innovative decision-

exhibit in hall 2 at stand 2318.

range of requirements for individual and

making models to make their production

extremely flexible system solutions: visitors

processes more intuitive and smoother.

For further information:

should be inspired to rethink coating

The Venjakob R&D team invites visitors to

www.venjakob.de/en

Sistemi di Profilazione della Temperatura

a à Nnoovvaziiotne e sicurezz In

Vieni a trovarci in fiera:

Sistema Ottico

Completo:

Video e Temperatura

a a cos rno!

Guardede nel fo c suc

Sistema ATEX

Nuovo Software

Certificato per zone classificate ATEX

Graphical cure di facile interpretazione

Sicurezza:

Semplicità:

nix Phoe r !

Facto

PaintExpo Karlsruhe Hall 2 Booth 2238 www.phoenixtm.com info@phoenixtm.com

Distributore unico per l‘Italia DELTA STRUMENTI S.r.l.

Via Mattei 6 - 21036 GEMONIO (VA) Tel. 0332 604.667 Fax. 0332 610.511 info@deltastrumenti.it www.deltastrumenti.it

BRAND-NEW

SPECIAL ISSUE - PaintExpo

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.

J

. Wagner GmbH has recently announced that it will showcase its

In addition, the flushability of the liquid coating pumps has been

range of smart and sustainable solutions for the coating process at

significantly improved: the Cobra high-pressure double diaphragm

PaintExpo, the international trade fair dedicated to paints, coatings

pump has been optimised, so that the required volume of flushing agent

and surface treatments that will take place from 9 to 12 April 2024

and colour change time have been significantly reduced. Regarding

at the Exhibition Centre in Karlsruhe (Germany). The company will be in

powder coating, on the other hand, the focus will be on efficiency and

hall 3, at stand 3330.

automation.

Wagner will present several products, from individual components to

Furthermore, the WALTHER Spritz- und Lackiersysteme GmbH

fully automated coating systems with a major focus on saving solvents,

subsidiary (known under the brand name Walther Pilot) will be

materials and energy. For example, their manual and automatic liquid

represented at the stand with product highlights in material preparation

coating guns are characterised by high application efficiency and

and application technology. The event will be rounded off by field

economical use of materials. Moreover, the new high-speed rotation

reports on analogue and digital services, including the COATIFY

atomizers for solvent-based and water-based paints developed by the

information & management platform, the service app and the Online

company play a major role in the implementation of highly automated

Academy.

th

th

liquid coating systems and robot solutions – supported by updates in control technology.

For further information: www.wagner-group.com

© J. Wagner GmbH

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BRAND-NEW

SPECIAL ISSUE - PaintExpo

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.

T

he wastewater incurring in painting technology

the excess heat of the vapour from the VACUDEST

is increasingly posing an economic challenge

for evaporation. Particularly interesting: the residue

for many companies operating in this

often contains valuable raw materials, for example in

arena. The solution from H2O GmbH: high-quality

the form of oils, whose recycling harbours additional

rinsewater treatment that saves costs. The experts for

economic potential. The VACUDEST ZLD secondary

wastewater-free production will explain how this can

concentrator is available for wastewater volumes

work at the PaintExpo, the world’s leading trade fair

from 2,100 to 16,000 m³/year.

for industrial painting technology that will take place

H2O GmbH is one of the world’s most experienced

in Karlsruhe from 9th to 12th April 2024.

expert in the sustainable treatment and recycling of

By treating wastewater with a VACUDEST, companies

industrial wastewater. With their efficient and safe

can reduce the amount of wastewater they produce

VACUDEST vacuum distillation systems, they achieve

and significantly lower their disposal costs. However,

a wastewater-free production for customers in more

the residual water content of the concentrate can still

than 50 countries around the world.

make complete disposal more difficult. This is where

Since its spin-off from the Mannesmann Demag

the VACUDEST ZLD post-concentrator comes in. It

Group in 1999, H2O has gained an increasing number

reduces the residual water content of the concentrate

of loyal customers as an owner-managed company.

in a downstream evaporation stage and as such

More than 120 employees at the headquarters in

reduces the final quantity to be disposed of by a

Steinen in southern Germany and at the branches in

further 50 per cent.

Switzerland, Poland and China contribute to this high

Even more, it does so in a particularly energy-efficient

level of customer satisfaction.

way thanks to clever energy recycling: the ZLD uses

For further information: www.h2o-de.com

© H2O GmbH

via Bassa Prima, 219 S. Andrea di Campodarsego (PD) T +39 049.5564837 info@feltanireti.it www.feltanireti.it WHAREHOUSE READY FOR DELIVERY

BRAND-NEW

SPECIAL ISSUE - PaintExpo

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.

F

rom 9th to 12th April 2024, Axalta

campaign ‘Sustainability, Together’ embodies

At the booth 3240 in hall 3, the company will

Coating Systems will showcase its

the vision of Axalta, which aims to promote

highlight four thematic areas:

comprehensive industrial portfolio

collaboration among stakeholders for shared

 ‘Sustainability, Together’: as part of this

at the PaintExpo in Karlsruhe (Germany).

sustainability objectives.

campaign, Axalta will present its latest

The focus will be on a range of innovative

“For Axalta, ‘Sustainability, Together’ is not

developments in sustainable coating solutions.

products contributing to sustainability,

just a slogan but our guiding principle. Our

Bio-based powder coatings are a highlight

including curing and thermoplastic powder

participation in PaintExpo 2024 is a testament

of the booth, representing the commitment

coatings and liquid and electrocoat paints, as

to our commitment to sustainability and

of Axalta towards environmentally friendly

well as electric insulation materials.

innovation. Our mission is to provide our

alternatives within the thermosetting category;

The company will then address the diverse

customers with exceptional total solutions

 Battery solutions for electric vehicles: amidst

needs of various industrial markets with

that meet the evolving needs of industries and

the shift from internal combustion engines to

its groundbreaking solutions. The clear

contribute to a more environmentally friendly

electromobility, Axalta focuses on advanced

commitment to sustainability acts as a

future,” has stated Steffen Bormet, Regional

coatings for battery applications. Visitors

catalyst for positive changes in the industry,

Sales Manager for Central and Northern

can learn more about dielectric coating and

aligning with global sustainability goals. The

Europe at Axalta Coating Systems.

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

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N. 86 - MARCH/APRIL 2024 - international PAINT&COATING magazine

© Andreas Brücklmair

ADVANCEMENTS

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).

T

o ensure components coated with various technologies would

perfectly compatible, but they must also present a homogeneous and

ultimately present a flawless finish, a number of years ago

coherent overall appearance in relation to colour, gloss and surface

FreiLacke developed its system coating concept. Factors such

structure. Meeting these demands while maintaining or improving

as sustainability, energy efficiency, waste reduction and climate

quality standards despite increasingly stricter VOC regulations and faster

protection have an increasingly important role to play in this. In this

cycle times requires application solutions.

endeavour, the system coating manufacturer has been driving ahead

This is where FreiLacke system coatings come into their own: with

with developments in the fields of powder, liquid and electrodeposition

its system coating concept of powder and liquid coatings, EC and

coatings as well as composite solutions, and is also now even more

composite solutions, the coating specialist from the Black Forest is

committed to direct and close service and contact with customers in the

focussing firmly on uniform surfaces irrespective of the diverse systems,

development of an appropriate solution.

application processes and facilities involved. Customers with various

Components and parts are increasingly manufactured globally before

production sites, sometimes even located on different continents, are

ultimately being locally assembled and coated entirely or in part with

already using the system coatings with great success.

various different coating systems. Workpieces not only need to be

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

40

N. 86 - MARCH/APRIL 2024 - international PAINT&COATING magazine

ADVANCEMENTS

coordinate the coatings in the course of

including steel and alloy wheel production,

structure in the range between 80 and

product development and production,”

the automotive industry, mechanical and

160 μm is very homogeneous. This has

explained managing directors Rainer and

apparatus engineering as well as the wind

allowed FreiLacke’s coating specialists to

Hans-Peter Frei. “Consequently, not only

power industry and rail vehicle sector.

successfully provide automated coating

can we offer our customers all the principal

Particularly the solutions for large and

system processors and manual coaters with

coating technologies, we are also able to

bulky components that forego the baking

significantly greater flexibility and scope when

harmonise these to optimum effect in terms

process accentuate the cost-efficiency and

it comes to coating their components with

of coating structure and finish to provide

sustainability approach.

fine-textured powder coatings.

a suitable solution, comply with stipulated

Solutions have also been developed to meet

In the case of low temperature powder

framework conditions and ensure cost-

the challenge of seamlessly distributing

coating (NT), the baking temperature can

effectiveness and sustainability.”

the powder coating layer thickness on

be significantly lowered and heating energy

Against this backdrop, FreiLacke is unveiling

sophisticated geometric workpieces, which

consumption appreciably reduced. NT

a variety of further system concept

is often possible only to a limited degree.

coatings also help to considerably shorten

developments in all four product areas at this

In order to adequately cover undercuts

the oven throughput time and consequently

year’s PaintExpo.

or cavities, other areas of the component

increase the conveyor speed. FreiLacke has

frequently feature denser layer thicknesses.

also successfully pressed ahead with further

“Here is what that means for conventional

development in this key area.

EC without labelling requirements for greater sustainability

finely-textured powder coating systems: the

Aspects such as sustainability and VOC

denser layer thickness will exert an optical

New Trend Collection

reduction have long been priorities for

influence on the structure or even cause the

This is a modern, matt powder coating

the coating manufacturer and are a prime

powder coating layer to foam. In the end, this

with innovative colours, ideally suited for

reason for the continuous range expansion

leads to defective goods or costly extra work”,

interior use – whether for ultimate design

and development of new solutions at the

explains Andreas Hepting, responsible for

aspirations or for rugged applications. Powder

Döggingen/Black Forest site. One example is

FreiLacke’s Sales Industry Groups.

coatings are similarly a suitable option for

the electrodeposition coating (EC) ‘EcoOne’,

However, with the new PP5011A product

coating materials such as SMC/BMC in that

a two-component (2K) system free of any

range, FreiLacke has been able to successfully

they are simply sprayed into the mould.

solvents and neutralising agents that require

counter this issue: Even with layer thicknesses

The highly reactive coating hardens within

labelling.

that are far greater than those specified in

a few seconds allowing the SMC/BMC to

The system is environmentally friendly and has

the technical data sheet, the surface will

be immediately placed and pressed. After

no implications for the health of employees.

remain uniformly flat; that means the surface

pressing, the finished, coated component

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

© FreiLacke

international PAINT&COATING magazine - MARCH/APRIL 2024 - N. 86

41

SPECIAL ISSUE - PaintExpo

can be demoulded as usual. The surfaces

efficient solutions for surfaces in industrial

Cleverly manufactured composites

generated in the PIMC process feature

applications. Whether subject to corrosion,

The benefits of glass-fibre or carbon fibre-

excellent chemical and mechanical resistance

chemicals or weather, FreiLacke delivers the

reinforced composites (GFRC / CFRP) are

and are well-suited for continuous use

optimum protective coating for substrates

self-evident. They are light, extremely durable

outdoors. The material is free of solvents,

such as steel, stainless steel, galvanised

and they can be pressed into just about any

hazardous substances and carcinogenic

substrates, aluminium and plastic. The liquid

shape. In addition to a diverse range of surface

raw materials. PIMC is fire-retardant in

coatings are used at every level of the coating

coating materials, FreiLacke now also supplies

accordance with EN45545, HL3, R1 and,

structure: as a primer or filler, basecoat or top

components for manufacturing parts. One

thanks to its good properties, it can be used

coat as well as in single coat systems. Industry

example is the new CM powder technology.

for many applications – for example kitchen

coatings are available in a variety of finishes

Due to a special two-stage principle, this

sinks, shower trays, facades, lights, athletic

and gloss grades for interiors and exteriors.

innovative composite powder stands out

equipment or in vehicle construction.

Increasingly stricter requirements placed on

against conventional composite material resin

A major benefit of this process: by combining

surface coatings and the continuous reduction

systems in that it can be melted on without

pressing and coating into a single work step,

of the VOC content in paints and coatings led

starting the hardening process.

the laborious subsequent coating (including

FreiLacke to develop ultra-high solid systems

FreiLacke offers numerous coating solutions

the associated parts handling) can be

(UHS). For conventional coatings, completely

for composite materials, ranging from colour

eliminated, as well as the extensive logistics

new coating systems with a solids content of

pastes and fillers to gel coats. These constitute

required when transporting the components

up to 80 percent by weight and a VOC value

durable-coloured coatings that are applied

to the internal coating plant or for external

of less than 350 grams per litre have been

directly into the mould and provide moulded

coating. When using the PIMC process, the

developed and brought to series maturity.

parts with long-term protection against

components stay in-house until they are

They facilitate rapid drying and accelerated

moisture, UV radiation and impact damage.

completed and can then be shipped to the

production processes. FreiLacke consequently

The system coating specialists have also

customer right away. Another advantage:

has various single- and double-coat solutions

succeeded in significantly reducing the

Added value for the operators and lower

on hand that offer high resistance for this

percentage of styrene in the gel coats as the

costs and higher quality for customers.

purpose. Coatings are available in all RAL

substance is deemed hazardous to health and

colours as well as special colours. Easy

problematic to the environment. “Using an

application – whether pneumatic, air-assisted,

alternative monomer, we have manufactured

Airless or ESTA – and excellent resistance

a reduced styrene gel coat that delivers even

levels distinguish this system.

better results than conventional systems in

Liquid coatings: from filler to top coat FreiLacke liquid coatings provide highly

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

42

N. 86 - MARCH/APRIL 2024 - international PAINT&COATING magazine

Aluminum

finishing treatment From Anodizing & Painting Line to Waste Water Treatment Plant

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

ANODIZING & PAINTING LINE

+39 02 9810470

www.cieengroup.it

info@cieeng.com - info@cisartgroup.com

HIGHLIGHT OF THE MONTH

SPECIAL ISSUE - PaintExpo

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.

D

irect-to-Metal (DTM) products

growing popularity is therefore due to their

The term Direct-to-Metal denotes two-

have been a major innovation in

unique functional and aesthetic properties

component paint products acting as primers

the industrial coating sector over

and ability to streamline and speed up the

and top coats, whose formulations are

the last few years. Thanks to their ability to

application process, as nowadays, users pay

specifically designed to adhere directly to

adhere directly to metal surfaces and ensure

particular attention to consumption and cycle

metals without needing a base coat. This is

effective protection against corrosion, they

time duration and are constantly looking for

possible thanks to resins (epoxy or acrylic) and

have become popular in many industries,

high-performance solutions that, at the same

special polymers that feature good adhesion

from agricultural machinery and off-road

time, reduce coating times, thus cutting both

properties and to additives or inhibitors that

vehicles to metalwork fabrications. Their

process and procurement costs.

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? © Mirodur

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

44

N. 86 - MARCH/APRIL 2024 - international PAINT&COATING magazine

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

HIGHLIGHT OF THE MONTH

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

© Mirodur

include industrial coatings. What is your

Mirodur’s laboratory.

core business?

Riccardo Vitelli: In addition to paint formulation, Mirodur specialises in the

and they enable to achieve a thickness of

retention (Xenon test) and excellent impact,

manufacturing of a wide range of industrial

around 100-120 microns without surface

abrasion, and corrosion resistance (salt

products, including the Miromix colour

defects with just one coat. Often, especially

spray test). We have recently also launched a

matching system for both water- and solvent-

with formulations containing acrylic resins,

new DTM product line offering much higher

based paints, our protective coatings mainly

it is difficult to achieve a thickness of 70-80

paint adhesion properties on metal than the

for the gas and water pipeline sector, and our

microns without the occurrence of surface

standard DTM coatings available.

ultra-thick coatings for the remediation of

defects, such as bubbles due to solvent

hydrocarbon and solvent tanks.

entrapment in the film; our DTM products,

ipcm®: Where did the need to formulate a

however, can reach thicknesses of up to 110

new DTM range come from?

ipcm®: What DTM products do you have in

microns in a single coat without any defects,

Riccardo Vitelli: The need to formulate a

your product range?

even with glossy finishes.

new range of DTM coatings emerged to meet

Fernando Rosa: Mirodur’s portfolio has

Riccardo Vitelli: The top product in our

the specific requirements of a major Polish

always included a wide range of Direct-

DTM range is POLIACRIL DTM. It is a two-

customer that demanded exceptional paint

to-Metal coatings, including one- or two-

component coating based on non-yellowing,

adhesion on a variety of metal surfaces,

component and solvent- or water-based

hydroxylated acrylic polyols with excellent

including carbon steel, galvanised steel, and

products. Recently, we have seen a significant

direct adhesion on carbon steel and

aluminium. This posed a significant challenge

increase in the market demand for these

galvanised steel. Once cured, its film ensures

for us but was also an opportunity to

coatings. Our standard DTM products,

excellent chemical and mechanical resistance.

demonstrate our ability to innovate and adapt

available with both glossy and matte finishes,

Particularly suitable for sectors such as heavy

to market requirements.

are suitable for various metal substrates,

and light metalwork, industrial bodywork, and

Fernando Rosa: The result of months of

including iron, aluminium, carbon steel,

agricultural machinery, POLIACRIL DTM is

research and development was a new line of

galvanised steel, and galvanised sheet metal,

characterised by exceptional colour and gloss

solvent-based 2K polyacrylic coatings with a

international PAINT&COATING magazine - MARCH/APRIL 2024 - N. 86

45

SPECIAL ISSUE - PaintExpo

significantly higher degree of direct adhesion to metal than the standard

end products’ prices to the rising energy costs associated, for example,

DTM products currently available on the market. This was achieved

with the paint drying phase. In this context, DTM coatings are becoming

through a series of targeted mechanical tests, including deep drawing,

increasingly popular because they allow reducing the number of coats

impact, cross hatch, and bending tests, which certified its excellent

applied, as well as the time and number of steps required for flash-off

properties in terms of not only adhesion but also durability of the paint

and drying. Unlike in traditional coating cycles, with DTM products, the

product on the metal substrate. To further enhance the performance

parts to be treated only undergo one application phase (primer+top

degree of our product, we also included corrosion inhibitors in its

coat) and, consequently, one drying phase.

formulation for additional protection against weathering and other

This improves productivity, helps optimise energy resources, and

environmental factors that can compromise the film’s integrity; the

reduces the operations’ environmental impact through lower

presence of UV filters also protects the film from external agents.

greenhouse gas emissions. Therefore, DTM products are gaining in

The main challenge in developing this new DTM line was balancing

popularity because, in addition to providing economic and ecological

several key factors: depositing a uniform film without aesthetic

benefits, they achieve the same aesthetic and functional performance as

defects, achieving the required thicknesses, providing all the necessary

traditional coatings, thus guaranteeing a high degree of quality.

mechanical and functional properties, and maintaining a price

Riccardo Vitelli: Another issue we tackled was the need to avoid

consistent with customer expectations. Although we did not face any

pre-treating (in the strict sense of the term) specific substrates before

cost pressure, as is often the case in this industry, the project still

applying a DTM product. Traditionally, properly preparing a metal

required careful work in terms of resource management.

substrate before the coating cycle is paramount to ensure optimal performance and service life of the coating itself. Such preparation

ipcm : Did you analyse the industry before formulating this DTM

phase may include mechanical processes, such as shot blasting or

product line? What were the applicators’ primary needs?

sandblasting, or chemical processes. However, subjecting the parts

Fernando Rosa: In recent years, the coating industry has been facing

to be treated to these operations is often difficult: for example, in

multiple challenges, from the increasing raw material costs affecting the

the heavy metalwork sector, where DTM products are widely used,

®

© Mirodur

The salt spray and Xenon test chamber.

46

N. 86 - MARCH/APRIL 2024 - international PAINT&COATING magazine

EPISTOLIO EPISTOLIO

HIGHLIGHT OF THE MONTH

towards the future

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.

SOLUZIONI ROBOTIZZATE DI ROBOTIC PAINTING SOLUTIONS VERNICIATURA

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.

Epistolio Srl.

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

© Mirodur

Publierre_Milano

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

© AdobeStock

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

FOCUS ON TECHNOLOGY

SPECIAL ISSUE - 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.

A

ccording to research institute Eurispes’ 2023 study1 on water

agriculture. Every year, more than 30 billion m3 of water are withdrawn

consumption, Italy ranks third among Europe’s nations with the

within its borders, of which 17 billion are used in agriculture, 9.1 billion

highest availability of water resources.

for civil use, and around 3.8 billion for industrial use, with the highest

However, it is also the European country with the highest per capita

consumption recorded in specific sectors such as chemicals, metallurgy,

consumption of drinking water and the second highest consumption in

rubber, plastics, and textiles. The study emphasises the alarming, constant reduction in the amount of renewable water in recent years

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

1

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N. 86 - MARCH/APRIL 2024 - international PAINT&COATING magazine

and the increasingly urgent need to improve and update old water

FOCUS ON TECHNOLOGY

systems and, at the same time, adopt water recovery and reuse

it is rare to serve customers located many kilometers away for logistical

solutions, particularly for the agricultural sector. The industry world is

reasons. Nevertheless, our company is highly sought after because we

the most active and advanced in this context: technological innovation

provide various sectors with a comprehensive service that includes

has already reached a high level of development, and numerous

the treatment of large-sized pieces. Arco’s main target markets include

companies have long since adopted zero liquid discharge (ZLD) systems

the automotive, ACE, HVAC, furniture, construction, and many other

to treat the water used in their processes.

sectors.”

In our sector, in particular, the largest volumes of water are utilised in

“Whereas this broad customer base shields us from market fluctuations,

cataphoresis pre-treatment and coating plants. Claudio Malaman, the

it also makes our business less streamlined than it could be if we

owner together with his brother Johnny of Arco Srl (Gazzo Padovano,

focused on just one sector, as each workpiece is profoundly different

Padua), a long-established coating contractor in Northern Italy, confirms:

in terms of peculiarities and treatment specifications. Moreover, thanks

“We have long since installed an evaporator for total water recovery and

to our experience, we not only apply coatings with high functional and

have recently implemented a new system to cope with the increasing

aesthetic performance but also serve as coating consultants for any

water volumes required due to intensified production, which was

customer requiring it – which is highly appreciated by the companies

designed and supplied by Simpec Srl (Nova Milanese, Monza e Brianza,

we work with daily. Our professional approach is based on using simple

Italy).”

language, which makes our processes and treatments understandable even to those without expertise in our field.”

The reasons for Arco’s success

Another aspect for which Arco is well known in Northern Italy is

“My father,” adds Malaman, “started this contract coating business

its classic car restoration service, a market niche that is difficult to

almost by chance in the late 1970s. He originally focused on the

penetrate due to the high complexity of the body repainting task. “The

construction industry, but soon the coating business took off, and the

size of our plants enables us to handle very large-sized products such

company grew rapidly. Today, we work in an 18,000 m -wide plant with

as cars and vans. The treatment cycle we carry out for the restoration

62 employees and provide not only high-quality application processes

of classic cars includes paint stripping in a pyrolytic oven with a capacity

and coatings but also all-round consulting services for small and

of 6 x 2 x 2 m, effective with all types of paint for deep cleaning of the

medium-sized companies in our area.” According to Malaman, contract

body; pickling for completely removing any oxides and traces of rust;

coating companies are firmly rooted in their communities due to their

and cataphoresis, which is the best coating solution to reach all areas of

intrinsic characteristics: “This kind of business is highly localised because

a car body evenly.”

2

© ipcm

© Arco

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.

international PAINT&COATING magazine - MARCH/APRIL 2024 - N. 86

49

SPECIAL ISSUE - PaintExpo

Plant equipment

water, nanotechnology application, and a final rinse with demineralised

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

water. “This pre-treatment cycle deposits a high-thickness iron

for powder coating.

phosphate film on the workpieces,” notes Malaman. “On request for maximum performance, a nanotechnology film can also be applied to

The cataphoresis plant

metal surfaces to increase corrosion resistance significantly. Our salt

Cataphoresis coating is a surface treatment process designed to

spray test results are 700 hours for the two-coat cycle (cataphoresis +

give the treated components considerable resistance to chemical

top coat) and 1,000 hours for the three-coat cycle (cataphoresis + epoxy

and environmental corrosion. Arco’s pre-treatment phase involves 2

primer + top coat).”

spray and immersion degreasing stages, a rinse, pickling, activation

The first powder coating plant, equipped with semi-automatic booths,

and phosphating with microcrystalline zinc salts, and a final rinse with

can process parts with dimensions of 6.4 x 1 x 2.5 m and has a load

demineralised water. “Our new-generation epoxy cataphoresis system,”

capacity of 1,000 kg. The second line is an extremely flexible step-by-

explains Malaman, “can process parts up to 6.4 m in length, 1.8 m in

step system, ensuring fast colour change operations and handling even

depth, 2.5 m in height, and 1,500 kg in weight. If our customers require

small batches. It can treat parts with a size of up to 8 x 2 x 2 m and

a particularly high level of adhesion, strength, and finishing performance,

a maximum weight of 1,500 kg. “We perform a minimum of 2 and a

the resulting film can be used as a primer for a subsequently applied

maximum of 7 colour changes per day because we organise our daily

powder layer.”

schedule to minimise them as much as possible, both to optimise our production flow and to achieve higher coating quality.”

The powder coating plants “Our 2 powder coating systems are equipped with manual and

Smart water management

automatic stations that guarantee consistent quality and constant

Arco’s plant equipment ensures extreme flexibility and the ability to

control of the electrostatic application process, from small to extremely

meet the most diverse customer needs. “Over the years, diversifying our

large parts. Applied as a top coat or primer depending on the type of

production has enabled us not only to stay afloat at critical times but

paint product chosen and the part’s intended environment, powder

also to increase our volumes consistently. This, however, has recently

coating is particularly suitable for materials that require an elastic,

led us to face an important choice related to the management of energy

cosmetic coating.” Arco’s plant equipment includes an 8-stage in-line

resources. We had long since installed an evaporator to purify the waste

pre-treatment tunnel, a drying oven, 3 powder coating booths, and

water generated in our cataphoresis and coating plants by distillation

a curing oven that works with an average temperature of 180 °C and

and recirculate the clean liquid into our production flow, but it could no

features 6 temperature control zones. The 8 pre-treatment stages are

longer handle the high amounts of water we now normally use: this is

as follows: 2 phosphodegreasing stages, a rinse, acid deoxidation for

why we decided to implement a new, closed-loop water recovery system

aluminium surfaces, a rinse with mains water, a rinse with demineralised

provided by Simpec.”

© ipcm

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

50

N. 86 - MARCH/APRIL 2024 - international PAINT&COATING magazine

© ipcm

The ultrafiltration system.

FOCUS ON TECHNOLOGY

Main features of the water treatment plant

© ipcm

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), The evaporator unit.

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

and an activated carbon system that absorbs

concentrate to be disposed of, whereas the

to trigger reactions at the right time. This is

any organic pollutants still present.”

distillate and permeate are filtered in a UV

where sludge starts to form, which is conveyed

Such purified water can be discharged into the

debacterisation system and recirculated back

to a flocculation tank together with water: the

environment or recovered, as is the case with

into the production flow. In total, therefore,

addition of a polyelectrolyte reagent favours

Arco. “From the activated carbon filter, it is

we recover and recycle 95% of water, of which

the aggregation of the flakes made insoluble

sent to a storage tank, from where it is drawn

70% is water recovered by reverse osmosis

in water and their transfer to a decanter,

by an ultrafiltration plant. After pH is corrected

and 25% is distilled water resulting from the

where the sludge is separated from the liquid.

by dosing an acidic agent, it is conveyed

evaporation process.”

It then reaches the thickener and, finally,

to a reverse osmosis system, recovering

the filter press, which it leaves in the form of

70% of the purified water with an electrical

panels ready to be disposed of by authorised

conductivity of less than 100 microsiemens/

Optimising consumption as a sustainability driver

companies. Meanwhile, the water is conveyed

cm, whereas the remaining 30% is discharged.

“This new plant was started up in September

towards a tank and, subsequently, a sand

The latter is then sent to a 25 m storage tank

last year,” says Malaman, “and has reduced

filtration system that cleanses it of any residue

and, finally, to the evaporator; this produces

the volume of water sent to our evaporator,

3

Paint Expo | April 9-12,2024 Karlsruhe | hall 2, booth #2318

EVERY CHALLENGE IS DIFFERENT.

And so are our finishing solutions.

venjakob.com

SPECIAL ISSUE - PaintExpo

© ipcm

The control electrical panel of the water treatment plant.

© ipcm

The HMI control panel.

allowing it to continue working. Designed and installed by Simpec, it is

system. Today, thanks to the new plant, our performance is also better

excellent in terms of both technology and component quality. For my

in this respect. And, in addition to considerable cost savings, the quality

employees and me, this is our first experience with a system of this type,

of our products has also improved. Simpec also helped us leverage the

and we have yet to fully master all its functions. Just like the kidneys in

existing evaporator, previously integrated into a sub-optimal recovery

the human body, it is also important to learn that the treatment system

system. This is the most environmentally sustainable aspect of our

of a production plant cannot just take in any kind of waste water to be

investment: not so much the technology selected – since we had already

purified, but it must rather be fed correctly.”

opted for a ZLD system before – but precisely the choice to make the

As the system has only been in operation for a few months, it is not

most of the plant resources already in use by optimising them thanks to

easy to estimate the savings achieved in terms of water consumption.

the collaboration of a strategic partner such as Simpec.”

However, the company has already seen an improvement. Malaman

Arco’s physical-chemical plant recovers 95% of waste water and is a

confirms that “the pre-treatment rinsing baths are cleaner, and this is

virtuous example of how to make the most of a key, limited resource:

reflected in the aesthetic quality of our coating, which is much higher.”

water. The Eurispes study mentioned at the beginning of this article

In terms of maintenance, the Arco team has also experienced significant

concludes that “Italy would have all the natural, cognitive, financial,

benefits: “The fact that waste water was treated with the evaporation

and technological resources to solve the current water crisis. What is

plant alone meant that our heat exchanger was often covered in fouling

lacking is an institutional and organisational system that is effective

that needed to be removed by an external company. This resulted in

in implementing projects and efficient in managing and maintaining

a considerable loss of time for the disassembly and reassembly of the

infrastructure.” The industry would have much to teach in this respect.

52

N. 86 - MARCH/APRIL 2024 - international PAINT&COATING magazine

INFRARED THERMAL SOLUTIONS

www.infragas.com

ADVANCEMENTS

SPECIAL ISSUE - PaintExpo

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

© Gema Switzerland GmbH

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

The OptiCenter All-in-One OC11.

54

N. 86 - MARCH/APRIL 2024 - international PAINT&COATING magazine

ADVANCEMENTS

PaintExpo

HALL 1

G

ema Switzerland GmbH is a leading supplier in the area of

STAND 1430

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),

THE FUTURE OF INDUSTRIAL COATINGS AGAINST THE BACKGROUND OF SUSTAINABILITY We invite you to a dialogue at PaintExpo 2024. #FocusSustainability

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.

Book your appointment with our experts at PaintExpo.

www.kansai-helios.it

SPECIAL ISSUE - PaintExpo

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 © Gema Switzerland GmbH

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 The OptiCenter All-in-One OC10.

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.

56

N. 86 - MARCH/APRIL 2024 - international PAINT&COATING magazine

Thank you 35 35 34 33 32

29,5

31 30

30,6

29 28

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.

27 26

25,4

25 24

22,4 19,1

20,2

20,6 19,5

18 15,4 14,1

7,9

5,9 5,8

4,6

M€ 2008

2009

2010

5,6

6,7

9,8

8,7

9

17

17,6

18,2

14,2

13,1 9,4

16,5

Growth Chart 2008-2023

6,2

0,3

0,5

0,7

0,8

1

1,2

1,5

2011

2012

2013

2014

2015

2016

2017

Machinery department

+10% forecast 2024

Job coating

2,1

2,6

2,4

2018

2019

2020

4,1

4,4

2022

2023

2,9

2021

Total M€

60% export share

Eurotherm S.p.A. Volpiano (Torino, Italy) T +39 011 98 23 500 M info@eurotherm.eu

Eurotherm France S.A.S. Lyon (France) T +33 6 76 72 48 65 M france@eurotherm.eu

Eurotherm Oberflächentechnik GmbH Sigmaringen (Germany) T +49 7571 92795 10 M germany@eurotherm.eu

Eurotherm Benelux Srl Brussel (Belgium) T +33 6 47 44 96 27 M alexis.dekergorlay@eurotherm.eu

90% internal production

www.eurotherm.eu

BRAND-NEW

SPECIAL ISSUE - PaintExpo

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.

T

he PaintExpo is the place to be for

The GSB offers a reliable quality assurance

Over the years, GSB Coatings gained

the entire coatings industry. Needless

system that provides building owners with

widespread recognition in the market and

to say, GSB will be present. Quality

long-lasting value retention.

became part of many tenders. It is therefore

assurance for coatings on aluminium, steel

At GSB, the entire coating process chain is

not surprising that coatings from GSB-certified

and galvanised steel is a hot topic across the

assured by independent accredited testing

coating companies are also demanded

board when it comes to outdoor architectural

institutes - the pre-treatment, the coating

by many tendering bodies outside the

applications.

materials, and the coating companies.

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/

© GSB International e.V.

58

N. 86 - MARCH/APRIL 2024 - international PAINT&COATING magazine

Werner Mader, Managing Director of GSB at PaintExpo.

BRAND-NEW

SPECIAL ISSUE - 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.

A

s 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/

QUALITY | PERFECTION | PERFORMANCE DUO A 22 - The new innovation in Air-assisted Airless technology.  innovative post-air control  rapid and precise on/off switching time  low overspray and high material efficiency  compact and long service lives

Hall 3 - Booth 3360

www.krautzberger.com

BRAND-NEW

SPECIAL ISSUE - PaintExpo

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.

A

lbert Krautzberger from Friedland, near Breslau, filed a patent

Optimisation via numerical flow simulation

application for a “painting device operated by compressed air”

 Further improved transfer rates through the optimisation of interior

on 9 October 1902. With that he laid the foundation of today’s

geometry

Krautzberger GmbH and of a complete revolution for paint application.

 Reduced soiling due to new exterior design

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.

Automated 100% control integrated in production process

Even today, the vast majority of compressed air guns work with the

 Zero defect strategy for continuous quality improvement

system by Albert Krautzberger.

 Improved reproducibility of the spray pattern

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

Functional improvement of the air nozzles

In 2011, Krautzberger received the Hermes Award, an international

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

technology award. Today, Krautzberger GmbH is a medium-sized family

spherical system

business with 90 employees and customers all over the world and is one

 Improved separation of flat and round jet air

of the leading industrial companies specialising in surface technology.

Krautzberger products combine proven technology with innovative

Improved handling and simple nozzle adjustment

methods. Be it small parts or series production – with Krautzberger

 Trapezoid threads enable insertion and tightening in one step

product range, painting processes can be improved effortlessly,

 Simple and exact positioning and fixation of the air nozzle

efficiently, and sustainably.

Following the launch of the first XLINE manual and automatic sprayers in

Colour-coded identification of the spray procedures

2017, Krautzberger has converted all manual and automatic sprayers to

 BLUE: conventional compressed air

XLINE over the next 6 years until 2023. All spray guns are equipped with

 DARK GREEN: HVLP procedure

XLINE material and air nozzles: available in anodised aluminium (60%

 LIGHT GREEN: LVLP procedure

weight reduction) or stainless steel for heavy duty application, the air nozzles come in the conventional and HVLP range. The new and ultra-

Krautzberger looks forward to welcome you at PaintExpo 2024, Hall 3

modern production process of the XLINE series offers to the customer a

booth 3360, to present the new XLINE nozzle range and all its industrial

number of advantages:

benefits.

© Krautzberger

For further information: www.krautzberger.com

60

N. 86 - MARCH/APRIL 2024 - international PAINT&COATING magazine

SUCCESS STORIES

SPECIAL ISSUE - PaintExpo

© J. Wagner GmbH

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.

S 62

hoemaker, headquartered in Cle Elum (Washington, U.S.A.), has

The company employs an advanced powder coating process to impart

been a pioneering manufacturer of air diffusers and heating coils

colour to their intricate multi-layered parts, fabricated from various

since 1947.

metals.

N. 86 - MARCH/APRIL 2024 - international PAINT&COATING magazine

SUCCESS STORIES

SPECIAL ISSUE - PaintExpo

Initially, the coating process involved automatic booths for white and

automatic booth equipped with the SprayPackE, a user-friendly

brown colours, while all other shades were applied manually. However,

application control system that ensures impeccable coating results while

as the demand for non-white or non-brown components surged,

optimising material consumption. For all other colours, the specialists

Shoemaker encountered formidable challenges.

from the company introduced the E-Line system, complemented by

Substantial manual involvement, which resulted in potential variance in

the PXE powder centre. This compact and efficient system seamlessly

coating quality, depending on the expertise of the operator performing

blends superior coating quality with exceptional productivity. It boasts

the task, slowed down the production pace. Furthermore, inadequate

strong application efficiency, rapid colour transition times and an

powder extraction mechanisms undermined overall process efficiency.

intuitive interface, providing Shoemaker with consistent results under all

Shoemaker, committed to meeting escalating market demands and

conditions.

staying ahead of the competition, embarked on a journey to optimise its

Thanks to this state-of-the-art Wagner coating system, Shoemaker

coating process. The objectives were crystal clear: the company needed

has achieved remarkable milestones: it has automated the coating

to automate the coating process for all colours applied with minimal

of all parts in a full spectrum of colours, obtained a 90% reduction

transition time, ensure a consistent quality of the coating layer, minimise

in personnel needed for rework during each shift and a production

rework, enhance the efficiency of the powder extraction cycle and also

boost of up to 30% coupled with a significant reduction in powder

accelerate the production speed and its volume.

consumption through intelligent powder recovery as well as a drastically

In just nine months, Wagner has engineered a groundbreaking facility

improved efficiency through automatic colour change.

that revolutionised production methodology of Shoemaker.

The white components are now expertly coated in an expanded

For further information: www.wagner-group.com

MADE IN ITALY

IMPIANTI

we design, build and install plants for the surface treatment of metals pre-treatment | anodizing | wet paint application | powder coating plastic coating | EDP (electrophoresis) | enamelling systems

visaimpianti.it

ROAD TO 2050

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.

A

dapta Color, a Spanish company specializing in manufacturing

construction products). It is crucial to verify the reference PCR (Product

powder coatings, remains faithful to its commitment to provide

Category Rules) followed when comparing EPDs of similar products. The

appropriate environmental information about its products, as

PCRs define the rules that must be followed by the LCA studies, and the

stated in its management policy. With a clear and transparent strategy

information to be displayed in the EPD. This allows understanding the

to showcase the environmental aspect of its activities, the company has

working parameters followed to obtain various indicators.

prepared an Environmental Product Declaration (EPD) for its super-

The Carbon Footprint, which is a highly relevant indicator of the

durable product line, ADAPTA VIVENDI SDS.

contribution to climate change, is one of the indicators obtained in the

Environmental Product Declarations (EPDs) transparently include

development of the EPD. It measures the amount of greenhouse gases

information – verified by an independent third party – regarding the

associated with that product or activity. In reality, the carbon footprint is

environmental performance of the product based on its Life Cycle

a simplified version of the Life Cycle Analysis (LCA), focusing on a single

Analysis (LCA). The information is divided in several impact categories

environmental impact category, specifically related to global warming.

(global warming, ozone depletion, acidification, etc.), along with

The VIVENDI SDS Collection has also been tested according to the ISO

additional details such as emitted emissions, generated waste, and

16000-9:2006 standard for determining the emissions of volatile organic

more. The EPD allows for the comparison of environmental information

compounds from building and furnishing products. Based on the

among products or services that perform the same function. The Adapta

results, the company has achieved Class A+ (very low emissions) for wall,

Color’s environmental product declaration has been verified according

ceiling, window, and door panels.

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

64

N. 86 - MARCH/APRIL 2024 - international PAINT&COATING magazine

For further information: www.adaptacolor.com

Get more from water

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

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

Beware of imitations, buy the original!

info@waterenergy.it

www.waterenergy.it

SUCCESS STORIES

SPECIAL ISSUE - PaintExpo

© ipcm

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

An Automatic Pre-Treatment Pilot Plant, Tailor-Made for Chemetall’s New Global Aluminum Competence Centre From an interview with Andrea Monti and Fabrizio Grassi from Chemetall Italia and Gilberto Riva from O.M.SA.

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.

T

he surface treatment global business unit of BASF’s Coatings

The centralisation of the Group’s research and development activities

division, under the Chemetall brand, opened its new Global

in the aluminium sector in this new facility will allow the testing and

Aluminum Competence Centre in Giussano (Monza e Brianza, Italy)

development of new technologies more quickly and efficiently, as well as

1

on Tuesday, 13 February 2024.

1

Further information on the event at page 228.

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N. 86 - MARCH/APRIL 2024 - international PAINT&COATING magazine

innovations in the anodising and pre-treatment areas. The new hub aims

SUCCESS STORIES

SPECIAL ISSUE - PaintExpo

to encompass all the company’s competencies

subsidiary: an anodic oxidation pilot line

in the field of aluminium surface treatment,

called “Jacqueline”, 5 climatic chambers for

especially for the architectural and wheel

accelerated corrosion testing (neutral, acetic,

sectors, within one structure. The choice of

cupro acetic, and SCAB corrosion tests), and 2

Chemetall’s current Italian site resulted from

humidistats with the ability to perform filiform

an intensive analysis of the existing capacities,

corrosion tests. In addition, the Centre also

which took into account development priorities,

accommodates instrumentation for testing

market requirements, and customer needs.

anodised aluminium according to QUALANOD

Chemetall’s new Global Aluminium Competence Centre

specifications, glossmeters, a pilot line for spray pre-treatment on car wheels (performing 5 process stages and 2 rinses), and an 11-stage

Indeed, BASF selected the Giussano plant

automated spray-dip pilot plant for multi-

for two main reasons: the multidisciplinary

metal pre-treatment. The latter was supplied

nature of its personnel’s skills, covering all its

by O.M.SA. Srl (Besana in Brianza, Monza

served markets’ supply chains, and its existing

e Brianza), a company working in the plant

infrastructure, which was the most suitable for

engineering sector since 1967 and specialising

expansion works. The new Global Aluminum

in designing and constructing automatic

Competence Centre, therefore, strengthens

systems for surface treatment and finishing.

Chemetall’s position in the aluminium finishing

The spray and immersion tanks that make up the line.

boost to the development of technologies and

Beyond aluminium: an all-round service

solutions for all industries.

At the same time, the new Centre is not

“The Italian aluminium market is the second

devoted exclusively to aluminium, but takes

largest in Europe in terms of turnover, making

advantage of the Chemetall Italia personnel’s

an Italian hub a significant strategic opportunity.

expertise to provide an all-round service.

We decided to create a centre of excellence

“Our Centre plays the role of a technical hub,

for the treatment of aluminium that also deals

a laboratory capable of actively listening to

with architectural and wheel-related solutions

our customers’ needs and meeting them with

within one site with multiple additional

innovative, cutting-edge solutions within the

competencies, thus handling all the main

market’s required timing,” explains Monti. The

operational phases in one place and creating a

new Global Aluminum Competence Centre

world-class benchmark hub for the processing

employs 13 Chemetall technicians working

of aluminium surfaces. This is a concrete

on specific tasks. Besides VIANT, the new

investment perfectly in line with Chemetall’s

coating technology that combines conversion

strategy of focussing on its customers by

coating and primer paint in a single layer,

providing them with tailored services,” says

and other pre-treatment technologies, the

Andrea Monti, the technical director and lab

Centre also deals with product development

manager of Chemetall Italia.

in the fields of metalworking fluids, inter-

With this appointment, the company has also

operational degreasers, beverage cans, waste

had the opportunity to expand its laboratory

water disposal, electrochemical surface

by renovating the upper part of its existing

characterisation, and optical and ionic

building, creating a new office area and

microscopy (SEM-EDX), as well as performing

allocating the previous one for testing and

laboratory and customisation analyses.

R&D activities. This also made it possible to

Indeed, all the Group’s customers can use this

accommodate equipment from the German

hub in different ways with the company’s weekly

segment while, at the same time, giving a solid

© ipcm

© ipcm

The sideshifter designed by O.M.SA.

international PAINT&COATING magazine - MARCH/APRIL 2024 - N. 86

67

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© ipcm

© ipcm

The numerous technologies available to Chemetall Italia.

or monthly assistance, offered as part of customised service packages.

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

Depending on the type of supply relationship established, through the

This 6-metre long and 4-metre wide pilot plant, featuring 100-litre spray

“Gardobox” service, Chemetall sends special sheets or vials for collecting

and immersion tanks, carries out 11 stages: 2 stages of alkaline spray

bath samples that will then be analysed in the new research centre to

degreasing, 2 rinses, spray and immersion deoxidation, nanotechnology

give personalised feedback with valuable tips to maintain or improve the

conversion, passivation, and 2 final rinses. The plant also includes an

existing processes.

additional 200-litre tank for applying VIANT technology for black and light

“Besides being a global hub for aluminium, our Giussano laboratory has

grey, an in-line drying oven, and a sideshifter.

been assigned several tasks over the years: we have been responsible

The integrated PLC enables to programme the sideshifter so that recipes

for wastewater treatment worldwide for more than two decades and

can be entered to include or exclude certain tanks, to measure and

for mechanical plastic recycling since 2012. Since 2018, we have been

calculate immersion and drying times reliably, and to adjust parameters

in charge of R&D on inter-operational degreasers and the deputy

such as the operating temperature for precisely simulating what

staff for the product group of alkaline cleaners, acid pickling agents,

happens in the paint shop of each customer. It also allows managing the

inhibitors, and surfactants. In 2020, we became responsible for R&D

recirculation and spray pump and it can be combined with the Gardocam

on metal packaging treatment, and now for the Aluminium Finishing &

technology (which enables to use a camera inside customer tunnels to

Wheels division. So, in addition to conducting research and development

find the cause of any problems, such as clogged nozzles, and quickly

activities on aluminium, we also provide technical support for all these

resolve them) to reproduce in an accurate way the customer process.

product types,” adds Monti.

“When we were selected to host the new Global Aluminum Competence

The company, therefore, wanted to find a solution that would allow it to

Centre, we also decided to capitalise on that investment. Although not

expand its aluminium-related research activities while also being able to

exclusively devoted to aluminium, O.M.SA.’s plant plays an essential

provide technical assistance for the treatment of other substrates and

role within our Centre because it enables us to conduct tests on any

the many processes analysed and tested at its Giussano plant. That is

metal substrate and analyse and set parameters such as cycle times,

why, in addition to incorporating technologies from the German site,

dripping times, and travel times from one stage to the next. As a result,

Chemetall requested a new customised pilot plant from O.M.SA.

we use it both to develop new solutions and to analyse our customers’

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SUCCESS STORIES

processes for optimising their performance,” illustrates Fabrizio Grassi,

SPECIAL ISSUE - PaintExpo

© ipcm

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.

© ipcm

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

The test stations in the new Global Aluminum Competence Centre.

Competence Centres throughout Europe, where in EMEA we are present with dedicated labs in 12 countries ,” says Monti.

© ipcm

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

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FOCUS ON TECHNOLOGY

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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). © Univer 2000

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FOCUS ON TECHNOLOGY

W

ithin a production process, the coating phase is of crucial

© Univer 2000

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

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

equipped with a Morris chain conveyor capable of handling large-sized components, supplied by Nuova Catena (Uboldo, Varese, Italy), and an

industrial automotive sectors. “Our ability to manage complex and

IPS powder centre provided by Wagner (Valmadrera, Lecco, Italy).

delicate projects, offer rapid responses to customer requirements,

Innovation and quality research: a perfect combination that describes

and always guarantee the highest level of excellence at every stage of

Univer 2000’s philosophy

the coating process is ensured not only by our operators’ expertise

Founded in 1991 in Zané, in the province of Vicenza, Univer 2000 has

but also by the state-of-the-art technologies and systems we have

established itself in the industrial coating sector thanks to its constant

chosen to install,” confirms Panozzo. “One of them is the new plant

commitment to innovation, quality, and service excellence. Initially

designed and installed by a pool of Italian companies in 2022, which

specialising in powder coating alone, the company has grown over

has enabled us to further improve our coating cycle while increasing

the years, expanding its factory in 1996 and adding liquid coating and

plant flexibility, productivity, and finishing quality.”

sandblasting to its portfolio of contract services.

“Our steady growth has been driven by a continuous search for

The new powder coating plant

innovative solutions and exclusive finishes to meet our customers’

In operation since July 2023, the new powder coating plant has been

needs. The quality of our service has also been ensured through

designed to serve as many sectors as possible and meet the greatest

the training and specialisation of our personnel and the constant

number of customer requirements. It can coat both small and large

upgrading of our equipment and technological systems,” states Günter

batches of parts up to 7 metres in length, 2.2 metres in height,

Panozzo, the owner of Univer 2000. Today, the company has a factory

and 1.5 metres in width. “In our factory, we process different metal

of over 18,000 m2, one of the most advanced technological facilities

substrates for a wide variety of industries, from automotive to interior

in Italy and Europe. It collaborates with the most important Italian

design and from agricultural machinery to electrical components.

interior design brands, as well as with major companies in the civil and

Therefore, we can subject the components to two different pre-

international PAINT&COATING magazine - MARCH/APRIL 2024 - N. 86

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treatment cycles, one specifically developed for aluminium and one for

The reliability of Morris-type chains and of Nuova Catena

iron. Both pre-treatment cycles, using chemicals supplied by Henkel,

Nuova Catena supplied the track, bearings, chain, and all supporting

consist of the following steps:

structures for the conveyor system integrated into Univer 2000’s new

 alkaline degreasing;

powder coating plant. “During the design phase of the new plant, we

 rinse with mains water;

assessed several conveyor technologies available on the global market

 rinse with demineralised water;

and thoroughly analysed the advantages and disadvantages of each

 nanotechnology passivation.

solution. Eventually, we opted again for a Morris chain system, which we

“The pre-treatment cycle has been completely revolutionised compared

had already used before, relying on the expertise and professionalism

with the past, bringing qualitative improvements, especially in terms of

of Nuova Catena’s team,” states Univer 2000’s owner. “The Morris-

aesthetic results,” illustrates the owner. Afterwards, the components

type chain proved the ideal choice for us thanks to its ease of use,

undergo an oven-drying phase and then, once cooled, they reach a

reliability over time, and load capacity. This is especially important for

coating booth equipped with an IPS powder centre, both supplied by

a contractor working on three shifts and handling a wide variety of

Wagner. The curing and unloading phases end the process.

workpieces to be coated,” explains Panozzo.

This new powder coating system is going to further expand Univer

“Reduced maintenance requirements are another key benefit of Morris-

2000’s pool of potential customers, reaching even niche sectors that

type chains: by lowering the frequency and intensity of maintenance

require extremely high quality standards. “When designing this plant,

activities, plant downtime is minimised, greater operational continuity is

one of the main challenges we faced was related to part handling.

ensured, and maintenance costs are reduced. Finally, Morris chains are

Before it was installed, we processed several large and heavy parts on

known for their reliability. This is particularly significant in an industrial

a static plant. On the other hand, this new in-line system guarantees a

context where continuous plant operation is essential to meet

very high level of quality that enables us to also serve a new customer

customer demands and maintain efficient production,” says the owner

segment, especially thanks to its conveyor operating with a continuous

of Univer 2000. “Finally, the versatility of Morris-type chains allows for

flow at a fixed, regular speed and its automatic application booth,”

easy system upgrades, adapting to changing customer requirements in

notes Panozzo.

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.

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© 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

LEADING MANUFACTURER OF PVD COATING SOLUTIONS

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

© Nuova Catena

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.

Kenosistec S.R.L. - www.kenosistec.com Via L. da Vinci, 19, 20059 Casarile MI - 02 905 5200

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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

© Wagner

The IPS powder center supplied by Wagner.

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.

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Protection upgraded

Specialità chimiche per il trattamento delle superfici Lavaggio Industriale

Pretrattamento metalli alla verniciatura

Lavaggio di precisione

Processi di conversione esenti

Sgrassanti interoperazionali

Cromo e Fosfati

Miscele di tensioattivi

Fosfatanti a bassa temperatura

Protezione temporanea

Passivanti per acciaio zincato a caldo Passivazione conduttiva su Alluminio TCP

Galvanica Funzionale

Galvanica Decorativa

Zinco e leghe di zinco

Rame, Nichel e Cromo

Passivanti e Sigillanti

Deposizione su plastica (POP)

Rivestimenti resistenti all'usura

Stagno e leghe di Stagno

Pretrattamento

Pretrattamento

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

HIGHLIGHT OF THE MONTH

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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.

T

IGITAL® 3D-Set is a thermoset material. Thermosets are polymers

to heat or flames, chemicals, and electrical conductivity. Common

which are produced by curing reactive resins. Curing irreversibly

examples of thermoset materials include epoxy resins, phenolic resins,

transforms them into a hardened, infusible, and insoluble state.

polyurethanes, and unsaturated polyester resins.

Unlike thermoplastics, which can be melted and re-moulded multiple

Thermosets realize the full potential of 3D-printing to achieve the

times, thermosets cannot be reprocessed once they have been cured.

highest industrial standards.

The curing process of thermoset materials involves a crosslinking

Benefit of thermoset materials

structure. This crosslinking is typically triggered by heat, chemical

The material is used in Selective Laser Sintering (SLS) and can be

catalysts, or radiation. Once cured, the material retains its shape

processed at a very low printing temperature and a very low laser

and mechanical properties even at high temperatures, making it

energy at the same time, which makes it an excellent choice for energy

suitable for applications requiring dimensional stability and resistance

and time efficient production.

© TIGER Coatings

reaction, where the polymer chains form a three-dimensional network

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HIGHLIGHT OF THE MONTH

TIGITAL® 3D-Set SLS thermosets enable the end-user to produce

form the desired shape. SLS can produce complex geometries and

functional parts in small batches up to serial production. Thermoset

functional parts with good mechanical properties. It is often used for

polymers can withstand higher temperatures without losing their

prototyping, low-volume production as spare part production, and in

structural integrity and exhibit excellent mechanical and chemical

industries like automotive, rail and aerospace.

properties due to the high cross-linking density of the thermoset

The new TIGITAL® 3D-Set materials is a cutting-edge technology for

polymers.

Selective Laser Sintering (SLS) with a focus on flame-retardant and UV-

Application fields

resistant characteristics of the final object.

TIGER Coatings’ 3D SLS printers utilize the latest advancements in

The outstanding properties of thermosets make them suitable for a

additive manufacturing technology. With high precision and exceptional

wide-ranging field of applications in a variety of different industries

detail, TIGER can produce complex designs with unparalleled accuracy

such as the automotive-, aerospace-, railway-, electrical appliances-

and part properties. From prototypes to functional parts and even small

and consumer goods industries. The focus is on industries wanting to

series production, TIGER’s 3D printing services cover a diverse range

overcome the typical weaknesses of thermoplastic materials and to take

of applications. In addition, TIGER provides customization options,

advantages of TIGITAL 3D-Set, which are:

allowing the customers to choose surface finishes from its TIGER Drylac®

 higher flame retardancy

products. Beside the 3D-printing materials, TIGER offers top-of-the-line

 higher mechanical properties under heat

SLS 3D printing services with its TIGITAL® 3D-Set materials to help the

 no dripping behaviour under heat and higher dimensional stability

end-user to transform his own concepts into tangible objects.

under heat (no melting)

Among these services, there is the TIGITAL® 3D design guide that

 high electrical insulation

provides a comprehensive overview of the key principles and best

 high chemical resistance.

practices for designing 3D printed parts with TIGITAL® 3D-Set materials

®

Selective Laser Sintering: the technology

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

powdered materials, typically polymers or metals, layer by layer. The

contains the answers on all whats and whys about thermoset materials,

laser heats and melts the powdered material, allowing it to solidify and

3D printing technology, and much more.

© TIGER Coatings

SLS involves the use of a high-powered laser to selectively fuse

Thermoplastics: linear or branched structure.

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

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© 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

© TIGER Coatings

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.

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HIGHLIGHT OF THE MONTH

TIGITAL® 3D-Set Materials Overview

© TIGER Coatings

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 control in the TIGITAL® 3D-Print lab.

SPECIAL ISSUE - PaintExpo

TPP materials have great electrical insulating

NORM

INDUSTRY

RELATED NORM

DIN 75200

Passenger car interior

FMVSS 302, burning speed, JIS D1201, ISO3795

PV3357

VW Norm

-

DIN 45545-2

Flame retardancy in rail transportation

-

 Minimal moisture uptake (<1%).

ECE-R118

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

Burning speed horizontal Dripping behavior Burning speed vertical

HPP-Series

FMVSS 302

US Federal motor Vehicle Safety Standard

IEC 60695, ISO3795, DIN 75200, JIS D1201

UL 94

Flammability of Plastics 5-VA, HB, V-0/1/2

Partly ISO10351, partly IEC60695-11-10

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

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.

A variety of standards can be fulfilled with TIGITAL® 3D-Set.

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.

CHARACTERISTICS

METHODS

UNITS

PPP 371 SERIES

TPP 371 SERIES

HPP 370 SERIES

Tensile modulus

ISO 527

[MPa]

2100-3200

3300

3300

Tensile strength

ISO 527

[MPa]

40

45

50

Elongation at break

ISO 527

[%]

2 - 5,5%

2,4 - 6%

3

HDT-A, 1.8mPa

ISO 75

°C

65/80

Up to 100

65

Flame retard.

ECE R118

Annex 6

2,5 & 3 mm

OK

NA

NA

Flame retard.

ECE R118

Annex 7

2,5 & 3 mm

OK

NA

NA

Flame retard.

ECE R118

Annex 8

3 mm

OK

NA

NA

UL94 V0

2 mm

OK

NA

NA

UV-resistance

+

++

+++

+

Chemical resistance

+++

+++

+++

+++

Benefits:  High reuse-rate  Vastly lower printing temperatures  Ability to print high wall thickness (>10mm)  Superior rigidity  Minimal moisture uptake (<1%).

Recyclability 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.

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

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N. 86 - MARCH/APRIL 2024 - international PAINT&COATING magazine

© ipcm

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.

FOCUS ON TECHNOLOGY

SPECIAL ISSUE - PaintExpo

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.

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FOCUS ON TECHNOLOGY

S

ome 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 © ipcm

those designer products that make the kitchen a favourite place in every home and, therefore, require increasing attention to their finishing

The component loading area in the paint shop.

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 © ipcm

resistance values, and its further development, engineered in collaboration with a first-class

The 5-stage pre-treatment tunnel.

international PAINT&COATING magazine - MARCH/APRIL 2024 - N. 86

83

SPECIAL ISSUE - PaintExpo

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 © ipcm

© ipcm

market. In a critical period like the current one, we have managed to confirm ourselves

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

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 © ipcm

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

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hoods since 2007. “Initially, it was our secondary activity, but as the years went by

FOCUS ON 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

www.cmautomazione.com

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

CM AUTOMAZIONE s.r.l.

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

SPECIAL ISSUE - PaintExpo

© ipcm

Manual retouching after coating.

© ipcm

White is one of the currently most popular colours in the household appliance sector.

industrialised part of our production flow,” says BS Service Group

and application technologies,” illustrates André Bernasconi, the general

S.r.l..’s plant manager, Manuel Silvi. “On the other hand, the finishing

manager of DN Chemicals. “Today, BS Service Group S.r.l. is among the

department’s activities are more artisanal, in line with the handcraft

first companies to use the new patented passivating agent from our

traditions of our region. Indeed, one of our company’s strength is the

Dollcoat line, called RS103, which is the evolution of our long-established

ability to offer a finishing quality above average market standards on

standard products SA115 and SA118. It is also closely following the

both uncoated stainless steel components and powder-coated parts.

development of another passivating product called temporarily GP107,

“The coating process takes place in one of the plants acquired from

which is the evolution of Dollcoat RS103 in terms of both formulation,

Tecnowind, which will soon be the subject of a replacement project

which is more complex, and performance.

in the context of a broader development plan for a new production

“Indeed, it is no longer only about synthetic oligomers obtained from

facility. Together with the staff of DN Chemicals, in anticipation of such

silanes: we have created a conversion nanoprimer that is applied in the

production expansion, we are now optimising the pre-treatment process

submicron range (between 50 and 80 nanometres). The result of close

prior to the powder coating step and the products required for it.”

cooperation with one of the most important international industrial

When innovation means experimenting with new products

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

With DN Chemicals, BS Service Group S.r.l. has developed a pre-

alone. It easily reached classes C3H (504 hours in salt spray) or CH4 with

treatment cycle that has enabled it to move from salt spray resistance

almost zero penetration in a strict test performed by blowing with high

values of 300 hours to the current 530 hours, with a notch detachment

pressure at 9 bar for 5 minutes. Our ultimate goal is to reach class C5M

well below the 3 mm required by the specifications. “This company

with one coat.

applies the cycle now widely established in the household appliance

“Finally, we are assessing the feasibility of replacing the alkaline

sector, which we have optimised with higher-performance products

degreaser with a nanoceramic product that is perfectly compatible and

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FOCUS ON TECHNOLOGY

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

© ipcm

consumption.

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.

“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.” © ipcm

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

international PAINT&COATING magazine - MARCH/APRIL 2024 - N. 86

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SPECIAL ISSUE - PaintExpo

Technical characteristics of DOLLCOAT RS 103 TABLE 1 PROCESS

in a new family of surface conversion agents for high-

Jcorr (A/cm2)

Phospho-degreaser-R-R-D

performance processes with minimum C3H corrosion

Alkaline-R-R-D-DOLLCOAT RS 103

DOLLCOAT RS 103 (patent pending) is the first product

Corrosion rate (mm/year)

Rp (Ω)

1,32 E-05

0,15328

144

3,53 E-06

0,0409595

544

class.

It has unique characteristics compared to currently

TABLE 2

available conversion products and gives the pre-treated surfaces very high protection and corrosion resistance properties, whatever the nature of the coatings used.

PROCESS

Max Z (Ω* cm2)

Min Z (Ω* cm2)

DELTA Z (%)

Alkaline-R-R-D-DOLLCOAT RS 103

7,21E+07

6,15E+07

0,87

Phospho-degreaser-R-R-D

5,58E+07

7,67E+05

24

DOLLCOAT RS 103’s main features include as follows:  multi-metal no-rinse product to be used at room temperature;

IMPEDANCE VS THE BS SERVICE GROUP’S CYCLE.

recirculation or immersion nozzles;

DOLLCOAT RS 103

 no sludge formation;

CYCLES

 applicable with atomisation modules through traditional

 compatible with any powder or liquid coating;  does not cause any aesthetic defects, even when used at high concentrations.

Table 1 compares some CRS panels pre-treated in

Z*AREA (Ω*CM2)

 excellent pre-treatment before cataphoresis;

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

FREQUENCY (Hz)

of pre-treatment quality, as confirmed by the salt spray penetration of less than 1 mm after compressed-air

PHOSPHO-DEGREASER

blowing at 9 bar for 5 minutes (Table 2). The Bode diagrams represent the different behaviours of the two achieved using DOLLCOAT RS 103 (Figs. 1 and 2).

Z*AREA (Ω*CM2)

pre-treatment cycles and the significant improvement

FREQUENCY (Hz)

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CYCLES

IMPEDANCE VS CYCLE.

tests, whose results consistently reach 504 hours with

The right partner in the green transition WE WILL BE AT:

OUR STAND IS LOCATED: Hall 3 - Stand 3511

HIGHLIGHT OF THE MONTH

SPECIAL ISSUE - PaintExpo

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.

T

echnological evolutions in the field of surface coating have

specialising in the development of engineering solutions for PVD

resulted in increasingly advanced, versatile, and environmentally

application since 2005.

sustainable processes ensuring excellent aesthetic and functional

performance. These include Physical Vapour Deposition (PVD), a process

About Kenosistec and its target markets

for the vacuum application of thin-film coatings, in which solid-state

Belonging to the Angelantoni Industrie Group, Kenosistec was founded

material is brought into the vapour phase and allowed to deposit on the

in 2005 through the merger of Kenotec and Sistec, two companies

substrate, where it condenses. This forms a film with various functional

specialising in sputtering and PECVD, respectively, and the acquisition

characteristics, such as resistance to abrasion and thermal shock, and

of Microcoat, specialising in cathode arc technology. Having established

exceptional aesthetic properties. In a market where sustainability is

itself early on as a benchmark manufacturer and a multi-technology

a key requirement for many companies, PVD stands out as a green

hub in the European PVD industry, it has been steadily growing in terms

technology offering numerous advantages in terms of performance

of experience, reliability, and production capacity. With a team of 22

and reliability. “Unlike other deposition coating processes, which

employees, Kenosistec produces customised PVD coating systems for

may generate toxic waste or require the use of polluting chemicals,

various sectors, including eyewear, lenses and mirrors for telescopic

PVD releases no residues at the end of the process,” confirms Mauro

systems, photovoltaic panels, and electronics.

Margherita, the CEO of Kenosistec (Binasco, Milan, Italy), a company

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

© Kenosistec

HIGHLIGHT OF THE MONTH

© Kenosistec

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

approaching the PVD technology, which they appreciate for its ability to

replacing some metal car components with lighter plastic ones. For

give different functional and aesthetic properties to the treated surfaces

example, if PVD had been adopted earlier and a number of automotive

while meeting sustainability requirements. In particular, the bathroom

parts currently made of metal had been manufactured with plastic, it

accessory and jewellery sectors are expanding their range of products

is likely that the range of today’s electric batteries would not have been

treated with this process. The same applies to the automotive industry,

400-500 km but would already have exceeded 700-800 km. This would

especially for interior and exterior chrome parts. Such increased interest

have guaranteed a convergence point between the batteries’ capacity

from markets that were previously unfamiliar with our technology is

and range requirements, significantly impacting the efficiency and

the reason why, in addition to continuing to supply our main target

emissions of cars.”

industries, we are leveraging our solid know-how to balance deposition

With the aim of expanding the huge application potential of PVD

process and performance-related requirements to meet the needs of

treatments and developing solutions better suited to its target sectors,

any company that is considering PVD as an alternative to traditional

Kenosistec has thus decided to move to new premises and establish a

technologies.

genuine “PVD Hub”.

One of the major difficulties in implementing PVD technology in the are subjected. “Research and development of new solutions will

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

soon enable PVD to meet these requirements as well. After all, this

“This year, we moved to a new building in Casarile (Milan), transitioning

coating process has many undeniable advantages, including the

from an area of 700 m2, of which 150 m2 were devoted to office space,

possibility of being applied to any type of plastic material, as opposed

to premises that cover almost 3000 m2 and are also significantly

to electrodeposition, which can only be carried out on acrylonitrile

higher. Of the total area, 1200 m2 will be allocated to the Coating

butadiene styrene (ABS) and polycarbonate/acrylonitrile butadiene

Centre and Innovation Hub, whereas 600 m2 will be used for offices.

styrene (PC-ABS) plastics. This peculiarity could even pave the way for

The new facility will enable us to expand our equipment fleet, enhance

automotive industry is related to the strict tests to which components

international PAINT&COATING magazine - MARCH/APRIL 2024 - N. 86

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SPECIAL ISSUE - PaintExpo

our manufacturing capabilities, and further improve our expertise in

avoid contamination and achieve optimal results. The maintenance and

producing PVD systems.”

management of the machinery and the optimal management of the

The new Coating Centre will initially focus on two types of substrates,

clean room processes, must become standard practices.”

metals and plastics, and will later embrace other materials, such as

The Innovation Hub will also be a centre of technological innovation for

glass. “The Centre is also a service technology hub, offering both

developing and implementing new technologies and methods. “This

contract PVD treatments and assistance in developing new processes.

means not only devising cutting-edge processes and solutions but also

It is conceived to help potential customers explore any PVD processes

combining different technologies to achieve different results, adaptable

still unknown to them, analysing their characteristics and advantages

to the specific needs of each target sector.”

and offering innovative solutions, such as selecting new colours or adopting new application technologies for the future. The Innovation

Future projects

Hub will also have the critical role of training the staff of customers that

The new Centre will not only be equipped with PVD deposition systems

choose to insource this operation. To ensure such a level of support,

but also with a coating plant. “I believe that the best innovations result

we put our specialised team, our plants, and our extensive experience

from synergy among different technologies: there are cases where one

to our customers’ disposal, helping them to effectively manage their

is preferable to another, but there are also cases where the integration

production and maintenance operations as well as supervise critical

of different coating solutions brings the best results. We also aim at

process parameters during the transfer stage.”

collaborating with new industrial partners to manage their machines

Physical vapour deposition must take place in a controlled environment

and identify optimal changes, developing processes that best meet the

with precise temperature and humidity conditions. Therefore, the

needs and demands of end customers.”

personnel managing the process must become familiar with several

Kenosistec’s new PVD Hub will be completed in two distinct phases.

required practices. “Regular cleaning of the machine, both during and

“The first phase will be completed by the end of 2024 and will include

after certain process stages, is essential because metal is deposited not

the installation of PVD metal deposition equipment, cleaning plants,

only on the treated substrates but also on the plant’s internal screens,

and final testing devices. The second phase will be completed by the

with the risk of contaminating the workpieces. Therefore, it is crucial

end of 2025 and will include the installation of the coating system. We

to understand that periodic cleaning of the machine is necessary to

plan to complete this Centre within two years. The number of people

© Kenosistec

A step of the vapor phase deposition process.

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HIGHLIGHT OF THE MONTH

Coatings according to GSB: who will work at the Innovation Hub and Coating Centre will depend

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

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 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

environment to test these processes, allowing different institutes to

p Ap

rove

d Pre t rea

tm

en

t

A p p rove d C o

a te r

© Kenosistec

Co

Coated Aluminium & Steel.

g

at

ed

in

M

ov

at

Approved Quality. e ri

Ap

al

pr

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

PaintExpo Mauro Margherita, CEO of Kenosistec.

World‘s Leading Trade Fair for Industrial Coating Technology 9 – 12 April 2024, Exhibition Centre Karlsruhe

We exhibit!

Hall 1

Stand 1118

HIGHLIGHT OF THE MONTH

SPECIAL ISSUE - PaintExpo

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.

A

round 430 exhibitors - including the who’s who of the coating

Over 40 per cent of exhibitors are international. Most companies from

technology industry with its market and technology leaders -

outside Germany are from Italy, Turkey and Switzerland. However, the

will fill three exhibition halls for four days at PaintExpo 2024 in

trade fair attracts exhibitors from far beyond Europe and companies

Karlsruhe. The exhibitors at the world’s leading trade fair for industrial

from countries such as the US, India and China are also represented.

coating technology will cover the full range of products and services

“The signs for PaintExpo 2024 are very good - despite the current

across the entire supply chain.

challenging conditions. We can already sense tremendous excitement © Leipziger Messe GmbH/Tom Schulz

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HIGHLIGHT OF THE MONTH

building for PaintExpo among exhibitors and visitors alike. The world’s

© Leipziger Messe GmbH/Tom Schulz

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

international PAINT&COATING magazine - MARCH/APRIL 2024 - N. 86

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SPECIAL ISSUE - PaintExpo

© Leipziger Messe GmbH/Tom Schulz

adhesives precisely, this system not only makes more efficient use of

Corrosion protection is also a major theme. Multiple product lines

materials but also optimises the quality of the joints.

including thermoplastics, thermosetting primers, industrial liquid

The exhibitor is also focusing on predictive maintenance as a way of

solutions and their AquaEC electrocoat products mean that customers

minimising downtimes and maximising efficiency. Leveraging sensor

can select the right product for their needs. Visitors to the stand can

systems and data analysis makes it possible to continuously monitor

also look forward to a ColourDesign area displaying the full spectrum of

machines so that problems can be identified and fixed early on before

colours available from Axalta.

the equipment fails.

Experience four different themes up close at one exhibition stand

Comprehensive exhibitor directory, tickets only available for purchase online A number of exciting exhibitor innovations can also be found in the

Axalta Coating Systems is likewise focusing its trade fair appearance on

digital exhibitor and product directory on the PaintExpo website. In

a series of products geared towards sustainability. At the company’s

addition, visitors can plan their time at the trade fair in advance and

stand, four topics will be highlighted. As part of its “Sustainability,

on-site by using an interactive map of the halls, creating bookmarks lists

Together” campaign, Axalta is presenting its latest sustainable coating

and browsing the special interest topics on sustainability, careers and

solutions with a particular emphasis on biobased powder coatings as

live experiences.

an environmentally friendly alternative. With a view to electromobility,

At the ticket shop on the event website, visitors can purchase tickets for

Axalta will also be showcasing coatings for battery applications, including

the trade fair and redeem invitations from exhibitors. The online ticket

dielectric and thermally insulating coatings.

gives visitors fast and easy access to the PaintExpo in Karlsruhe.

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BOND

PROTECT

BEAUTIFY

Expert in paint application

Visit us Hall 2 Booth 2516 Expert in high viscosity dispensing

Expert in rotary bell atomizer

Expert in powder coating

Simply applying most efficient solutions

www.sames.com

© Bucher Municipal

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

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.

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FOCUS ON TECHNOLOGY

S

now 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

© ipcm

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.

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/

© ipcm

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.

four weeks from order receipt to shipping.

international PAINT&COATING magazine - MARCH/APRIL 2024 - N. 86

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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 © ipcm

“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.

© ipcm

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. © ipcm

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The OMSG automatic cluster shot blasting machine with two hoists.

FOCUS ON TECHNOLOGY

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

EQUIPMENT FOR

powder coating

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

we introduce you

JGEN 02

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.

9th-12th april

Find out more about ZEUS

“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

VISIT US! HALL 2 | STAND 2348

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

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© ipcm

© ipcm

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

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

production more sustainable, as we have eliminated a curing stage,

Features of the new coating plant

thus lowering energy consumption and costs. Not to mention increased

Giletta turned to Eurotherm to develop a plant suitable for this new

production speed: the liquid primer developed for Giletta by Sircolor (La

finishing cycle. “This project goes back a long way: we started with a

Morra, Cuneo, Italy) has a water-based epoxy matrix with metallic zinc,

market survey on possible suppliers in 2018-2019. Initially, we were

only requiring a 10-minute flash-off phase at room temperature with

thinking of an automatic in-line plant. However, the Covid pandemic

forced ventilation before being overcoatable with the polyester powder

slowed the project down, and when we took it up again, we realised

top coat supplied by Pulverit (Milan, Italy). This translates into significant

that such a system would be difficult to manage, since our production is

operational, economic, and time savings, especially considering that

seasonal and alternates between peaks and substantial slowdown. Giving

heating the high mass of the parts we coat on this line to 180-190°C

it the right size to meet our high-season needs would have meant leaving

requires considerable expenditure of energy.

it almost idle in the low season. This is why the concept that convinced us

“On the other hand, we have maintained the use of a powder top coat

most was the box design presented by Eurotherm. In the same period, we

because it gives the surfaces a more robust, harder, and damage-resistant

also began assessing a possible switch to a mixed coating system.”

coating with better aesthetics, even if applied by less experienced

“We provided Giletta with a manual coating system to replace its old

operators. Today, with this coating cycle combined with mechanical shot

step-by-step in-line plant,” says Rocco D’Aloia, project manager at

blasting pre-treatment to clean the parts and reach a surface roughness

Eurotherm. “Among other requirements, the new machine had to double

of 30 microns for greater paint adhesion, we effortlessly exceed 2000

the previous production rate while increasing management flexibility and

hours of salt spray resistance.”

energy savings. We achieved all these goals: the company moved from

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HP series

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

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



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

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

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



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

Pulverit S.p.A. Italia Via Carlo Reale, 15/4 20157 Milano-Italy Tel +39 02 376751 email: pulverit@pulverit.it

Pulverit Polska Sp. z o.o. ul. Strefowa 16 43100 Tychy-Polska Tel. +48 32 329 14 11 email: biuro@pulverit.pl

Pulverit Deutschland GmbH Im Wert 3 73563 Mögglingen- Deutschland telef.: +49 7174 7193000 email: info@pulverit.de

www.pulverit.com

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

SPECIAL ISSUE - PaintExpo

© ipcm

© ipcm

The three curing ovens.

Coated parts inside one of the ovens.

working on two shifts, including Saturdays, to one shift for processing the

 2 vertical-flow pressurised liquid coating booths with an air handling

same quantity of coated parts, with significant gas and electricity savings

unit for heating and drying at 70 °C, with a size of 4x9 m

compared with the old in-line plant. Apart from some components that

 2 vertical-flow powder coating booths, of which one is equipped with a

are pickled, most of Giletta’s production is coated. The company prefers

cyclone for colour recovery, with a size of 4x9 m

mechanical pre-treatment: all small to medium-sized parts are shot

 3 curing ovens with temperatures up to 250 °C

blasted in a cluster machine, except for the containers, treated in the

 3 semi-automatic transfer carts

already existing Carlo Banfi shot blaster, which we revamped in terms

 2 lifting stations for loading/unloading

of both software and mechanical aspects to lengthen it and connect

 overhead conveyor

it to the blowing station shared by the two systems, which can work

 1 climate-controlled paint storage module

simultaneously. The automatic cell pre-treatment tunnel is used to clean

 1 existing Carlo Banfi in-line sandblasting machine, revamped with 4.0

all parts, such as hydraulic cylinders and gearboxes, that cannot be

digital software and connected to the manual blowing station

sandblasted. Although integrated with the rest of the line, the cleaning cell

 1 OMSG cluster shot blasting machine with maximum workpiece

is now used for treating other components that are coated off-line.”

dimensions of ø 2500 x 3000 H mm.

The latter machine has a Y-shaped handling system with two hoists, each

Giletta’s current production cycle is as follows:

with a load capacity of 2000 kg. When one hoist is inside the machine for

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

the shot blasting phase, the other is outside for loading/unloading parts,

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

thus reducing idle times of the machine. The machine has four 15-kW

3. Powder coating

turbines with special alloy components in K110. It meets the Industry

4. Curing.

4.0 parameters and is equipped with an inverter to adjust the kinetic energy of the abrasive projected by the centrifugal turbines, thus avoiding

The machines installed by Eurotherm were as follows:

possible damage and deformation of thin metal parts.

 1 3-stage cleaning cell

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

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FOCUS ON TECHNOLOGY

© ipcm

Gianpaolo Candelero from Eurotherm with Fabrizio Abello from Giletta.

the-art manual unit from Zeus Electrostatic System; the liquid base coat is

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

applied with manual electrostatic units from Wagner, fed by an Intellimix

“Eurotherm’s box concept with four booths and three curing ovens gave

mixer installed in a separate compartment.

us a degree of flexibility and speed that an automatic in-line system

maximum length of 7.5 m. The powder top coat is applied with a state-of-

could never provide,” emphasises Fabrizio Abello from Giletta Spa. “The plant’s lifting devices facilitate the operators’ work in loading and

“Depending on output demand, we decide whether to use one or more

unloading heavy parts,” adds Rocco D’Aloia. “After the hanging operation,

ovens, whereas having two booths available for both base coat and colour

the first transfer cart enters the sandblasting machine, equipped with a

application enables us to use them two by two or all four at the same time

one-rail ring. At the exit, the parts pass through a manual blowing station

during production peaks: in some periods, we use one or two booths per

for cleaning. A second transfer cart takes them to the masking station,

day, whereas if necessary we can paint with the four booths operating

if required, or directly to the base coat application booths, applying the

simultaneously. Our goal was to implement a highly technological but at

same light grey liquid paint on all components. The same cart transfers

the same time flexible system: Eurotherm has fully met this requirement.”

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.”

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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.

© Bucher Municipal

A Bucher Municipal runway deicing machine.

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SUCCESS STORIES

© Bialetti

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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.

S

teeped in Italian culture and synonymous with high design and

In 1933, engineer and entrepreneur Alfonso Bialetti began

quality, Moka coffee makers made by Bialetti are cherished for

manufacturing the Moka Express, the aluminium coffee maker that

producing bold and great-tasting brews. Whether it is made in

revolutionised the way coffee was made by using high pressure to force

the original Moka Express or one of the many models produced by the

steam through the grounds. The name derives from the city of Mokha in

Italian manufacturer throughout the years, the aesthetically beautiful

Yemen, one of the first and most renowned coffee production regions of

pots are beloved by coffee enthusiasts around the world.

that era.

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SUCCESS STORIES

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Since then, more than 300 million units have been sold, almost

 Matte colours for the Fiammetta;

unchanged from their original octagonal shape that is widely heralded

 Green for the Break Alpina;

as the pinnacle of Italian design. Today, the iconic appliance is a staple

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

in kitchens around the world, particularly in Europe and Latin America.

race;

But the Moka Express is not the only popular pot sold by Bialetti,

 Golden yellow for a top-selling Christmas collection

headquartered in Coccaglio (Brescia, Italy). Every year, millions of the

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

company’s pots are bought by coffee aficionados in various models and colours.

A new era of colours

Trendy aesthetics and sustainable solutions: the new Moka Exclusive line The Moka is a more sustainable device that brews coffee from

For generations, all Bialetti models had uncoated aluminium exteriors.

powdered coffee beans, eliminating the need for disposable plastic

That all changed about twenty years ago, when the company wanted to

pods. In addition, it only requires water to clean – no soap or detergent

add beauty to the daily ritual of making coffee through colour. Bialetti

needed. In 2023, the PPG team began development of a series of

then reached out to an Italian-based industrial coatings company

PPG Envirocron® powder colours for the new Moka Exclusive line, a

whose powder business was acquired by PPG in 2021.

collection that would launch for that year’s Christmas holiday season.

The first collaboration yielded the Mukka Express, a cappuccino

“We wanted something new, elegant and refined to fully enhance the

machine with a cream and black powder coat that resembles the

Moka Express icon. By researching and examining aesthetic and stylistic

spotted hide of a cow. The two companies worked in partnership to

trends, our style department proposed a new Moka Exclusive collection

develop several polyester and epoxy-polyester coatings for various

featuring seven trendy colours to fit a wide variety of tastes,” explained

Bialetti coffee maker lines, including:

Marco Vanoli, Bialetti product manager.

EVAPORATION TECHNOLOGY APPLIED TO INDUSTRIAL PAINTING AND COATING WATER RECOVERY MINIMIZATION OF WASTE TO BE DISPOSED OF REUSE OF DISTILLATE COST REDUCTION ZLD: ZERO LIQUID DISCHARGE

MEET US AT PAINT-EXPO – EXHIBITION CENTRE KARLSRUHE, GERMANY – 9-12 APRIL 2024 – HALL 1 – BOOTH 1541

SUCCESS STORIES

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© Bialetti

© Bialetti

One challenge was to create a powder and application process that

over high heat. The tests were very aggressive, yet crucial to ensure that

would cover the entire pot with the exception of the embossed

an optimal coating was used. The PPG powder coatings products met

Moustachioed Man icon and the company logo. These two visual

every requirement, from performance to beauty. The new collection

elements were integral parts of the new line’s branding and helped to

launched in time for the 2023 holiday season.

create a high-end and trendy aesthetic.

“We are highly satisfied that our coating has been chosen for the top

“This was a challenging project,” commented Cristoforo Brendas, PPG

exclusive colours of the 2023 Moka Exclusive collection and we are

business development manager, powder coatings. “It took several trials

particularly happy to continue collaborating with Bialetti Industries. We

to find the right balance between the colour and the final effect that

share the same passion for Italian excellence, innovation and attention

Bialetti wanted. The work done in our laboratory was key.”

to quality of the company” declared Brendas.

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

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For further information: www.ppgindustrialcoatings.com

OptiCenter® All-in-One OC11 9.-12. April 2024 Karlsruhe | Germany

Hall 2 | Booth 2426

Double your efficiency!

Fusion of electrostatics and dense-phase powder delivery The system with OptiSpray All-in-One pump technology and double OptiSpeeder powder hoppers (DualSpeeder) enables handling and preparation of two independent colors sequentially for ultra-fast color change or in parallel for simultaneous coating from both OptiSpeeder hoppers.

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

gemapowdercoating.com

FOCUS ON TECHNOLOGY

SPECIAL ISSUE - PaintExpo

© ipcm

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.

I

n 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.”

Parts coated by Metalux (Castelfidardo, Ancona).

FOCUS ON TECHNOLOGY

© ipcm

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

Facing the challenges of the post-pandemic market, this Marche-based

components for both indoor and outdoor use.”

company adopted a growth strategy geared towards sustainability

“Besides its chemicals, we adopted two technical devices designed by

and efficiency, renovating its paint shop with a focus on chemical

Chemtec: a complete skid for spraying the PRONORTEC product and

pre-treatment. In particular, it took a big step forward by abandoning

a reverse osmosis system for producing pure water, which replaced

the now obsolete phosphating + trivalent chromium process to adopt

our old demineralisation plant fed by well water. These machines

a more efficient and environmentally friendly approach. This is why

completed an extensive renovation of the cleaning tunnel we used for

it chose the PRONORTEC nanotechnology developed by Chemtec,

the phosphating + trivalent chromium cycle, as chromium had eroded

an Italian company specialising in the formulation, production, and

its stainless steel sheets over time,” says Bettucci.

marketing of speciality chemicals for surface treatment.

The modernised paint shop

The two coating lines using Chemtec products Line 2 is devoted to indoor components that are pre-treated with

Metalux currently has four powder coating lines, of which one is

multi-metal phosphating agents supplied by Chemtec, suitable

equipped with a shot blasting machine for mechanical pre-treatment

for treating steel, aluminium, and galvanised sheets. Its process is

and three implement a chemical pre-treatment process in a cleaning

optimised to meet the needs of customers requiring standard durability

tunnel. “Since last summer, we have been using Chemtec chemicals on

in salt spray tests. It includes a pre-treatment cycle consisting of a

two of our four lines, one of which employs the innovative PRONORTEC

phosphodegreasing stage and a series of rinses, the last of which is

nanotechnology,” explains Giacomo Bettucci from Metalux. “From

with pure osmosis water.

a practical point of view, this choice was driven by the need to

Line 4, which recently underwent revamping, is devoted to medium-

replace the phosphating + trivalent chromium process and align our

and large-sized components with maximum dimensions of 3000 x 1000

operations with a more environmental sustainability philosophy, thus

x 2500 mm. It treats parts for both indoor and outdoor use and in all

making Metalux a chromium-free company. At the same time, we

types of metal alloys, which are pre-treated with the nanotechnology

wanted to improve the operational flexibility of our plants, which treat

passivating agent PRONORTEC and then coated with specific indoor,

international PAINT&COATING magazine - MARCH/APRIL 2024 - N. 86

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SPECIAL ISSUE - PaintExpo

outdoor, or silicone coatings. “The

corrosion resistance compared to

objective is to ensure high corrosion

a standard degreasing step or even

resistance, which is why we have

reach the performance levels of

conceived a pre-treatment cycle

trivalent chromium phosphating,

including phospho-degreasing, a rinse

as in the case of Metalux. Chemtec

with osmosis water, and the rinse-

offers two options to implement

free application of the PRONORTEC

PRONORTEC: a fully automated 4.0

nanotechnology solution,” explains

system and a more user-friendly one.

Carlo Guidetti, Chemtec’s CEO &

Both are designed for ease of use and

co-founder. Bettucci confirms: “We

efficient product application on all

aimed to implement a versatile line

metal surfaces, as well as being low-

capable of handling a wide range of

maintenance and easy to integrate

materials, a goal achieved thanks to

into the plant’s control panel.”

the exceptional user-friendliness of

The advantages of the new nanotechnology

PRONORTEC.”

Technical and application characteristics of PRONORTEC

“The PRONORTEC nanotechnology’s application represents a significant advance over traditional phosphating

“PRONORTEC is a nanotechnology

processes, offering a remarkable

based on organic phosphorus

improvement in pre-treatment

compounds that deposits a layer

performance. However, what makes

of approximately 50/60 nm, thus

this new nanotechnology so effective

guaranteeing excellent adhesion

is its extreme ease and flexibility of

on any metal substrate that has

use, which translates into greater

been suitably degreased and

operational efficiency, easier cycle

rinsed, while ensuring excellent

planning, and the ability to treat a

corrosion resistance thanks

wider range of products, especially

to its hydrophobicity. This is

when using Qualicoat 2 instead of

why PRONORTEC can replace

Qualicoat 1 certified coatings,” says

obsolete and environmentally

Bettucci.

impactful yet high-performance

Metalux conducted several corrosion

technologies, such as trivalent

resistance tests to validate the

chromating, with nanotechnology guaranteeing the same degree of quality but with environmentally

© ipcm

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

performance of PRONORTEC, which were carried out by Chemtec directly at its laboratory. This is equipped with

sustainable operations. Unlike other

two new 4.0 salt spray chambers, one

nanotechnology processes on the

devoted to neutral salt spray tests

market that take advantage of the chemistry of zirconium, titanium,

and the other to acetic salt spray tests for non-ferrous metals, as well

or organic silanes, we have developed an innovative solution that

as electrochemical impedance spectroscopy and ACET test devices.

simplifies industrial applications and does not require rinsing to ensure

“This approach guarantees real-time results, enabling us to analyse the

high results,” illustrates Guidetti.

kinetics of electrochemical reactions on metal surfaces and identify any

“Two conditions are necessary to achieve this quality improvement

problems or issues that may arise during the process,” adds Guidetti.

with PRONORTEC: the first is a rinse with essentially pure, osmosis or demineralised water performed upstream of the PRONORTEC

Conclusions

application; the second is sufficient space available in the existing

Thanks to its investments, Metalux has established itself as a company

pre-treatment tunnel to integrate a simple spray bar. This can improve

specialising in high-quality powder coatings for indoor and outdoor

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FOCUS ON TECHNOLOGY

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 © ipcm

in line with the needs of the most demanding customers,” notes Emanuele Zepponi, sales

The PRONORTEC product’s automatic mixing and dosing system.

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SPECIAL ISSUE - PaintExpo

agent for TIGER Coatings and Chemtec.

“We are very pleased to have found a reliable and efficient partner in Chemtec, as it proved to be right from the design phase of the line revamping project. Our collaboration with this company began in February 2023, when we started the first tests with PRONORTEC on one of our four lines. The results confirmed the quality and effectiveness of this new nanotechnology, bringing interesting advantages in both the pre-treatment and coating processes. First of all, we eliminated the use of chromium, making our production operations more sustainable. In addition, in terms of occupational safety, the introduction of PRONORTEC has enabled us to eliminate the use of acids and concentrated alkaline substances,” says Bettucci.

© ipcm

Chemtec CEO Carlo Guidetti concludes by emphasising the importance of replacing the demineralisation system fed by well water, which served both the pre-treatment lines using Chemtec products, with a reverse osmosis plant. “Implementing a reverse osmosis water purification system has guaranteed output water with constant conductivity, regardless of the frequency of regeneration. It has also reduced the cost of disposing of resin regeneration waste and limited water consumption.”

The reverse osmosis water purification system provided by Chemtec.

From left to right: Giacomo Bettucci from Metalux, Carlo Guidetti from Chemtec, Chemtec and TIGER Coatings sales representative Emanuele Zepponi, Beatrice Turri from Chemtec, and Marco Tridenti RSGQ from Metalux.

© ipcm

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HIGHLIGHT OF THE MONTH

SPECIAL ISSUE - PaintExpo

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.

I

n an ever-changing world, social responsibility and sustainability cannot

in the production of water-based coatings for wood substrates, ICA

be considered an option but rather a moral and strategic imperative

also stands out in the market for other features, including water-based

that can be summarised with three verbs: Inspire - Commit - Act. This

and bio-paints – i.e. with raw materials from renewable sources –,

mantra has always guided the growth of ICA, an Italian company founded

the chemical-physical analysis laboratory available to customers, the

in 1971 and run by the Paniccia family until its acquisition by The Sherwin-

professional training service provided by ICA Academy, and the always

Williams Company, which was formalised in December 2022. Specialising

high focus on environmentally sustainable practices and technologies.

© Hydro Italia

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

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“The HYDROFLOTY 12M physical-chemical plant was built by Hydro Italia

when cleaning its mobile drums, but also its stationary production and

for the treatment and purification of waste water generated in our paint

treatment lines’ mixers, cleaned automatically with maxi brushes and a

drums and containers’ cleaning operations," says ICA’s Communications

combination of mains and osmosis water.

Manager, Valentina Cesari. Commercial Director Davide Solmi has closely

“The goal was to find a treatment and purification system that would

followed the project for this turnkey, complete, closed-loop purification

substantially reduce our amount of waste water, enabling us to efficiently

plant and, thanks to the technical direction of Hydro Italia, has developed

reconvert it into water to be fed back into the cleaning cycle. As we are

the most effective process combining the most suitable equipment and

certified by three schemes (ISCC Plus, EcoVadis, and Sedex, including the

chemicals from this supplier.

ISO 14001:2015 standard), reducing our environmental impact was a

The company’s sites in Civitanova Marche (Macerata, Italy) and Romano

categorical imperative,” explains Federica Paggi, Quality, Safety, Health &

d’Ezzelino (Vicenza) produce wood and glass coatings, whereas its

Environment Specialist.

foreign subsidiaries are mainly devoted to customer support services a production plant, the Marche site uses large quantities of cleaning

The analysis phase and the selection of a clariflocculation process

water, which have increased considerably in recent years due to rising

The company thus embarked on an analysis phase to identify the best

production volumes. Therefore, ICA identified the need to reduce

suited process for its needs and the right partner for developing the

its environmental impact and disposal costs resulting from these

purification technology. The process began with a laboratory step, where

manufacturing operations as part of its commitment to sustainability.

treatment tests were conducted to assess the feasibility of reusing

Initially, the company decided to focus on the waste water generated

waste water in the cleaning process. This initial study, which lasted

and the production of new colours with innovative tinting systems. As

© Hydro Italia

The clariflocculation tank.

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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 © Hydro Italia

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

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have surfaced, a blade sends them into the

HIGHLIGHT OF THE MONTH

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.

© Hydro Italia

Another view of the plant.

Better for you: Sustainable & smart solutions for your coating process wagner-group.com

Visit us from April 9 - 12, 2024!

Hall 3, booth 3330.

SPECIAL ISSUE - PaintExpo

“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 © ICA

The flakes incorporaing the contaminants suspended on the surface.

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.”

© ICA

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

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PASSION FOR MASKING SOLUTIONS

info@global-mask.com

www.global-mask.com

© AdobeStock

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

FOCUS ON TECHNOLOGY

SPECIAL ISSUE - PaintExpo

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.

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© ipcm

Overview of the coating plant.

I

n the vibrant two-wheeler scene, Italy is steadily one of the world’s

the installation of Super Cube booths. One of the main peculiarities

leading bicycle manufacturing countries, combining traditional

of this new plant is the possibility to apply decals in-line, thanks to

craftsmanship and cutting-edge technology. The beating heart of this

the integration of an infrared oven with panels provided by Infragas

sector lies within the Turin-Milan-Genoa “industrial triangle”, an area

(Mappano, Turin). “Applying decals off-line can cause several operational

steeped in passion and expertise, which has been attracting talent and

issues, including longer cycle times due to the need to manually handle

investment over the years to become a beacon for companies aspiring

the components among different workstations. However, the layout

to excellence in this world. BEEP, an acronym for Bike E-bike European

devised by Visa Impianti with an in-line infrared oven has allowed us

Production, stands out among them: headquartered in Tortona, in the

to optimise and make our entire coating process more efficient,” says

province of Alessandria, it specialises in powder coating and assembly

Nicholas Giaime, project manager at Telai Olagnero.

of bike and e-bike components on behalf of the world’s leading sports retailer, Decathlon.

Excellence in the bicycle sector

It recently installed a new frame coating system, and when it came

BEEP Srl was established in 2021 in Tortona, founded on a passion

to choosing the technological partners to rely on, it had no doubts

for sport and the relentless pursuit of technological innovation, and

in turning to three Italian companies with which it has already been

has since been specialising in powder coating and assembling bicycle

successfully collaborating for years1: Visa Impianti (Triuggio, Monza e

frames. “BEEP’s creation stemmed from the need for a factory that

Brianza), which designed and installed the new powder coating line,

would coat and assemble electric and mountain bikes exclusively for

Futura Convogliatori Aerei (Robecco Pavese, Pavia), which supplied

French multinational Decathlon, which is actually one of this company’s

the power&free conveyor, and Wagner Italia (Valmadrera, Lecco) for

shareholders together with Vittorio Olagnero, the owner of prestigious

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

1

manufacturer Telai Olagnero, and Francesco Russo, a former Decathlon executive,” illustrates Nicholas Giaime.

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© Visa Impianti

A detail of the pre-treatment tunnel.

For several years now, e-bikes have been winning the hearts of cycling

the operators manually load the frames onto the coating line. Each load

enthusiasts worldwide, who increasingly demand bicycles with high-

bar accommodates four frames regardless of their type and size.

quality components and customised finishes. “Most of the parts used

The pre-treatment phase uses chemicals supplied by Chemetall

to produce e-bikes come from Asian markets. This new factory was

(Giussano, Monza e Brianza) and includes the following stages:

established in response to Decathlon’s need for a production and

 Pre-degreasing

assembly hub for e-bikes in Italy to limit the geographical distance

 Degreasing

and, consequently, all costs and any logistical issues,” adds the project

 2 rinses with mains water

manager. With a total area of 11.000 m2, the new BEEP facility will be

 1 rinse with demineralised water

able to coat and assemble up to half a million bicycles per year within

 Nanotechnology passivation

five years.

 1 final rinse with demineralised water.

The production cycle and the new coating line

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

In its plant, BEEP produces a wide range of bicycles, ranging from classic

nanotechnology product,” says Giaime.

mountain bikes to electric bikes, both with frame-integrated batteries

After the drying phase, which takes place in a conventional bell

and with external batteries (for adults only). “The coating of e-bikes

furnace with an indirect heat exchanger and a heat recovery unit, the

accounts for 80% of our production and that of regular bikes for the

power&free conveyor designed by Futura Convogliatori Aerei takes

remaining 20%,” explains Giaime. BEEP’s production process begins

the frames to the Wagner Super Cube booths. “We have two booths,

right with the preparation of the surfaces to be coated. Components

applying coloured base coats and clear coats, respectively. However,

such as frames, forks, and rear racks are supplied directly by Decathlon

the system is prearranged for integrating an additional booth in future,”

and stored in the company’s adjacent warehouse. After quality control,

indicates Telai Olagnero’s project manager. As for the paint applied,

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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.

SPECIAL ISSUE - PaintExpo

© Visa Impianti

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

The self-learning robot provided by CMA Robotics.

“We are also developing a finishing cycle that includes the application of water-based decals, a state-of-the-art process used © ipcm

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

Wagner's Supercenter Evo powder centre.

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do not have to be taken to the infrared oven,” explains Massari.

FOCUS ON TECHNOLOGY

Flexibility is also ensured by the power&free

© ipcm

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

The PLC of the coating plant.

At BEEP, paint products are applied inside the Super Cube booths supplied by Wagner, which are air-conditioned and located inside

© ipcm

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

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

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

© ipcm

to cover the whole Decathlon portfolio are over 50. At BEEP, we are

A successful partnership

currently applying 22 different tints, but we will certainly be using more

“When deciding on the coating system to be installed, we did not do any

and more of them in the coming months. Therefore, we are going to

market research but turned immediately to suppliers we had already

install another Wagner booth to further speed up and optimise our

worked with. The decision to rely on manufacturers with whom we

coating cycle and better manage the necessary colour change phases.”

already had positive experiences was a crucial element in the success

“As far as paint products are concerned, we decided to continue working

of this partnership during the installation of our new plant. Relying on

with Adapta Color and Tiger Coatings, which were already the suppliers

the same team, whose skills and dependability had already been proven

of the SMW factory in Romania, our company’s other subsidiary that

in previous collaborations, guaranteed optimal operational efficiency

coats frames on behalf of Decathlon,” says Giaime. “We decided to

right from the start of the project. Although the plant is not yet at full

continue this partnership based on the high quality of the coatings

capacity – it will be at the end of March 2024 – having already worked

supplied by these manufacturers. Another key factor in choosing to

with the same partners on two other plants and, of course, with the

collaborate with Adapta and Tiger was that both companies only have

same customer, namely Decathlon, we can accurately predict our short

one production site in Europe: we consider this a significant advantage

and long-term results. Our goal is to coat 150,000 bicycles in the first

because it guarantees greater reliability and quality consistency of the

year, 250,000 in the second year, and over half a million by the fifth

supplied paint products. Past experiences with other manufacturers

year, working in two shifts,” indicates Giaime. “We are confident that, by

have taught us that mixing two paint batches from different production

continuing to collaborate with this expert and reliable pool of companies

sites often leads to slight colour differences. If not detected by our

and using the cutting-edge technology they provide, we are going to fully

operators, such inconsistencies risked adversely affecting the quality

meet Decathlon’s needs and achieve excellent results in terms of both

of our finishes. However, by using Adapta and Tiger powders, we can

production capacity and coating quality,” he concludes.

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.

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SPECIAL ISSUE - PaintExpo

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.

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HIGHLIGHT OF THE MONTH

T

he history of Helios Italquartz dates back to 1940, when its

modules according to specific needs, which can be managed through

founder, Armando Giro, took over Actinia, a company specialising

switchboards and control systems also supplied by us.

in infrared and ultraviolet lamps. Since then, several ups and

“The outstanding know-how gained over these ninety years has enabled

downs have led this business to evolve, change names, and undergo

Helios Italquartz to become extremely flexible and able to meet the

mergers, but always maintaining the same focus on quality standards of

demands of different markets despite its small to medium size,” says

excellence. Today, the Helios Quartz Group, with its sites in Cambiago

Luigi Gastaldo. Today, the company is ready for a new challenge:

(Milan, Italy) and Novazzano (Switzerland) and representative offices

conquering the industrial coating sector, where quartz infrared lamps

in America and Asia, has become one of the main international

are not so widespread and well known, yet. For this reason, it will once

benchmarks for the production of quartz lamps.

again participate in PaintExpo, the major global trade fair for industrial

“We specialise in producing and processing quartz and all its derivatives

coating technologies, to be held in Karlsruhe (Germany) from 9 to 12

and our core business is infrared lamps. Manufactured in our Cambiago

April 2024.

and Novazzano plants, they have a variety of fields of application, including glass, plastics, rubber, textiles, and research equipment

Helios Italquartz at PaintExpo 2024

for universities. In addition, to meet the needs of the most varied

Indeed, besides the sectors mentioned above, Helios Italquartz strongly

industries, we have been producing and marketing complete systems

believes in the positive impact that its infrared and UV lamps can have

for about ten years now, that is, infrared lamps fitted inside customised

on the surface treatment industry. “Participating in PaintExpo for the

© Helios Italquartz

Quartz infrared lamps.

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© 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.

second time is a significant occasion for us because the feedback we

two options. “Our company would like to inform the industry about

received during our last participation in 2022 was extremely positive.

infrared technology because “piercing this veil” means bringing infrared

This trade fair is well focused on the technological aspects of processes

lamps into drying processes, making it commonplace, practical, and

and its visitors are very knowledgeable: this enables us to have

above all usable in mixed systems to optimise consumption, machine

interesting exchanges of technical information and, of course, continue

flexibility, and energy savings – all factors that are truly relevant today,”

to be up-to-date on new materials and technologies, which ultimately

adds the sales manager.

helps us produce reliable solutions for an ever-changing market,” notes The objective pursued by participating in PaintExpo is, in Gastaldo’s

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

words, “piercing the veil of power of traditional systems”. As mentioned,

Quartz infrared lamps use radiation heating to bring heat to a surface

infrared technology still struggles to emerge in the surface treatment

without any contact with it or the presence of “intermediary” agents such

sector and is often perceived as a usurper of the technologies classically

as air. These lamps can emit infrared radiation in a wavelength range

used for curing and drying paint products. “There is a sort of diatribe

of 0.9 µm (short waves) to 3.5 µm (medium waves), which allows the

between infrared and hot-air processes that leads operators to believe

heating cycle to be adapted to the specific requirements of the treated

they necessarily have to opt for one of the two alternatives. Helios

material. Compared to traditional forms of heating, such as hot air,

Italquartz, however, aims to champion the possibility of integrating these

infrared lamps emit more energy per unit area. In addition, this energy

the sales manager of Helios Italquartz.

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HIGHLIGHT OF THE MONTH

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

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

Helios Italquartz’s systems also have the advantage that they are

UV lamps and other technologies from Helios Italquartz

extremely flexible and easy to install because they only require

Besides infrared lamps, this company also specialises in designing

mechanical support and mains power, as they do not consist of

and producing medium-pressure, low-pressure, amalgam, and black

heavy machinery requiring special insulation or suction mechanisms.

light (Wood’s light) UV lamps. The result of many years of experience

Moreover, compared with other technologies, infrared lamps guarantee

in the industry, guaranteeing advanced technology, careful selection

high temperature accuracy on paint through easy power adjustment,

of materials, and maximum reliability, this type of lamp is suitable for a

thus preventing over-curing. Another significant benefit relates to

wide range of applications, including the curing and drying of UV glues,

energy saving: infrared lamps switch on in maximum 60 seconds and

paints, and coatings.

do not require pre-heating time, speeding up the process and reducing

Helios Italquartz’s catalogue also includes scientific equipment

consumption.

and laboratory devices such as diode lamps. “Helios has been

The flexibility of these lamps also lies in the possibility of integrating

manufacturing scientific instruments that take advantage of ultraviolet

them into both new and revamped coating systems. “In brief, we can

and infrared radiation’s properties for over seventy years, providing

provide a solution for any application that is presented to us because

its customers with professional and reliable solutions for applications

we manufacture lamps with all wavelengths and carry out preliminary

in multiple sectors. From drying UV-reactive inks and paint to glass

tests in our laboratory to offer each customer a system that is truly

bonding, from detecting the glass watertight side to material ageing

satisfactory, as economical as possible, and with the highest possible

tests, Helios Italquartz’s scientific equipment has been developed

degree of quality,” states Gastaldo, emphasising that the real benefit of

through close collaboration between our R&D department and

We create chemistry that makes lines love curves.

Coatings give a car more than just long-lasting protection.

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

SPECIAL ISSUE - PaintExpo

© Helios Italquartz

UV lamps manufactured by Helios Italquartz.

research centres, universities, and laboratories of leading private

a renovation project that will soon lead to tripling the area devoted to

companies operating in various industries,” says Gastaldo.

production. This will enable it to always meet customer demands and

Helios Italquartz between distinctive features and future challenges

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

Luigi Gastaldo reports that the company’s main target market is Europe,

categories. Usually, the former are intrigued by new solutions but

but says he is seeing significant developments in the United States

always keep their focus on costs and the need not to revolutionise

of America and to a lesser extent in South America, but also in China,

the machines they market to avoid carrying out major redesign

where demand for quality machines for the domestic market is growing

work, whereas the latter are often in search of a solution to specific

exponentially. “Conquering new markets is only possible by working daily

production problems and are very keen to embrace innovation. We will

to ensure our product quality consistently comes to light. That is why, at

be open to understanding everyone’s needs and present ourselves as

Helios Italquartz, we strive to offer not only products but also services

an ideal partner for continuous development,” concludes Luigi Gastaldo.

and pre- and after-sales assistance of excellence,” notes the sales

Do not miss the chance to meet the Helios Italquartz team at PaintExpo,

manager. Continued growth has also translated into the need to expand

awaiting you at Stand 3245 in Hall 3 to show its technologies and

the company’s available spaces: the Cambiago site is now undergoing

discuss new horizons in the industry.

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The only European producer of customized electrodialysis cells and ultrafiltration membranes for cataphoresis / anaphoresis application.

Our cells are made with tubular extruded membrane.

ELECTRODIALYSIS CELLS models available: AUF65 diameter 65 mm - AUFL80 CELL diameter 80 mm ULTRAFILTRATION MEMBRANES models available: AUF80 - AUF80 PLUS HIGH-PERFORMANCE new model 2023!

ENERGY SAVING | QUALITY PROCESS | IMPROVED LIFETIME | REDUCED MAINTENANCE

info@avin.it professionality

know-how

punctuality

www.avinsrl.com

BRAND-NEW

SPECIAL ISSUE - PaintExpo

© acp

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.

W

hen removing loosely adhering, particulate contamination, the

and film contamination. The liquid carbon dioxide is compressed into

newly developed rotary two-substance ring nozzle enables a

granular cleaning granulate in an integrated system and accelerated

high area performance with minimized carbon dioxide and

with compressed air before being blasted onto the surface to be

compressed air consumption. The quattroClean snow jet technology

cleaned. This enables a fully automated, uninterrupted cleaning process

is the ideal solution if, in addition to particulate contamination, filmic

to be realized.

contamination also needs to be removed reliably over the entire surface

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

or partially. acp systems has developed the quattroClean power jet technology for the complete or partial removal of stubborn particulate

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

BRAND-NEW

SPECIAL ISSUE - PaintExpo

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

C

ONDOROIL CHEMICAL, a company that

savings and lower water consumption thanks to less

has been specialising in the research,

frequent bath changes. It can also be used in a one-

development, and production of chemicals

stage surface degreasing/conversion process, as it is

for the surface treatment of metals for over fifty

enriched with surfactants that allow for the perfect

years, will present its nanotechnology pre-treatment

removal of oils and greases commonly found on iron

solutions at PaintExpo 2024, including in particular

and galvanised iron parts.

Condorcoat EC 930. Condorcoat EC 930 is a

Condorcoat EC 930 is diluted preferably with

nanotechnology passivating agent for the surface

demineralised water and can be used by either

conversion of ferrous materials, galvanised iron, and

spraying or dipping in AISI 304 or 316 L stainless

aluminium. Free of phosphates, heavy metals such

steel plants. The treatment of workpieces is followed

as zinc, manganese, and nickel, COD, and VOC, and

by a rinse with demineralised water.

therefore highly environmentally friendly, it creates

Pre-treatment with Condorcoat EC 930 is compatible

a highly compact inorganic layer, although over 10

with all coating processes. CONDOROIL’s technical

times thinner (approx. 40 nm) than iron phosphate

assistance service is at the customers’ complete

phosphating, ensuring higher protection and lower

disposal for application tests that can be carried out

operating costs.

in its technology laboratories located in Casale Litta

This product can operate at room temperature, thus

(Varese, Italy).

reducing the running costs of conversion baths, with less sludge production, which extends the service

For further information:

life of the baths themselves and guarantees further

https://condoroil.com/EN/

BRAND-NEW

SPECIAL ISSUE - PaintExpo

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.

T

he most common type of curing ovens

piece support bars enter the oven, absorbing

does not heat/cool down with each cycle,

typically installed involves pieces

energy. We thus developed a new oven concept,

allowing for significant energy savings and

entering and exiting at floor level. This

and already in the initial study phase, significant

drastically reducing expansions, stresses,

configuration necessitates long pre-ovens

results emerged. Our focus was on an approach

and wear.

equipped with air curtains that inevitably

involving efficient handling to reduce space and

As we progressed towards the realization

consume a certain amount of electricity.

enable material entry and exit from the bottom

of the second oven, we further refined

Despite the pre-ovens, however, this solution

with minimal openings to minimize heat loss to the

our solution by defining and optimizing

results in significant losses of hot air and

hoods.

every aspect of the system, we ensured

consequently energy.

The first prototype we developed clearly showed

greater consistency in performance and

To mitigate this problem, we constructed the

markedly superior performance compared

maximized benefits.

so-called “CANOPY ovens” with bottom entry

to conventional systems. The combination of

The clear evidence of the high

and exit. This solution eliminates air curtains,

optimized handling and an elevated oven proved

performance already observed in the first

but the entry/exit mouths are quite wide and,

to be a winning solution, highlighting tangible

prototype was consolidated, confirming

in turn, cause losses through convection and

benefits in terms of energy efficiency and space

the validity and effectiveness of our

radiation.

utilization.

innovative proposal. In conclusion, our

Additionally, in both aforementioned solutions,

Furthermore, with this system, the overhead

steadfast commitment to achieving the

the conveyor chain and the corresponding

conveyor no longer passes through the oven, so it

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

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BRAND-NEW

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

A

irgenex® 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

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

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.

© Harter GmbH

For further information: www.harter-gmbh.de

Via Vincenzo Monti 173 20099 Sesto San Giovanni (MI) - ITALY Tel.(+39).02.24.89.583/02.26.224.313 Fax(+39).02.26.21.065 e-mail: info@defil.it www.defil.it

HIGHLIGHT OF THE MONTH

SPECIAL ISSUE - PaintExpo

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

Karla Roncevic, R&D Director at Kansai Helios.

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Kansai Helios feel as a player in the chemical industry?

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

HIGHLIGHT OF THE MONTH

© Shutterstock

chemicals are considered unsafe and dangerous by their very nature.

ipcm®: What are the current developments in the market of

Innovation, therefore, is a big responsibility that we feel, inspiring us

organic raw materials?

to develop products that help us build a better, more sustainable

KR: Kansai Helios prides itself on having a fully integrated production

society. These are exciting times to live in, as far as research is

flow that goes all the way back to raw materials, because this enables

concerned. Kansai Helios is embracing this important task and this

us to develop polymers that perfectly fit to our coating formulations. We

great opportunity to create a more sustainable world, as coatings are an

have strived to increase our share of bio-based raw materials to replace

excellent example of how it is possible to reduce one’s environmental

fossil-based ones. We have achieved extraordinary developments in

impact.

this area, although it also entails several challenges. Our engineers have been working hard to develop various product types for the ACE sector,

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

which are containing bio-based raw materials. Of course, one cannot

KR: Continuing to refer to the ACE and commercial vehicle industrial

expect all raw materials to be replaced by elements of organic origin:

segment, the first sustainable innovation to be mentioned is using raw

it is not possible and would not even make sense to do so. Sustainable

materials of organic or biodegradable origin. However, sustainability

coatings aim to reduce the environmental impact by improving the

goes far beyond this. Another aspect is undoubtedly reducing

overall lifecycle, and incorporating renewable recourses is just one of

dependence on fossil fuels as much as possible, not only in terms of

the ways to do so.

raw materials and paint formulations but also in other areas of the application process – for instance, eliminating the need for a curing step

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

in a two-coat cycle, significantly decreasing energy requirements, or

origin?

formulating paint products with greater durability to extend the service

KR: The advantages, of course, include decreased dependence on

life of components. Other sustainable choices are improving paint

fossil fuels and the great opportunity to collaborate with agriculture

application process, by for example lowering the curing temperature

to promote the cultivation of certain plants useful to the chemical

of powder coatings from 180 to 160 °C or less – this results in

industry, without negatively affecting the food chain or biodiversity. The

considerable energy savings, making it even more sustainable than

first disadvantage is that, as I mentioned earlier, some raw materials of

using organic raw materials.

organic origin require enormous amounts of energy and water for their

international PAINT&COATING magazine - MARCH/APRIL 2024 - N. 86

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SPECIAL ISSUE - PaintExpo

© Shutterstock

extraction and processing. This is something we have to keep in mind,

from 80 °C to room temperature for certain one-coat products. These

without being fooled by the term “organic” and without over-using them.

all result in significant improvements for our customers, especially in

The second disadvantage is the higher difficulty in meeting the technical

an industrial sector like the ACE and commercial vehicle one, where

requirements of specific applications when using raw materials of

one-coat paint products are widely used because they ensure the same

organic origin. Bio-based raw materials certainly pose some challenges

degree of performance as conventional two-coat systems but with a

that require great attention.

faster and more streamlined production process.

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

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

KR: It can do a lot process-wise. There are also functional paints that

KR: Exactly those I mentioned. First of all, we will present a low-

contribute to energy savings thanks to their intrinsic characteristics,

temperature cure cataphoresis product. As for liquid paints, we will

such as products reflecting sunlight and preventing buildings from

present a wet-on-wet two-coat system for the ACE sector. In addition,

overheating, thus lowering the cooling requirements in buildings. The

we will introduce a direct-to-metal product partly of organic origin and

thermal barrier coatings can enhance the insulation properties of

an epoxy primer also partly based on organic raw materials. Finally,

surfaces, reducing the need for heating or cooling.

we will present a two-coat powder system that does not require any

When it comes to standard coatings for the ACE sector, Kansai Helios

intermediate curing phase and a super durable low-temperature

has successfully developed and implemented wet-on-wet liquid systems

powder coating. Last but not least, a “green” powder coating based on

that eliminate the need for drying after the first coat. In the powder

a recycled polyester resin will make its debut – indeed, recycled raw

area, we have devised two-coat systems that do not require complete

materials are another crucial area of research for our Group. These are

intermediate curing, thus dramatically reducing energy consumption,

all outstanding contributions of Kansai Helios to sustainability and we

as powders cure at temperatures between 160 and 180 °C. We have

want to present to our customers!

also successfully developed liquid coatings that need less energy to dry,

Kansai Helios will be pleased to welcome you at PaintExpo 2024 in

lowering the required temperature, for example, from 80 to 40 °C or

Karlsruhe (Germany) from 9 to 12 April at stand 1430, Hall 1.

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We convey the future since 1959

Future-proof and reliable overhead

and floor MONORAIL and P+F CONVEYOR systems that can be perfectly integrated into your production processes.

We take care of all your requirements and create a tailor-made and cost-optimized concept for you.

segreteria@conveyors.it

FOCUS ON TECHNOLOGY

SPECIAL ISSUE - PaintExpo

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.

D

ry-on-dry powder coating, the most common powder

infrared heating; afterwards, the part enters the oven for final curing,

application technology, calls for the intensive use of energy

initiating the process known as “dry-on-fused” precisely because the

resources to cure the base coat and then the top coat. For

pre-cured coating is melted and not fully baked, thus avoiding a double curing step. Integrating the gelling phase also results in a coating

to the coating cycle to overcome this problem, which returns the

layer that gives the substrate higher corrosion and UV-resistance

base coat layer applied on the substrate to a molten state through

properties, making it ideal for all products intended for outdoor use,

© Vermobil

several years now, an additional step called gelling has been added

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.

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FOCUS ON TECHNOLOGY

such as those manufactured by Vermobil Style Srl (Marsciano, Perugia,

In fact, coating objects or structures intended for outdoors involves a

Italy). The company, celebrating its 30th anniversary this year, designs

more complex process than those intended for indoor use. “We have

and manufactures outdoor furniture and accessories in line with

carefully improved each phase of our coating cycle because even

contemporary trends to meet the most advanced design requirements.

though this is our final production step before assembly and packaging,

“What we do here,” says one of the founding partners, Mauro Baiocco,

it is responsible for the appreciation of our furniture nationally and

to present its business, “is making outdoor spaces more comfortable

internationally. Therefore, we started by perfecting the pre-treatment

and liveable thanks to our furniture and accessories made in durable,

phase and then optimising the gelling phase before curing, which we

premium materials, created with functionality and style in mind, and

have been carrying out for over 12 years with Infracat® catalytic panels,

characterised by a refined combination of lines and colours. The

to which we have recently added a series of RHT gas radiant burners.

attention we pay to green spaces and nature in general is also reflected

Infragas Srl (Mappano, Turin, Italy) supplied us with both technologies.”

in the standards we adopt to ensure fair, environmentally friendly production processes, also protecting the safety of our employees

The history of Vermobil

and geared towards providing durable, high-performance finishes.”

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

© ipcm

The pre-treatment tunnel using Chemtec’s multi-metal product Toran 3.

© ipcm

The inside of the oven with the 22 Infracat® catalytic panels.

international PAINT&COATING magazine - MARCH/APRIL 2024 - N. 86

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SPECIAL ISSUE - PaintExpo

always been an important district for the furniture industry. “In 1993

grow in size. “Our original factory occupied an area of about 4,000 m2, to

there was the beginning of the adventure of our company, founded

which another hall of 2,000 m2 was soon added. Both the facilities were

to offer a contract coating service for metal furniture, although it soon

addressed to the production department. "In recent times, an additional

moved on to manufacture its own products thus meeting the needs

building spanning 7,000 m2 has been acquired for shipping warehouse

of an increasingly demanding market. In 1995, the major players in

and offices purposes. The three buildings currently house a total of 60

the sector gathered, first, at the SPOGA fair in Cologne (Germany) and,

employees."

then, at the Sun trade fair in Rimini (Italy), the most important outdoor

Today, the company’s main target market is Italy and its core business

furniture exhibitions in Europe at that time. Our presence at these

is outdoor furniture for the contract industry, especially for bars and

events enabled us to make a breakthrough in the Swiss market and

restaurants. “We have established important partnerships with leading

begin to distribute our products throughout the DACH market, as well

outdoor furniture companies. Our collaboration with them also raises

as in Italy.”

the reputation of the products marketed under our own brand name,

The success of its furniture and accessories also enabled Vermobil to

which can now be found in the high-end design segment.”

© ipcm

The gelling phase on some chairs.

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© ipcm

The RHT burner section integrated in 2022.

FOCUS ON TECHNOLOGY

Care at every production stage From the purchase of raw material, consisting mainly of carbon steel

on the workpieces, trapping them in the three-dimensional structure

and aluminium, to final shipment, the entire production process takes

of the polymer formed on the metal, thus avoiding waste generation

place in-house, except for cold galvanising, which is outsourced. When

and converting the contaminants into an active part of the process.

they go back to Vermobil’s factory, components have already undergone

The result of the pre-treatment stage is functional to the aesthetic

degreasing, perfected with a pre-treatment process, followed by

performance of the coating system, as well as to the environmental

drying, base coat application in a booth designed and installed by

friendliness of our manufacturing operations: Toran 3 does not generate

Siver (Corciano, Perugia, Italy), gelling in an Infragas IR oven, top coat

any emissions or waste to be disposed of.”

application in a quick-colour change booth equipped with Nordson

The oven installed in Vermobil’s paint shop is used for both drying

dense phase guns (of which Siver is the exclusive dealer for Italy), and

after pre-treatment and curing. “To avoid any risk of contamination, we

final oven curing.

compartmentalised it. On one side, the burner feeds the oven for drying

“For about a year now,” says Baiocco, “we have been using the one-stage

up to a temperature of 150 °C. On the other side, our Qualicoat class 1

product Toran 3 supplied by Chemtec (Corbetta, Milan, Italy) in our pre-

and 2 polyester thermosetting powders are subjected to the final curing

treatment process, after numerous tests carried out with an in-house

stage at 190 °C for 15/20 minutes.”

large-sized salt spray test device capable of accommodating up to 3 chairs. This multi-metal product is suitable for both iron and aluminium,

The infrared gelling system’s upgrade

a valid alternative to phosphodegreasing or phosphating followed by

Vermobil has been using infrared technology for powder gelling since

passivation. As the product dries, it deposits a very thin, continuous,

2012. “Previously, we were forced to pass our parts through the curing

three-dimensional conversion film that promotes paint adhesion and

oven twice, which meant a considerable waste of energy and time,”

increases the corrosion protection performance of the coating system.

emphasises Baiocco. “The installation of the Infragas oven was such a

The organic polymer film obtained encapsulates the oily contaminants

turning point in our production flow that 10 years later, we decided to

SPECIAL ISSUE - PaintExpo

© ipcm

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

© ipcm

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

upgrade its technology with the integration of RHT burners.”

achieve by implementing a new RHT radiant burner section.” Following

“The first equipment provided to Vermobil,” indicates Francesca

the tests, the company opted for adding a section of 3 RHT burners, 2

Marabotti, Business Development & Marketing Manager at Infragas Srl,

7C vertical ones and one 7L floor one, for a total installed power of 210

“included 20 catalytic panels from the Infracat series, a name chosen

kW and manageable power up to 105 kW, in order to achieve a better

by our team to emphasise the combination of infrared energy and

powder curing performance.

catalytic technology. With a surface temperature that can be adjusted

“Infragas’ RHT gas radiant burners are infrared, pre-mixed gas systems

from 180 to 550 °C and a power output ranging from 1.5 kW (1290

that reach a surface temperature of 950 °C,” illustrates Marabotti. “They

kcal/h) to 17 kW (14617 kcal/h), these panels are designed to develop

are a safe and reliable source of heat generated by burning natural gas

®

a power density of 20 kW/m at a medium to long wavelength (2 to 10

or propane, transmitted through short-wavelength infrared rays. The

μm). This guarantees infrared radiation that is, first of all, safe thanks to

structure of Radiant High Temperature burners is made of stainless

the absence of flames and, secondly, effective because the prolonged

steel for excellent robustness over time. Each burner has a control

permanence of the electromagnetic wave on the parts’ surfaces results

and pre-mixing unit for properly mixing air and gas. The micro-flame

in better absorption by the organic material, leaving the characteristics

combustion on metal surfaces produces extremely low amounts of NOx,

of the substrates unaltered. In this specific case, the panels supplied to

carbon monoxide, and unburnt emissions, an important factor from an

Vermobil belong to our 18.60 Infracat series and have a power range of

environmental and safety point of view.”

2

7.2 to 12 kW.” “In 2022, after 10 years of truly satisfactory use,” explains Baiocco,

The advantages of the new hybrid system

“we decided to test the Radiant High Temperature (RHT) technology.

“With the parts dwelling in the oven for just 3 minutes and the double

We visited Infragas’ test centre together with a team from Siver, our

curing stage being eliminated, the advantages of catalytic technology

long-standing plant engineering partner, to assess the results we could

were already obvious in terms of energy and time savings, but today,

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FOCUS ON TECHNOLOGY

© ipcm

© Siver

Manual top coat application with a Nordson gun.

Vermobil’s catalogue includes 6 standard colours, as well as special finishes made to customer specifications.

Sustainable infrared catalytic technology thanks to this hybrid system, we have further

“Infrared radiant panels use catalytic gas oxidation

improved our coating quality,” confirms Baiocco. “The

technology to emit heat in the form of infrared

integrated RHT burners increase the effectiveness

rays,” adds Marabotti. “As a result, they can heat the

of radiation, enabling all-round heating of the entire

material’s surface alone, improving the production

surface of each component. This prevents the base

process’ overall efficiency. They are equipped with

coat layer from surfacing after the top coat has been

a highly effective catalytic converter that allows

applied. To avoid this problem, we were previously

achieving high temperatures with low electrical

forced to apply dark top coats on dark base coats and

power consumption during the pre-heating phase,

light top coats on light base coats. Now, we can use

thus ensuring energy savings. In some cases, when

only one monochrome base coat regardless of the

treating parts such as cylinders or tanks that can

colour of the top coat, with excellent results that are

turn on themselves 360°, our IR ovens can replace

also highly appreciated by our customers in Northern

conventional hot-air ovens by reducing curing

Europe – who differ from the rest of the market in the

times by at least 3 times. In the case of Vermobil,

strictness of their finishing specifications, as outdoor

we developed a system to speed up the coating

furniture is put to the test by the harsh weather

cycle that was also endorsed by plant engineering

conditions of those geographical areas. Saving

company Siver.”

energy and increasing the speed of the coating cycle

“Siver has been working with Vermobil since 1993,

also enables us to offer an even more sustainable

the year of its foundation,” says Marcella Baldoni,

production flow.”

the owner of this Perugia-based company, “and has always affirmed the effectiveness of catalytic and RHT

SPECIAL ISSUE - PaintExpo

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.” © ipcm

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®.

“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,

© Vermobil

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.”

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

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AUTOMATE YOUR ENTIRE PAINTING PROCESS Lesta srl Lesta srl Lesta

info@Lesta.it www.lesta.it/en/

© ipcm

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

FOCUS ON TECHNOLOGY

SPECIAL ISSUE - PaintExpo

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.

I

n the industrial coating sector, providing superior-quality products

critical elements in meeting the demanding requirements of customers.

is the cornerstone for standing out in the market and maintaining

The coated components must not only guarantee excellent strength

a competitive advantage. The expertise and experience of the

and durability but also impeccable aesthetics.

operators involved in the coating process, together with the careful

And if there is one sector where quality and aesthetics play a primary

selection of the paint products, technologies, and equipment used, are

role, it is undoubtedly the design and furniture one. Here, every detail,

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FOCUS ON TECHNOLOGY

© ipcm

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

© ipcm

Components at the entrance to the pre-treatment tunnel.

shade of colour, and surface finish contributes to the product’s added

liquid coating, we made a clear choice to shift our core business and

value. Therefore, for a coating contractor specialising in the indoor and

devote our services exclusively to powder coating, because we believe

outdoor furnishing sector, ensuring high-quality finishes is not just a

that that when choosing the right products and processes, powder

duty but a real mission.

coating ensures superior resistance and durability performance,” states

A tangible example of such dedication to quality is D.P.F. Srl

Paolo de Palma, the company’s owner and a member of the second

(Trebaseleghe, Padua, Italy), a company specialising in contract powder

generation at its helm.

coating for a wide range of industries, including furniture and design.

“With a team of 12 people, we have been able to consolidate our

To meet the growing needs of the market and continue on the path

market presence as a contractor operating with world-renowned

towards excellence, it recently inaugurated a new plant accommodating

companies from a wide range of sectors, including heating, plumbing,

an innovative coating system from Verona Impianti 2002 (Colognola

construction, and lighting, mainly from Italy’s Veneto and Friuli-Venezia

ai Colli, Verona, Italy), a supplier that has been designing and building

Giulia regions. However, the sector that is of the utmost importance

industrial coating systems for over twenty years.

to us is that of indoor and outdoor furniture. In this industry, surface

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

finishing is not only a matter of functionality but also of aesthetics.

Indeed, our finishes are of the highest quality, and we are constantly

D.P.F. Srl was founded in 1996 thanks to the entrepreneurial vision

searching for the best coating technologies to meet our customers’

of Onofrio De Palma. With constant commitment, dedication, and

needs. For us, excellent aesthetics are synonymous with quality and

experience, it has grown to become a well-established player in the

attention to detail.” That is why, when D.P.F. had to purchase a larger

industrial coating sector. “Although originally we were focussed on

plant a few years ago to meet its customers’ growing requests, it chose

international PAINT&COATING magazine - MARCH/APRIL 2024 - N. 86

155

SPECIAL ISSUE - PaintExpo

© ipcm

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

© ipcm

The drying oven.

to install a new coating system that would allow it to achieve a higher

differing in size and weight and fill the previous plant’s gaps, especially

degree of quality in line with the latest market demands.

in the pre-treatment cycle. “Verona Impianti 2002 provided us with

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,

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.

we felt the need to expand our production department, since our

The coating cycle

old building was becoming too small to fulfil all the orders we had to

“The plant is designed to treat both minute workpieces, such as small

process. We started looking for new, suitable premises, and at the

metal parts, and large components, such as metalwork fabrications. Its

same time, together with engineer Albino Tamellin, the owner of Verona

conveyor can handle up to 20,000 kg on the line and 150 kg per hook,”

Impianti 2002, and his sons Pietro and Stefano, we embarked on a

illustrates De Palma.

journey to build a new coating plant, which turned out to be a success,”

The process begins with the manual loading of the workpieces onto a

acknowledges D.P.F.’s owner.

monorail chain conveyor featuring rotating hooks, which are essential

The company’s main goal when designing the new line was to equip

for parts requiring rotation during coating. Subsequently, the parts

itself with a versatile system that could coat a wide range of parts

undergo a pre-treatment cycle consisting of four stages:

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FOCUS ON TECHNOLOGY

YOU THINK IT, WE MAKE IT.

© ipcm

Top view of the coating plant.

 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

di Pozzi Sergio Via Concordia 41-43 23854 Olginate - LC - ITALY P.I. 00414390138 www.sepoitalia.it info@sepoitalia.it

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

PA SS I

5 Y 0 EA

1 ON 97 FO 4 R 20 AU 24 TO M AT I

RS

ON

SPECIAL ISSUE - PaintExpo

© ipcm

© ipcm

Manual coating application inside the booth.

Coated components entering the curing oven.

standard to all our customers,” says Albino Tamellin.

flexibility and the possibility to also treat complex parts, especially when

“Moreover, the spray bars are fed by a manifold at the top of the tunnel,

it comes to furniture components requiring meticulous finishes,” notes

which ensures more constant water supply pressure and prevents

De Palma.

the formation of sludge due to water stagnation, since the bars empty

“Thanks to dedicated software, the air-convection drying and curing

automatically by force of gravity when the tunnel is turned off. Feeding

ovens record temperature trends and display diagrams that help

often occurs from the bottom up, leading to much more frequent

ensure curing uniformity and consistency while maintaining low energy

nozzle clogging issues and uneven pre-treatment results over time.

consumption. After powder curing at 180 °C, the parts are conveyed to

Therefore, this has also long been the standard for our plants.”

the cooling area, manually unloaded by the operator, and subjected to

After pre-treatment, the components are taken to the drying oven,

rigorous quality controls,” explains Pietro Tamellin.

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

Sustainability measures

with a varying number of layers depending on customer requirements.

One of the main difficulties D.P.F. encountered with the previous

D.P.F. has only one booth for both primer and top coat application.

plant concerned pre-treatment. For this reason, Verona Impianti 2002

“We already used it in our previous line. As we are fully satisfied with

devised a series of measures – the heating boiler separated from the

its efficiency and reliability, we asked Verona Impianti 2002 to integrate

tunnel body and the spray nozzle’s feeding from above – creating

it into the new line’s layout. The powders are applied manually with

an optimal cycle that would guarantee excellent paint adhesion and

Zeus Electrostatic System’s Gen 01 electrostatic guns, ensuring greater

durability over time.

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FOCUS ON TECHNOLOGY

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

© ipcm

The coating system is managed by the PLC.

the temperatures inside the ovens and pretreatment baths. In the former, we constantly monitor the temperatures to ensure they

have integrated advanced technologies to

In addition, the plant has a remote service

are optimal and stable. Similarly, we perform

ensure analytical management and high-

and control system that allows for quick

regular checks on the temperatures and

quality production. One of its main features

intervention in case of production anomalies

substances contained in the pre-treatment

is the PLC control system, enabling us to

or defects. “Thanks to full process traceability,

baths,” says De Palma.

manage the plant from the terminal. We

we can identify and correct any issues

can monitor and control all key parameters,

promptly. In the event of anomalies, the

including speed values and oven and

system emits an alarm enabling the operators

bath temperatures, thus ensuring optimal

to intervene quickly to solve the problem,”

“The plant was developed in compliance with

operation and maximum precision in the

says De Palma. “Computerised production

the Industry 4.0 principles, which means we

coating process,” indicates Stefano Tamellin.

management has revolutionised our

Maintenance and full process traceability for higher quality

SPECIAL ISSUE - PaintExpo

© ipcm

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.

approach to coating, enabling us to optimise the part’s feeding speed

40% saving on methane gas, which is a major achievement that fits

and monitor the production flow in real time.”

into a broader strategy aimed at energy efficiency and using alternative

The importance of finishing

sources,” states De Palma.

Another advantage of the new system is the increase in quality, which

Quality is a non-negotiable for D.P.F., but its range of finishes also plays

was an essential requirement for the success of D.P.F. “Attention to

a key role in its success. This coating contractor offers a wide choice of

detail is a hallmark of our work, especially in the furniture and design

finishes, including epoxy, polyester, epoxy-polyester, and polyurethane

sector. To achieve better results in terms of durability and quality of

coatings in their gloss, semi-gloss, matte, and super-matte versions and

finishes, we have improved our pre-treatment cycle by adding a rinse

with different effects, from textured to wrinkled. “We coat 90% of parts

with demineralised water, which was implemented just after the plant

with polyester powders purchased from some of the most important

was commissioned precisely to further improve paint adhesion and

paint suppliers. We chose to mainly use this type of coating due to the

durability,” says De Palma.

variety of intended uses of the components we treat, which could also

“In addition, again to optimise the coating cycle, we have installed an

be exposed to marine environments. Polyester powders guarantee high

oil seal channel on the conveyor to prevent chain lubrication oils from

mechanical, weathering, and corrosion resistance properties, ensuring

dripping on the parts’ surfaces,” adds Pietro Tamellin.

reliable performance in any context,” the owner of D.P.F. continues.

“We are pleased to confirm that we have achieved our initial objectives.

Reduced consumption and improved quality: the main advantages of the new line “From the energy consumption point of view, we recorded a significant

160 N. 86 - MARCH/APRIL 2024 - international PAINT&COATING magazine

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.

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ANALYSIS

SPECIAL ISSUE - PaintExpo

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.

P

roduction without well-functioning quality control is not possible.

environment. In addition, there is a completely revised user software

The demands are constantly increasing. Customer specifications

that has been specially optimised for the paint shop area.

must be met and verified, as well as the specifications of the paint

The TS04 Finishing System is a complete solution for monitoring temperature data, especially in coating processes. The system is easy

and more standards and certifications, compliance to them is essential.

to operate and records the temperature data of the product during

But how can all these specifications and decrees be integrated into the

the oven cycle. By attaching the thermocouples directly to the product,

operating processes as effectively, economically and simply as possible?

such as a car test body, it is possible to bring it into the coating line

PhoenixTM has been very successfully with the design and development

at any time. There, the actual product temperatures are recorded.

of temperature measuring systems for 10 years now. In addition to the

The pyrometers permanently installed in the oven can only measure

well-known systems, there are always new products that are added to

the ambient or external surface temperatures. They therefore do not

the product range and further developments. PhoenixTM has been

provide any information about what is happening in the more difficult-

very active in this area over the last two years. In addition to the new

to-reach areas of the product, for example in flanged sheet metal parts.

and innovative optical systems, there is the Epsilon system, which has

Before the measurement, a test product (e.g. the aforementioned car

been approved for ATEX zones and can be used safely in the hazardous

body) is fitted with thermocouples at all relevant points in order to

areas of the paint shop, thus contributing to a legally compliant working

obtain a comprehensive picture of the heat distribution over the entire

© PhoenixTM GmbH

manufacturers. Especially in the coating industry, there are also more

The standard FIS04 temperature measuring system.

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N. 86 - MARCH/APRIL 2024 - international PAINT&COATING magazine

ANALYSIS

process. The data obtained in this way are stored in the data logger. This

understandable and comparable as a numerical factor. The curing of the

is protected from the temperatures prevailing in the oven by a thermal

coating is dependent on both time and temperature. For this reason,

barrier. At the end of the process, the data logger is removed and read

paint and powder manufacturers specify recipes or curing charts

out. With the help of the ThermalView finishing software, the raw data

according to which the paint should be baked in order to achieve a good

is converted into meaningful process data. With this information, quick

quality result. This recipe is stored in the software as a ‘time at a certain

and well-founded decisions can be made to solve baking problems.

temperature’ curve.

The measurement results are available as a complete temperature

If we look at these curves taking into account separate firing windows,

profile at a glance and can be used, for example, for process or product

we find that the time at 180 °C is identical for both curves, although

optimisation, customer audits, reduction of operating costs, saving of

the curves are in fact very different. If we take these curves and analyse

resources and much more.

them as they are against the specifications, we must conclude that undercuring has occurred here. Time at 180 °C for only 7 minutes,

ThermalView Finishing Software

instead of the specified 12 min (Table 1).

This software has been specially developed for the coating industry

But how to analyse the holistic nature of the results? The application of

and is an easy-to-use tool. The entire oven process is displayed using

mathematics allows the exact calculation of the curing of lacquers or

detailed graphical data. For example, the heat source and fan positions

powders including all curves in the temperature profile. The Arrhenius

can be stored so that problem areas can be located quickly. The

equation, named after its inventor Svante Arrhenius, describes

possibility to store cure chart and their factorisation on the basis of

approximately a quantitative temperature dependence in physical and

user-defined specifications shows at a glance whether all measuring

chemical processes in which an activation energy (here the transition to

points are within the specifications. Profile comparisons with other

cross-linking) must be overcome at the molecular level. For coating, it is

measurements are also possible. A standard report shows all relevant

assumed that the frequency factor (k) refers to the reaction temperature

information and a graph. Subsequently, various detailed evaluation

at which A and E both constantly cause cross-linking.

reports can be created.

In relation to the temperature curve, this means that a reference curve is created using three temperature points specified by the coating

Phoenix Factor

manufacturer in order to determine the values between the points

The Phoenix Factor as a curing index is the exact calculation of the paint

by interpolation (Table 2). In this way, the required curing time at any

or powder coating process by means of temperature profiles including

temperature is calculated for each measuring point. Then, taking into

the cross-linking temperature with the aim of presenting the result easily

account the total curing time, the total equivalent of the curve at a given

© PhoenixTM GmbH

Screenshot from the new ThermalView finishing software.

international PAINT&COATING magazine - MARCH/APRIL 2024 - N. 86

163

SPECIAL ISSUE - PaintExpo

© PhoenixTM GmbH

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 © PhoenixTM GmbH

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.

© PhoenixTM GmbH

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.

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N. 86 - MARCH/APRIL 2024 - international PAINT&COATING magazine

ANALYSIS

TWO PROS WITH TRADITION Dual expertise for the perfect surface

Profile splitting for more flexibility

logger. The resulting Epsilon series is intended to

For example, a car body passes through four ovens

meet the requirements of the ATEX regulations

to finish the paint. With the PhoenixTM FIS04 system,

(ATmosphere EXplosive = Explosive Atmospheres).

all ovens can be recorded in one run and with one

Since the last amendment in 2015, these have

measurement. This means that the test car body is

been transferred from the BetrSichV (Ordinance

prepared once and automatically passes through

on Industrial Safety and Health) to the GefStoffV

all areas. This makes the measurement effort much

(Ordinance on Hazardous Substances)

easier and more accurate, as measurements are

In the course of this transition, various new

truer to the process. If the ovens are measured

requirements were added to the regulations, which

individually, there is undesired cooling on the

must now be taken into account. In order to be able

body each time, which can affect the final result.

to offer legal certainty to those responsible in the

Afterwards, the measurements can be split to make

company, PhoenixTM has further developed the data

detailed statements and add separate process

logger and the associated components so that they

parameters.

comply with the valid ATEX approvals according to Directive 99/92/EC (or ATEX 137). It has been certified

Current zone temperatures

accordingly and is approved for Ex zone 2. This is

The ability to include target and actual temperatures

particularly important for wet painting systems, as

in the analysis means that deviations from these can

the paints are outgassed during the curing process

be quickly identified and rectified. By including these

and, depending on the recipe, explosive gases can

in the evaluations, the auditor can be provided with a

be produced.

Hall 2 Booth 2410

comprehensive picture of the drying process and its parameters.

The Optic System With the optical system, PhoenixTM has added

New coating and process library

another effective tool to optimise process control to

In addition to the proven features, the default

the product family. Optical checks usually take place

variants for the evaluation as well as the Phoenix

after the drying process. Defective products are then

Factor and the curing charts have been added. The

sorted out or reworked at great expense. PhoenixTM

process library makes it possible to archive the

has now expanded its existing portfolio for in-

various firing processes with the respective furnace

process temperature monitoring in paint dryers with

settings.

the new optical monitoring system. This is used by the technician to view the interior of the oven as well

Cold junction temperature

as the product under production conditions. Like

As an additional safety feature for the proper

the temperature measurement system, the system

operation of the data logger, it is now possible

travels directly through the process and videotapes

to display the temperature curve for the cold

the entire process as it passes through the oven,

junction sensor. This shows the internal operating

providing a complete picture of the paint drying

temperature of the data logger in a separate graph.

process.

In this way, the user can see at a glance whether the

In paint drying processes, so-called paint noses,

data logger has been used reliably.

drops or similar can occur from time to time, which represent a quality defect. The causes are known,

Focus on operational safety

for example, fans or burners generate air currents

The focus of the considerations was to create

that can push up the still moist paint or the melted

a device that meets the strict requirements of

powder. But it is not always easy to find out where

explosion protection at the workplace according

and when these arise in the dryer. The new optical

to the latest EU standards. The basis for further

system now makes this possible directly in the

development here is the proven PTM1-200 data

process, in which a camera travels through the oven

We system are provid for po er wd and li er coating quid c s oating s

Zwei Unternehmen der

SPECIAL ISSUE - PaintExpo

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 © PhoenixTM GmbH

light source is designed to withstand the The ATEX-compliant Epsilon system.

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.

© PhoenixTM GmbH

The optical system with data logger.

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BRAND-NEW

SPECIAL ISSUE - PaintExpo

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. further enhance the inherent performance

- Excellent coverage and powder performance

advantages of the system. POLIFLUID®

with less micron even on problematic areas as

produces inert, anhydrous and clean fluid

weld joints;

carrier and enables constant humidity

- Improved control of electro-static charge with

and temperature values: two previously

reduction of the Faraday Cage effect;

uncontrolled variables.

- Quicker colour switch;

The application conditions can therefore be

- Increase of production line speed from 10 to

controlled and consistent all day long and

20%.

through all seasons. POLIFLUID is installed

 Quality

between the air compressor and the powder

- Uniform thickness and colour with excellent

coating application point.

appearance;

It does not replace users’ existing equipment

- Improved finish due to better lay down of

but operates with it for the application cycles,

coating material;

feeding:

- Less finishing defects, such as orange peel,

 electro-static application (so called

blistering, blushing;

“Corona”);

- Lower speed and powder volume at the gun

 tribe static application;

output.

 fluidizer bed.

 Environment and safety

© Eurosider

®

Various kinds of powder coatings can be used

- Improvement of working environment

with POLIFLUID :

conditions with cleaner booths;

 effect powders;

- Less stress for workers due to constant and

 metallic powders;

repeatable conditions of application;

 pearled powders.

- Increase of safety level in terms of fire

®

W

hen installed on powder coating

prevention.

lines with cyclone system, even

The advantages of POLIFLUID

®

with 99% of powder recovery,

POLIFLUID® guarantees a significant increase

 Economic aspect

Eurosider will exhibit at PaintExpo, hall 2,

of transfer efficiency and higher performance,

- 20-30% overage savings of coating materials;

stand no. 2528.

expressed in m2/kg of powder used. The

- Improved transfer efficiency of powder

Return on Investment (ROI) is calculated to

coating;

For further information: https://eurosider.com/en/

be from 6 to 8 months averagely. POLIFLUID

- Improved yield;

concentrates the nitrogen contained in

- Optimization of all application technical

compressed air through the principle of

parameters.

selective permeation and uses it as a fluid

 Productivity

carrier during all stages of powder application.

- Higher fluidity of powder during the

The temperature control of the fluid carrier

application, leading to better reach of difficult

and the positive or negative ionization

areas (as corners or edges);

®

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BRAND-NEW

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.

A

Efficient and reliable solutions for surface coating since 1988.

LIT 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

electrostatic systems for liquid painting

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.

electrostatic systems and spraying booths for powder coating

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.

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

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

For further information: www.alit-tech.com IR and UV drying systems

© TIMECORE

robot and reciprocators

CM SPRAY s.r.l. eosmarketing.it

www.cmspray.it

BRAND-NEW

SPECIAL ISSUE - PaintExpo

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.

A

NODIKIT® Zone is a new compact

very high, such as order changes, small colour

patented elements, is the rotative frame used

anodizing line that was developed

runs, or overnight orders. The key element

that, with its movement, allows that all profile

by Alsan as an affordable solution

that differentiates this line from traditional

faces can receive a homogenous application

to all those companies reluctant to install a

ones is that surface finishing is achieved

throughout the different treatment stages. The

traditional anodizing line in their factories

by means of a spraying system. In fact, this

loading system is completely different from

while also meeting all Qualanod quality

is what makes it possible to “compact” the

that of a traditional anodising system, because

requirements.

process and reduce the space required for

the finishing product is sprayed during almost

This installation only requires 200-250 m2 of

the line, that is, the number of tanks required

the entire process in order to achieve the

space because of its revolutionary concept

as well as their volume. This means that

same finishing quality as a standard plant.

and is completely made of plastic and glass

ANODIKIT® Zone concept saves a minimum of

Line automation is controlled by AluZone

fibre. With just 4 tanks, for natural version, it

six tanks for pretreatment stages which are all

software, which continuously and

is designed to provide high service quality and

done in just one tank. Another key difference

automatically collects more than 200 variables,

cope with production rhythms that are not

with traditional lines, and also one of Alsan’s

controlling all required parameters. The concept for this compact anodising plant, unique in the world and patented in 2020 by

© Alsan Alvarez Schaer

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/

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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.

A

t Carlisle Fluid Technologies the team is always supporting customers through products and services. The laboratory in Bournemouth, United Kingdom offers the latest technology

Sustainable

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

Economically

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.

Close to the customer

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

Sustainable and economical System coating solutions from one source!

Hall 1 | Booth 1420

www.freilacke.com

BRAND-NEW

SPECIAL ISSUE - PaintExpo

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.

C

hemtec, 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: © Chemtec

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www.chemtecitalia.it/en/

Scopri la nostra storia - Discover our story.

www.savimeurope.com Paint Expo : Hall 3 Stand 3324

Via Venezia, 2 Arbizzano (VR) – Italy +39 045 7514099 - info@savimeurope.com

Your Technological Partner

HIGHLIGHT OF THE MONTH

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.

F

or a company, its 40th anniversary is an opportunity to be grateful

employees, and its customers, reaffirming the value of its presence in

and recognise the path taken and the challenges overcome,

the industry and its commitment to the future.

reflecting on the importance of consistency, innovation, and

In 1984, a small business was founded in the province of Treviso (Italy),

commitment to achieving lasting results on the market. Celebrating

destined to become a benchmark supplier in the industrial automation

this milestone also strengthens the bond among the company, its

and surface treatment sectors: D.B.M. Tecnologie.

D.B.M. Tecnologie specialises in designing, constructing, and installing industrial cleaning and coating equipment. © D.B.M. Tecnologie

HIGHLIGHT OF THE MONTH

The first 40 years of activity and the D.B.M. Group

© D.B.M. Tecnologie

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,

D.B.M. Tecnologie’s headquarters in Casale sul Sile, Treviso (Italy).

automotive, fashion, electronics, aerospace, and medical, and conquer important markets

 limited overall space required;

in Europe, South America, and Asia-Pacific.

“In order to meet the needs of the surface

Spray booths

 automatic painting system.

treatment industry, D.B.M. Tecnologie has

The coating booths produced by D.B.M.

The VAA series system feature:

gathered a pool of companies that work in

are the result of years of experience in the

 front loading of the frames;

synergy to provide a comprehensive, reliable,

surface treatment industry. “Thanks to this

 automatic protection system of the frame

and accurate service from a single source,”

consolidated experience, we are able to offer

holding points;

explains Alessandro Mattiuzzo, Technical

booths that stand out for their high degree

 automatic painting system.

Sales Specialist.

of efficiency and reliability. Designed to meet

Both systems are managed by a PLC that

The D.B.M. Group is composed of the

the needs of small and medium productions,

allows the operator to select the most suitable

following divisions:

the booths are equipped with advanced

painting cycle for the specific needs, as well

 D.B.M. Tecnologie S.r.l., specialising in the

technical features that make them essential

as to set the translation speed of the painting

design and construction of industrial plants;

for a modern paint-spraying department.

unit and the number of turns of the piece-

 E-CHEM S.r.l., the chemical division involved

One of the main strengths of our product

holder frame (through electronic governor

in the formulation and supply of chemicals,

is the innovative four-stage coating removal

with agent display on inverter).

equipped with a laboratory and a test room.

system. It not only ensures high efficiency in

“Our company, which now employs over 60

the painting process but also ensures strict

Dip-coating e flow-coating systems

people, manages every process in-house,

compliance with emission limits. Furthermore,

Designed to meet the requirements of coating

guaranteeing a complete service from sales

all components used are ATEX certified,

processes that demand high quality and

to after-sales assistance. This enables us to

ensuring maximum safety in potentially

productivity, D.B.M.’s systems are tailored

monitor each process phase and guarantee

explosive environments”, emphasizes

based on the customer’s needs, from pre-

high quality standards and reliable customer

Alessandro Mattiuzzo.

treatment to the curing phase.

For the pre-treatment, the solutions

service,” indicates Nicoletta Mattiuzzo, Automatic painting systems

offered by the company include degreasing

“Our painting systems are engineered

and phospho-degreasing, rinsing and

maintaining all the innovative features of our

demineralized rinsing with dedicated

paint-spray booths and are integrated with

treatment, as well as chemical surface

The D.B.M. Tecnologie division offers a wide

automatisms that allow to obtain the ideal

conversion applications such as phosphatizing,

range of standard and custom-designed

painting even on extremely difficult pieces”,

etching, and passivation. As regards the

advanced surface treatment technologies to

affirms Mattiuzzo.

coating application phase, the systems allow

meet any requirement. The solutions that

The DAV/1 series systems feature:

different processes to be carried out including:

D.B.M. offers to the industrial coating sector

 top loading of the frames;

 immersion painting or lacquering (Dip-

include as follows:

 automatic protection system of the frame

coating) with tank movement with controlled

holding points;

speed and guaranteed stability;

Operations Planning Manager.

Overview of industrial coating solutions

international PAINT&COATING magazine - MARCH/APRIL 2024 - N. 86

175

 flow coating painting or lacquering with single or multiple nozzles applied to

engineers’ experience and the use of innovative IT systems, we

one or more robotic arms with flow control and total programming flexibility;

develop state-of-the-art systems that meet the highest quality

 paint treatment systems with temperature regulation and automatic mixing.

standards. The fact that we handle every order completely

The cycle concludes with the curing phase, for which D.B.M. provides flashing

in-house ensures a high degree of mechanical and electrical

and curing zones with automatically regulated temperature and controlled

specialisation, while our after-sales assistance service offers

humidity.

extensive documentation and highly specialised staff to

“The movement systems are customized based on the production needs of

guarantee the high efficiency and durability of the supplied

the project and can develop on one or more transport lines with centering and

equipment,” adds Mattiuzzo.

translation devices especially studied for a better positioning of the pieces,

D.B.M.’s management takes pride in emphasising that the

improving the high quality of the result”, concludes Mattiuzzo.

company’s policy is not to think in terms of figures but rather to direct its efforts towards customer loyalty. “Offering high-

Drying and curing ovens

quality assistance at all stages of the process with a consultative

As a corollary to the coating systems, DBM offers a series of static and

approach enables us to make customer satisfaction a

automatic ovens designed to meet the demands for flash-off, distension, drying

cornerstone of our work,” states Nicoletta Mattiuzzo.

and curing options. series, designed to rotate 12 piece-holder frames, and the static ovens of the

Evolution and continuity: the new corporate image

FS series (for drying pieces inserted using trolleys) and the P series (equipped

“On the occasion of D.B.M. Tecnologie’s 40th anniversary, we

with grid trays), we have developed automatic lines both for the drying of pieces

are excited to present our new corporate identity, including a

on a rotating frame and for applications that reach actual heat treatment, with

revamped logo and a completely new website,” says Alessandro

controlled temperature, ramps and thermally differentiated zones”.

Mattiuzzo. This significant decision aims to keep up with current

“Alongside standard products such as the flash-off stations of the SAR 16/12

graphic trends while maintaining a link with the past.

The advantages of turning to an all-round technology partner

“The new logo features a minimal, modern font while still

D.B.M. Tecnologie stands out in the market as a hi-tech partner that can

including the arrow symbol that has always distinguished us in

support its customers from the design to the after-sales phase. “Thanks to our

the market.” To celebrate this important milestone, the company has also recently launched a website to offer a better user experience by facilitating access to information on products and services. “In these forty years, D.B.M. has consolidated its position in the market by establishing itself as a benchmark

© D.B.M. Tecnologie

supplier in the surface treatment sector. Our ability to adapt to changing market needs, together with our dedication to our customers and service quality, makes us a reliable and trusted partner for companies worldwide,” states Mattiuzzo.

The automatic oven FAM 180.

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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

ROBOTISED PAINTING SYSTEMS

STANDARD AND CUSTOMISED RECIPROCATORS

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.

ASSOCIATED

www.hubo.it

AUTOMATIC FEEDING SYSTEMS FOR PAINTING PLANTS

HIGHLIGHT OF THE MONTH

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.

H

oneywell is a trusted name in the specialty additives industry,

finish, improve abrasion resistance and offer better slip control. Its

providing innovative solutions for over sixty years. Its experts

low molecular weight and micronised polyethylene polymer and

are dedicated to creating performance-driven solutions that

copolymer additives are perfect for achieving the desired performance in formulations.

Whether it is paints, coatings, inks, adhesives or colour master batches,

The company takes pride in being pioneers of innovative additive

its additives offer performance benefits that are unmatched.

solutions for the paints and coatings industry. Its team of experts and

Its synthetic waxes have been formulated to provide a deeper matte

R&D scientists are committed to helping improve the performance of

© AdobeStock

seamlessly integrate into the workflow and offerings of the customers.

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HIGHLIGHT OF THE MONTH

formulations with its vast range of offerings, including A-C®, AClyn®,

Explore a range of customizable solutions. Try to scuff our walls at ACS

Acumist®, NduroMatt™ and Cohesa® performance additives. Its synthetic

2024 and enter an exciting lucky-draw! We are waiting for you at booth

waxes are designed to influence many critical surface properties,

2454 at ACS 2024 which will be held from April 30 to May 2, 2024 at the

including mar resistance, abrasion resistance, improving slip, matting,

Indiana Convention Center, Indianapolis, USA.

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

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

Come over for a first-hand experience of NduroMatt™ at BOOTH 2454

burnish mar, and scratches, which can compromise the longevity and

to understand how our additives enhance surface properties. Meet

durability of the surface.

with the expert team behind our high-performance additives portfolio

The NduroMatt™ multi-functional additives are a game-changer in this

and talk to us about your unique paints/coatings and additives needs.

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.

international PAINT&COATING magazine - MARCH/APRIL 2024 - N. 86

179

© Getty Images

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 © Getty Images

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!

180 N. 86 - MARCH/APRIL 2024 - international PAINT&COATING magazine

Since 1964

s i l v i srl.it info@silvisrl.it

design and manufacture of complete lines for painting, e-coat, cleaning and thermal stripping

© Stardust

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.

S

and distributing powder coatings, founded in 2007 in L’Aquila

Customisation and small batches: the hallmark of Stardust Powder Coatings

(Italy). In just a few years, it has developed such a know-how and

Since the beginning, the company has chosen to work on order,

tardust Powder Coatings is a company specialising in producing

expertise that it has become an established player on the national and

offering tailor-made solutions according to customer requirements.

international scene. By focusing on the relentless pursuit of ever-higher

This strategy has always proved effective because, especially in an era

standards of excellence, this company has grown more and more, and

when customers prefer to order smaller batches due to the economic

now it provides its customers with the highest level of coating aesthetics,

situation, being able to supply volumes from 25 kg upwards means

resistance, durability, and efficiency.

responding to this precise need to limit large orders.

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HIGHLIGHT OF THE MONTH

the rare exceptions when customers order

The challenge of handling large batches won by Stardust Powder Coatings

certain products repetitively and we thus keep

Stardust Powder Coatings finds itself on a path

stocks accordingly,” says Guido Pozzoli, the

of continuous development, so much so that

CEO of Stardust Powder Coatings. In other

from January 2024 to date, it has grown by

words, this company has always offered hyper-

20% compared to last year. This has enabled

customised services, enabling customers to

it to become more and more structured and,

rely on it even to produce batches of paint

therefore, also able to meet the needs of

intended to “test the waters”: if the product

companies requiring larger product batches.

takes off, they can then manufacture larger

“High production volumes, which are much

amounts, whereas in all other cases, the small

more economically viable for a powder coating

quantities produced remain only colour proofs

manufacturer, are nothing new in our industry.

that are never marketed in large volumes.

In this case, the actual advantage Stardust

“For Stardust, this flexibility has always been

offers is production to order, in ultra-fast

a strength, a way to distinguish itself as

times,” says the company’s CEO. Guido Pozzoli

a partner capable of meeting the unique

tells us that a couple of years ago, when the

demands of every customer. Even at a time

market was going through some less than

that we can consider “of crisis”, this ability of

rosy developments due to the difficulties in

ours to handle small-volume orders promptly

sourcing materials, Stardust could still support

affordable prices despite the high production

has been our trump card, as well as an

customers needing to receive large quantities

costs, machines tooling expenses, and the

opportunity, since such flexibility enables us to

of paint in a short time. “At that point and

high costs of controlling coating’s stability and

offer something difficult to find on the market:

seeing such a rise in demand, we were

finish. In addition to these costs, higher logistic

speed, customisation, and the production of

certainly tempted to focus our energies on

fees must also be added, with an increase

small batches,” notes Guido Pozzoli. “Stardust’s

producing large batches alone, since working

of 4 times compared to the pallet costs.

adaptability also counteracts a phenomenon

with high volumes has a much lower cost.

Precisely to absorb these costs, Stardust has

that is occurring increasingly in this sector:

However, when analysing Stardust’s identity as

developed in recent years a series of complex

very often, customers are forced to purchase

a supplier that has always been committed to

management systems, as well as advanced

huge quantities of product that far exceed

tailor-made production and meeting customer

computerized automation and process control

their actual needs and end up being disposed

needs from the very beginning of its activity,

tools, through which it has succeeded in the

of, causing environmental and economic

we realised how important it was to maintain

challenge of not only containing the high costs

damage.”

this distinctive trait,” states the company’s

of small batches, but also positioning itself as a

CEO. From an economic point of view,

valid alternative in the production of medium

Stardust presents itself as a supplier that can

and large batches.

“Over the years, we have structured our business to work only on order, apart from

© Stardust

Guido Pozzoli, CEO of Stardust

provide small batches of powder coatings at

#GENTLE #PROCESS-SAFE #EXHAUST-FREE #EFFICIENT #GOVERNMENT SUB SIDISED

HOW TO DRY PERFECTLY AND SAVE UP TO 75 % ENERGY! PaintExpo

April 9 – 12, 2024 | Tr a d e F a i r K a r l s r u h e

Hall 3 | Stand 3541

© Stardust

Investment and growth for continued expansion

example, we purchased a new process line that will allow us to produce

In short, this company has reached maturity and set up a hybrid strategy

large batches even faster and thus be even more competitive. In

to achieve excellent performance with both small and medium-large

addition, the number of employees has grown significantly to 20 within

batches. “This growth, which results from huge investments and the

a two-years period,” illustrates Pozzoli. In this regard, he explains that

hard work done every day with commitment and dedication, means that

the reorganisation of human resources has played a central role in the

we are now a credible and trustworthy partner that all companies can

company’s development: “In the last few years, Stardust has invested

rely on for orders of any size.

not only in equipment and tangible assets but also in everything

In such a highly fragmented market, Stardust is still known as a small

that contributes to its actual functioning, making it come alive. All

company, specialised in the production of small batches. However,

departments, from logistics to production and administration, must

we believe that the time has come to make our true potential known

be perfectly synchronised to ensure efficiency and speed. To offer an

to the market, confidently asserting that we are one of the few

excellent service even with large stocks, we therefore had to analyse the

companies capable of handling even very large orders with the same

difficulties of some departments that were understaffed and take action

skills, meticulousness, and speed devoted to small volumes,” says

by hiring new employees and training them: it was a long and complex

Pozzoli. As mentioned, this growth has only been possible thanks to

process that, however, is ensuring and will ensure excellent results.”

the investments made over the past five years. Stardust has invested

Stardust, therefore, has decided to evolve in two specific directions,

considerable economic resources in acquiring and renovating its

ensuring the well-known craftsmanship of its “haute couture” products

premises, purchasing new technology and lab devices – not only

on both small and medium-large batches. In any case, be it with massive

machinery but also automation and process control systems and

volumes or smaller quantities, today Stardust is well positioned in the

software to govern this complexity – and hiring new employees.

market, responding to many customers’ need to rely not on a mere

“Although we are still planning more, we have already made many

powder coating manufacturer but on an all-round reliable partner with

investments that have affected the company’s entire operation. For

which to work consistently, synergically, and understandingly.

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SMALL PARTS COATING

SYSTEM SCAN ME World’s Leading Trade Fair for Industrial Coating Technology 9 - 12 April 2024, Exhibition Centre Karlsruhe We exhibit!

Hall 1

Stand 1330

Tel. +39 0432 908578 www.imelspa.com - info@imelspa.com Via Divisione Julia 10, 33033 Codroipo, UD - Italy

HIGHLIGHT OF THE MONTH

SPECIAL ISSUE - PaintExpo

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.

S

panesi is the ideal partner for the design and production of

Listening carefully to its customers’ needs, implementing the latest

coating systems for various sectors, from general industry to

technologies in terms of sustainability with the utmost attention to

aerospace, shipbuilding, and transport. One of its distinguishing

consumption and environmental impact, and providing its workforce

features is the ability to produce tailor-made plants by addressing

with a clean and ergonomic environment are the keys to the success

and solving problems in all application areas to consistently deliver

of this company and its customers as well. Both its in-house processes

customised, high-performance products.

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. © Spanesi S.p.A

HIGHLIGHT OF THE MONTH

the cornerstones that distinguishes its brand. Quality, innovation,

request that Spanesi be the sole interlocutor and equipment supplier,

meticulous attention to detail, refined design, and turnkey projects are

the 2000s were characterised by the introduction of coating booths

the hallmarks of Spanesi’s offer, making it unique and recognisable

and preparation areas in its equipment range. This entailed opening

worldwide.

an entire dedicated production department and an engineering department set up to design these systems since, from the outset,

History and identity

Spanesi’s approach has been based on supplying totally customised

Spanesi S.p.A.’s current identity is rooted in the past, shaped by

plants that fully meet its customers’ requirements and needs.

experience in the automotive field since its founder started out as a

This combination of product customisation and system reliability

small independent body shop mechanic in the province of Padua. Driven

gradually attracted the attention of players specialising in sectors

by curiosity and by the awareness that the market was not meeting the

outside the automotive field. That is why the company began to

needs of automobile repair shops and, above all, was not in step with

produce equipment for the wood industry, the coating industry in

the times and with the technological evolutions occurring in the sector,

general, the marine and aerospace sectors, and even the transport

he decided to start the industrial processes required for producing

sector with coating booths for trucks, trains, and buses of all kinds.

Spanesi-branded equipment, with the extraordinary peculiarity of being

Today, Spanesi is present with its products in every corner of the

its first user himself.

globe, thanks to its subsidiaries both in Europe and in America and

Keeping his own garage operational, Orazio Spanesi then began to

Asia and an extensive distribution network, meticulously developed to

collect feedback, listen more and more to other body shops, and

provide advice and assistance and meet the needs of each individual

participate in international trade fairs explaining his philosophy, and

user.

he soon gained worldwide recognition as a technical leader in the

The motto of the company’s founder, Orazio Spanesi, is: “It does not

automotive after-sales sector. Thanks to his company’s success and the

matter where you start. To go far, you need a dream to fight for with

quality of its products, which prompted a wide distribution network to

all your might.” And Spanesi S.p.A. fully reflects this.

© Spanesi S.p.A

General view of the production site.

international PAINT&COATING magazine - MARCH/APRIL 2024 - N. 86

187

SPECIAL ISSUE - PaintExpo

© Spanesi S.p.A

A detail of a processing phase taking place within Spanesi’s production department.

How Spanesi operates

The production plant

Every project is a story in itself. Plant dimensions, customer

The technical office carrying out the design operations and the factory

requirements, regulations, and production needs can be the most

devoted to the machines’ production are adjoining and cover a total

diverse. Therefore, collecting information is always the first step, with on-

area of 3000 m2. This allows for maximum cooperation and control

site visits and the assessment of regulations and environmental factors.

between the design and manufacturing phases, as well as a significant

Once the analysis process has been completed, the designers’ team

reduction in lead times. This area is equipped with state-of-the-

reproduces in 3D the factory hall accommodating the new coating plant,

art software and machinery. The production process is, therefore,

with two different approaches.

characterised by a high degree of automation, which makes the daily

The first concerns the project’s details: every internal and external

work for Spanesi’s employees light and fast and significantly reduces the

dimension of each element is included to the millimetre in the 3D layout,

time required to complete each project.

thus ensuring extreme precision both in the initial phase and in the

The quality of the products and of the pre-delivery stages is enhanced

subsequent installation phase. The second approach is creating a 3D

by this combination of technology and human expertise and

virtual tour, in which the customers can “immerse” themselves in the

subsequently reflected in the installation stages, where maximum

new plant to realistically visualise the expected final result and make any

precision is guaranteed – an essential factor, especially in particularly

adjustments according to their organisational needs and, why not, their

narrow locations or with uniquely complex projects. All these processes

tastes. Once full customer satisfaction, high energy efficiency, and low

make Spanesi’s products and services of excellent quality, reliability, and

environmental impact have been achieved, the plant’s production can

durability.

begin.

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).

188 N. 86 - MARCH/APRIL 2024 - international PAINT&COATING magazine

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.

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

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GENTLE

BRAND-NEW

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.

T

he multinational Henkel has launched

These systems must adhere to the highest

Loctite Stycast CC 8555 offers good

Loctite Stycast CC 8555, a coating

reliability and safety standards; protecting

resistance to adverse weather conditions,

designed to protect electronic

electronics is vital to their dependable

such as humidity, gas mixtures and various

components in extreme environments.

function and longevity. Conformal coatings

chemicals. In addition, it has a relative

As a matter of fact, the new solution can

are the go-to protective material for nearly all

temperature rating of 130°C per UL 746E

safeguard the printed circuit boards (PCBs)

PCBs used in power electronics, and Henkel’s

standard, a UL 94 V0 flammability rating

and sensitive components in demanding,

latest formulation rises above. It delivers

and meets IPC-CC-830 requirements. This

high-power applications, such as motor

on the reliability requirements foremost,

solution is essential for protecting industrial

drives, PLCs, electric vehicle charging

but is also easy to use, cost-effective, and

equipment, power conversion systems and

infrastructure, AC/DC power supplies and

lower-impact material. Loctite Stycast CC

alternative energy infrastructures, which need

other high-voltage electronic devices.

8555 covers all the bases and then some,”

to be reliable and durable.

“High-power electronics are integral to

has stated Justin Kolbe Director of Market

“Loctite Stycast CC 8555’s VOC- and

industrial manufacturing, human mobility

Strategy for Power and Industrial Automation

solvent-free formulation answers the call

and comfort, and global energy production.

at Henkel.

for environmental concerns and provides significantly lower cost from a surface area

© Henkel

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

190 N. 86 - MARCH/APRIL 2024 - international PAINT&COATING magazine

BRAND-NEW

SPECIAL ISSUE - PaintExpo

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. © BYK

T

he 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 Don’t hesitate to join us if you think this will be your future

Tel. +(34) 936 305 050 - spray@spray-sa.com - www.spray-sa.com

BRAND-NEW

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.

T

he powder coatings supplier IFS Coatings has recently launched

as fence wire weaving, that also require excellent abrasion resistance. It

IFS Puroplaz PE16, a durable thermoplastic modified polyolefin

can be used to replace nylon coatings in certain applications,” has stated

powder coating, which offers flexibility and good adhesion

Tim Brinner, Vice-President of Thermoplastics at IFS Coatings.

properties. In addition, this new technology offers a Shore D hardness

Puroplaz PE16 can be used for several applications, including woven

of 60 and excellent gravimetric performance as well as exceptional

wire fences, fence posts, waste bins, agricultural tools, automotive

resistance to impacts and abrasion.

components and pipelines. It is also available in both spray and dip

“This PE16 formula has a rare combination of hardness and flexibility.

formulations and is made without the use of PVC and BPA.

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

For further information: www.ifscoatings.com

© IFS Coatings

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IP

BRAND-NEW

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.

A

LTANA 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.

PCM int - Verind - 8 mm Schnitt For further information:

www.altana.com/divisions/eckart.html

Visit us at

PaintExpo Booth

3320

Painting for all industries

Bringing your surface to perfection.

Dürr offers painting solutions from manual to automatic application, high-quality and easy to integrate. www.verind.it

© Siberline Group

BRAND-NEW

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.

T

IMCD Group Acquired ResChem The acquisition of ResChem will allow IMCD to strengthen its market position in the paints and coatings market in Oceania.

T

he 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

he international chemicals and ingredients distributor Brenntag

and New Zealand with the advancement of innovative and sustainable

has recently announced it will acquire Solventis Group, a glycols

solutions. With the joining of ResChem, we can leverage their

and solvents distribution company. This acquisition will provide

complementary portfolio and technical capabilities to further develop

Brenntag access to the Port of Antwerp (Belgium), a major chemical hub

our footprint in the local markets,” has stated Frank Schneider, Global

in the EMEA region – thus strengthening its presence in the European

Business Group Director for Coatings & Construction at IMCD.

chemicals market.

“This is a wonderful opportunity for our employees to join a leading

“Brenntag Essentials combines a cost-efficient network of last mile

multinational company and the opportunities for advancement it

service operations with regional sourcing and supply chain services,

provides. We will continue to provide and improve the high level

and global sourcing. Solventis Group is a highly compatible fit to our

of service they are used to from ResChem for our customers and

strategy, adding tollgate capabilities and volume optionality via their

suppliers,” has added Bruce Forder, Managing Director of ResChem

Antwerp state-of-the-art site to our regional capacities, while opening

Technologies.

interregional optimisation potential. The acquisition will support our integration with increasingly global supply markets while strengthening

For further information: www.imcdgroup.com

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

For further information: https://corporate.brenntag.com

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EVOLUTION TO E-MOBILITY C O AT I N G

I M P R E G N AT I O N

CLEANING

Our 70 years experience in Surface Treatment is ready for the E-Mobility market.

Research, innovation, development.

In 70 years, our vision towards the future has never stopped.

Today, Tecnofirma provides quality to the electric market which is the most evolving technology in the automotive industry.

Our impregnation, cleaning and painting plants are the result of the constant commitment to offer cutting-edge solutions and products anytime, anywhere.

TECNOFIRMA SpA - V.le Elvezia, 35 - 20900 Monza (MB) - Tel. +39 039.23601 - Fax +39 039.324283 - tecnofirma@tecnofirma.com - www.tecnofirma.com

ASK JOE POWDER

The “Ask an Expert” Column Kevin Biller

kbiller@chemquest.com

Joe,

iron or zinc phosphate process to provide a surface more amenable to

I don’t know if you have covered this before. We notice that the

adhesion of a cured powder. A third option is physically abrading the

cured powder does not stick readily to edges that have been cut

edges. This can be accomplished either automatically (blasting or wheel

by a laser. What are the causes of this and what can be done to

abrading) or manually. If you opt for a blasting process, it is imperative

overcome the adhesion issues?

to keep your media clean; otherwise, you can contaminate the surface

Thank you,

you are attempting to clean. ScotchBrite® pads or wheels work well but

Brian Gurney

require additional labour. Keep in mind that these extra steps can be

Sidney, New South Wales

cost-prohibitive. I hope this helps.

All the best,

Hi Brian,

Joe

Indeed, we have not covered this one yet. Cutting steel with a laser offers many advantages, including precision, speed, less rejects, and low

Hey Joe,

labour costs. However, one of the problems inherent to laser cutting is

We powder coat formed wire products made from 1008/1010

the blue oxide edge it leaves on carbon steel. Powder coatings don’t like

grade steel. The powders are epoxy and polyester hybrid/

to adhere to this oxidised surface. Conventional iron or zinc phosphate

TGIC types. How long must we wait after cure to: [a] test for

does not adequately penetrate the oxide to provide adhesion of the

crosshatch adhesion and [b] before we do the MEK rub tests?

cured powder, resulting in a loss of adhesion and the potential for

If we recoat over a thin coat, will that affect the cure time,

serious corrosion problems.

affecting the same tests?

There are a few paths to compensate for this shortcoming. One is to

Thank you in advance,

employ a more aggressive pretreatment process. Using a strong acid

Norm Gajewski

etch prior to the phosphate stage can attack the oxide layer enough to

Angola, Indiana

allow the phosphate to do its thing.

Another option is to avoid creating the oxidation by using nitrogen in

Hey Norm,

the laser cutting process. It is more expensive than using oxygen, but it

First, let’s talk about the powder material types. It sounds like you may

minimises oxidation from the laser and therefore allows a conventional

be using two powders – a hybrid (epoxy-polyester) and a polyester-

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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

Engineering specialized in the supply of systems for surface treatment, painting and coating

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

E-COAT SYSTEMS

are performed? We test for a few parameters, for different customers, namely 96-192 hours to failure, sometimes over

LIQUID PAINTING SYSTEMS

a primer and sometimes over a double-pass topcoat.

Norm,

POWDER COATING SYSTEMS

A scribe into the coating should be done before the test panels/ parts are put on salt spray testing. We normally check for scribe

SELF-LEARNING ROBOTS FOR AUTOMATED PAINTING

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

SYSTEMS FOR THE TREATMENT OF VOCs EMISSIONS

UCIF Informs © AdobeStock

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

2

info@ucif.net

2 May marks the return of S.M.A.R.T. (Surface. Manufacturing.

practices, it is now reducing its environmental impact, improving energy

Advanced. Research. Trends.), the conference organised by

efficiency, and limiting polluting emissions. Innovation plays a crucial

UCIF (the Italian Surface Treatment Equipment Manufacturers’

role in pursuing such sustainability goals, reducing the investment and

Association), which has reached its third edition under the prestigious

operating costs of surface treatment plants. i4.0 solutions are making

patronage of the City of Milan, the Poliefun association, and the MADE

these systems more flexible, efficient, and safe, leading the industry

Competence Centre Industria 4.0.

towards a more sustainable future.

This year, the theme “The finishing of the future between innovation

The S.M.A.R.T. conference not only provides a platform for sharing

and sustainability” will be the focus of the eleven presentations given

experiences and innovative ideas but is also an opportunity to celebrate

by participating companies, exploring new technologies, interactions

the excellence of the Italian surface treatment industry globally. UCIF,

between machines and humans, and the importance of sustainability in

through its membership in ANIMA Confindustria Meccanica, is a point

manufacturing.

of reference for companies in this sector, with impressive figures

With its third edition of S.M.A.R.T., UCIF continues to be an important

confirming Italy’s leading role on the international scene.

point of reference in the surface treatment industry, offering a stage

S.M.A.R.T. 3 promises to be a unique opportunity to explore the new

for all companies that are driving innovation and sustainability – already

frontiers of innovation and sustainability in the surface finishing industry

with an eye to Industry 5.0, highlighting the importance of a human-

while joining forces to create a more sustainable and efficient world.

centred approach and technological progress.

The surface treatment sector has a considerable footprint on the environment and working conditions, making it a focal point for

Further information on the conference is available at www.smart-ucif.it

environmental regulations. Thanks to new technologies and sustainable

and the e-mail address info@ucif.net.

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© Evonik Coating Additives

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.

I

n the dynamic world of coatings, the continuous search for innovative

dispersion of aggregates and agglomerates, making optimal dispersion

solutions that streamline manufacturing processes and improve

of fumed silica one of the most technically challenging and time-

product performance is crucial. Evonik Coating Additives has

consuming steps in manufacturing coatings. Traditionally, a two-step

responded to this industry demand with its AEROSIL® Easy-to-Disperse

process is used: a pre-dispersion step using a dissolver to wet-in the

(E2D) product range: this advanced product line composed by four

powder and to break up large aggregates and agglomerates, followed

fumed silica-based additives is designed to significantly reduce the

by bead milling to achieve the desired dispersion quality. This process is

energy, time and costs associated with the dispersion process in coating

not only technically challenging, but also time and energy consuming.

formulations.

To address this, raw material manufacturers offer dispersions,

Fumed silica is a popular choice among coatings formulators for

preparations and pastes that have been optimised to disperse insoluble

rheology control. However, a persistent challenge has been the

solids (such as silica, pigments and fillers). However, these goods may

200 N. 86 - MARCH/APRIL 2024 - international PAINT&COATING magazine

ADVANCEMENTS

contain undefined amounts of solvents, water, binders or additives that

wide range of coatings, including wood, plastic, automotive and general

can significantly affect the finished coating system and are beyond the

industrial coatings. AEROSIL® E 972 is recommended for rheology

control of the formulator.

adjustment in a wide variety of formulations, while other silicas are tailored for specific applications – for example, AEROSIL® E 812 and

Eliminating one production step

AEROSIL® E 805 are especially suitable for automotive OEM and wood

“Our AEROSIL E2D is designed to be incorporated directly into coating

clearcoats, and AEROSIL® E 9200 is primarily used to improve durability,

systems without the need for extensive milling or high shear forces,”

such as scratch resistance.

®

stated Maximilian Cornelius, Head of Particle Design in the Research, Development & Innovation department at Evonik Coating Additives.

No need for formulation adjustments

“Thanks to this globally unique technology, our customers can now

“The viscosity curves at high and low shear rates are identical in the

perform wetting and dispersion processes in a single high-speed

key area of increasing viscosity, compared to the standard AEROSIL® R

dispersion step.”

grades” continued Cornelius. “This demonstrates another key advantage

This ease of incorporation is a game changer for coatings

of our AEROSIL® E2D products: it achieves the same level of efficiency

manufacturers, as it not only speeds up the production process, but

and optical characteristics, so manufacturers do not need to adjust

also minimises equipment wear and energy consumption. The result

existing formulations, and new formulations can be created using the

is a more sustainable and cost-effective operation that does not

same principles as previous coatings.”

compromise the quality or performance of the final coating product.

In addition, the AEROSIL® E2D versions of fumed silica are chemically

The AEROSIL E2D range is versatile, suitable for rheology control in

identical to the corresponding standard AEROSIL® products offered

both pigmented and clear coating formulations, and can be used in a

by Evonik Coating Additives. Using AEROSIL® E2D fumed silica reduces

®

AZ POWDER COATINGS

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© Evonik Coating Additives

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 Comparison of high shear milling and dissolver milling regarding time effort.

process. This environmental benefit can be quantified using the Cost Savings Calculator on

© Evonik Coating Additives

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 Milling processes for incorporation of fumed silica with high shear milling (left) and innovative dissolver milling (right).

process. With the innovation of AEROSIL® 2 E2D technology, Evonik has met this demand

© Evonik Coating Additives

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 between bead mill and use dissolver for 1% AEROSIL® for 1000 kg clear coating.

202 N. 86 - MARCH/APRIL 2024 - international PAINT&COATING magazine

A L M T EC H N O LO GY

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ROAD TO 2050

BASF Launched the GLASS Tool to Calculate CO2 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.

B

ASF has recently presented GLASS, an innovative tool that can

pre-treatment processes of the automotive industry – which accounts

provide a comprehensive life cycle analysis of the ecological

for more than 60% of all the energy employed in vehicle production at

footprint of the paint shops in automotive manufacturing plants

automotive factory. Through its new tool, the Coatings division of BASF

by calculating CO2 emissions and cost simulations.

will offer an analysis approach that enables transparency and support

goal for many industries and value chains, including the coating and

solutions.

© BASF

Reducing the ecological footprint towards CO2 neutrality is a significant

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customers in making informed decisions for sustainable surface

The GLASS (Global Life-cycle Assessment of

when applied,” has added Tim Banik, a lifecycle

Automotive Surface Solutions) tool analysis

assessment expert for BASF Coatings and

follows the cradle-to-grave approach, covering the

developer of GLASS.

entire value chain from raw material extraction

All information on products assessed with the

via pre-treatment to clearcoat as the final step of

footprint calculation method of BASF is available

the coating process. From this transparency, the

and usable in the GLASS tool. TÜV Rheinland

customers can then derive optimisations of costs,

has certified that the CO2 calculation method of

performances and ecological footprint.

the company and reporting of the cradle-to-gate

“A coating with its various layers of paint

Product Carbon Footprints fully comply with the

contributes approximately 30 kilogrammes of CO2

requirements of the Greenhouse Gas Protocol, the

per manufactured vehicle. However, the actual

DIN EN ISO 14040 and 14044 standards as well as

application process has a much larger impact,

Together for Sustainability (TfS).

accounting for at least 150 kg of CO2 per vehicle,

“We aim to lead the way in sustainability in our

which makes approximately one third of the vehicle

industry. Therefore, it is at the centre of all our

manufacturing process,” has explained Sabrina

actions. The positive feedback from the market

Platzek, the vice-president of Global Marketing

proves that this is the right way. That is why in the

Automotive OEM Coatings for BASF. “Therefore,

long term we are looking forward to offering GLASS

in addition to the product carbon footprint of the

not only to the automotive OEM coatings industry,

coating, it is important to make the footprint of the

but also to other application areas,” has concluded

coating process in the paint shop transparent – as

Markus Piepenbrink, the director of sustainability

well as the energy consumption and related cost.

for BASF Coatings.

Only with comprehensive data and simulation, it is possible to derive impactful measures. That is

For further information:

precisely what we can achieve for our customers

www.basf-coatings.com

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

FORNITURE TECNICHE PER LA VERNICIATURA INDUSTRIALE

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

info@guerrasrl.it www.guerrasrl.it

SUCCESS STORIES

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.

F

ounded in 1905 in the city of Hamburg (Germany) as hardware

short time period, they developed a viable equipment concept that

store, Carl Spaeter Hamburg became one of the leading steel

was perfectly adapted to our existing building and our technical

suppliers for retailers, mechanical contractors and industrial

requirements,” has explained Mike Barz, the general manager of Carl

manufacturers in Northern Germany and beyond. The success of the

Spaeter Hamburg.

company is based on a broad line of steel products, an inventory of

The equipment supplier from Untermerzbach won this substantial

more than 25,000 tons, short delivery times, high operational flexibility

purchase order against two competitors for the following reasons:

and numerous processing and refinement services.

Rösler adapted its equipment concept to the requirements of the

“Since our existing shot blast and painting line had reached the end

customers and, at the same time, the customer was impressed by the

of its usable life, and because we wanted to improve our customer

quality and sturdy equipment design. In addition, Rösler could show

support, we purchased the KON 34/6-HD from Rösler. Within a very

several reference plants in the field.

© Rösler Oberflächentechnik GmbH

The KON 34/6-HD preservation line developed by Rösler, adapted to an existing building containing an overhead crane.

206 N. 86 - MARCH/APRIL 2024 - international PAINT&COATING magazine

SUCCESS STORIES

Fully automatic and energy-saving shot blasting

© Rösler Oberflächentechnik GmbH

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

The preservation line can handle large-size steel components up to 3.2 m wide, 0.4 m high and 21.2 m long.

then automatically determines how many turbines must be turned on to clean the respective components. Other parameters like

transferred to the shot blast machine. The

performance and, at the same time, reduce

travel speed, paint type and thickness are also

machine housing is made from manganese

the energy consumption. Residual blast media

part of the processing programmes, which are

steel. In addition, the blast chamber is lined

and dust on the shot blasted components is

stored in the PLC and can be called up from

with overlapping liners made from manganese

removed with a combined brush-off/blow-off

the operating panel. In the first step, the steel

steel. Eight high-performance Gamma 400G

system at the exit of the blast chamber.

components are passing through a pre-heater

turbines, each with a drive power of 22 kW,

that prevents moisture from being carried into

ensure that the specified cleanliness of SA 2,5

the shot blast machine. The exhaust air from

is consistently and safely achieved at a travel

Low paint usage and minimal overspray

the pre-heater is guided to the paint drier,

speed of up to 4 meters/minute. Compared

To meet individual customer requirements

which helps to reduce the drying time of the

to conventional blast wheels, the Gamma

for the coating operation using a water-based

applied paint.

turbines with curved throwing blades in ‘Y’

primer, the integrated automated spraying

From the pre-heater, the work pieces are

design achieve an up to 20% higher blast

equipment is equipped with two independent

KNOW-HOW, EXPERIENCE, AND RELIABILITY 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.

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SUCCESS STORIES

© Rösler Oberflächentechnik GmbH

At the entrance of the automated painting system, special sensors measure the dimensions of the workpieces.

© Rösler Oberflächentechnik GmbH

The Gamma 400G high-performance turbines with ‘Y’ shaped throwing blade.

paint application systems. Prior to the paint process, special sensors

Optimised manufacturing processes and material flow

precisely measure the work piece dimensions. The gantry holding the

The work piece transport system of the new preservation line was

spray guns is then programmed for these measurements, ensuring

integrated into a building with an already-existing overhead crane.

that the primer is only applied onto the surface of the respective steel

The roller conveyors with forward and reverse transport direction

components. The result is minimum overspray and the prevention of

cover all four bays of the building with an area of over 42,000 m2. The

unnecessary waste of the valuable resource paint. The paint filter with

arrangement guarantees a highly flexible material handling operation.

air extraction points on both sides of the transport system collects any

For example, it allows the transport of steel components from anywhere

residual paint overspray, leaving only 0.2 mg/m3 of residual dust load

in the building to the preservation line, to other areas in the building

in the clean air – considerably below the official standard specifying a

or to the truck load station. The cross-transport systems, placed to

maximum of 1 to 2 mg/m . The residual dust in the clean air coming

the left and right of the roller conveyor, offer plenty of capacity for the

from the dust collector of the shot blast machine amounts to 1 mg/

intermediate storage of steel components.

m3, well below the legal limit of max. 3 mg/m3. Heating the paint drier

“With the new preservation line and the resulting further steel

with exhaust air from the pre-heating system is a further contribution

processing and refinement possibilities, we can fulfil customer requests

towards resource-saving operations. “With the new Rösler preservation

faster and more efficiently. This helps to reduce our lead times. In

line, we can run our surface treatment operations for steel plates,

addition, the new line, in combination with the roller conveyors and

beams, pipes and tubes and steel bars not only with an excellent

cross-transport systems, improves our logistical setup with shorter

finishing quality but also in a highly eco-friendly manner,” has clarified

walking distances for our employees and streamlines our entire

Reyk Hagelberg, the plant manager of Carl Spaeter Hamburg.

workflow,” has concluded Barz.

3

For further information: www.rosler.com

208 N. 86 - MARCH/APRIL 2024 - international PAINT&COATING magazine

CUSTOMIZED SOLUTIONS CIRCULAR ECONOMY & GREEN APPROACH ECO-FRIENDLY CHEMICALS NANOTECHNOLOGICAL CONVERSION COATING

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RESEARCH BREAKTHROUGH

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.

N

ew non-toxic materials could one day keep solar panels

The project includes researchers from Raytheon Technologies, North

and airplane wings ice-free or protect first responders from

Dakota State University and the University of Minnesota.

frostbite and more thanks to a new University of Michigan-led

Existing materials used to accomplish these feats come with serious

project funded by the Defense Advanced Research Projects Agency.

downsides. For instance, road salts prevent pavements and streets

The research team will study biological molecules used by other living

from freezing but also corrode concrete and enter natural freshwaters

things to survive freezing temperatures.

through runoff, to the detriment of aquatic life.

© Marcin Szczepanski, Michigan Engineering

RESEARCH BREAKTHROUGH

Spraying planes with de-icing fluids ensures that winter flights stay

and snow in several ways, including changing the temperature at which

safe, but the chemicals in such fluids are toxic and can also pollute

water freezes, increasing and decreasing how strongly ice adheres to

waterways. And some of what the researchers aim to make with the

surfaces, changing the structure of the formed ice and inhibiting or

up to $11.5 million project has no current analogue, like a lotion that

encouraging ice crystals to grow on surfaces.

protects from frostbite without heavy winter layers. “For the past seven

To meet their goals, the research team is looking to plants, animals and

or eight years now, my group has been making surfaces that have very

microbes for inspiration. Many organisms produce molecules that allow

low adhesion to ice. Such ice-shedding coatings can be very useful

them to survive freezing solid or stop their bodies from freezing. Wood

for a number of applications such as wind turbines, power lines or

frogs, for example, produce antifreeze lipids that prevent ice from

airplane wings,” has stated Anish Tuteja, the principal investigator of

damaging their cell membranes when they freeze over the winter.

the project and a professor of materials science and engineering at

Other organisms produce ‘ice-nucleating’ molecules that stimulate

the University of Michigan. “However, for many other applications, it

ice to form at warmer than usual temperatures. The bacterium

would be beneficial to completely eliminate ice formation. Preventing

Pseudomonas syringae produces ice-nucleating proteins to freeze plant

ice formation for hours on end in freezing conditions has thus far been

leaves. The ice helps break apart plant cells so that the bacterium can

very challenging to achieve.”

access the nutrients inside.

Taking inspiration from nature The project aims to find molecules that can be used to manipulate ice

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

© Marcin Szczepanski, Michigan Engineering

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.

international PAINT&COATING magazine - MARCH/APRIL 2024 - N. 86

211

© 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.

enable brand new technologies. “If you combine the molecules in the

many as 1,500 samples a day. The team hopes to narrow its search

right ratios, the freezing point can decline more than what would be

down to the 30 most promising candidate molecules for further

achievable by each molecule individually,” has added Tuteja.

study by the end of their first year. In the second year of the project,

Testing all the options

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

When starting from even a small subset of known molecules, the

liquids, creams and coatings. These experiments will not only help the

number of possible combinations and ratios can become unwieldy. The

researchers find the best antifreeze and ice-forming mixtures: the large

research team must measure the effectiveness of over 5,000 different

dataset will also help reveal how different ice-forming and ice-inhibiting

ice-forming and antifreeze molecules within the first year of the project.

molecules do their jobs. “Once we start to gather a lot of data on how

That number could double or triple as the project progresses.

these molecules work, we will work with machine-learning experts who

To quickly study these molecular combos, the team plans to build an

will be able to determine which parts of the molecule might be modified

automated platform to determine the freezing temperatures of as

to further improve their performance,” has concluded Tuteja.

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th

ANNIVERSARY 2009-2024 Celebrate with us at PaintExpo Booth 1442 - Hall 1

© Clint Strydom

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.

T

he Iziko Museums of South Africa and BMW are pleased to

became the first African and woman to paint a BMW Art Car in 1991. This

announce ‘Then I Knew I Was Good at Painting’: Esther Mahlangu.

collaboration marked a significant moment in the art world, blending

A Retrospective. The exhibition, curated by Nontobeko Ntombela,

African art with contemporary automotive design.

highlights Esther Mahlangu’s over 50-year long career and her

“Painting has always been a part of me. I cannot separate it from myself,

meteoric rise as a contemporary artist, earning her global acclaim. The

and neither would I want to. I look forward to sharing my practice

retrospective will be on view at Iziko Museums of South Africa from 18th

and long and colourful story with you on my upcoming Retrospective

February until 11 August 2024. From there, it will begin its global tour,

Exhibition”, stated Mahlangu.

stopping first at the Wits Art Museum in Johannesburg (South Africa)

Through the language of colour and form, the exhibition charts

before moving to the United States in early 2026.

Mahlangu’s contribution to contemporary art close to seven decades.

BMW is proud to support this landmark exhibition which honours

More than 100 artworks have been gathered from global collections. They

the talent of Esther Mahlangu and celebrates a shared history of

have been placed alongside historic photographs and a short film. This

collaboration. Included in this exhibition will be Mahlangu’s BMW 525i Art

diverse collection from Mahlangu’s expansive oeuvre which features in

Car, returning to South Africa for the first time in over 30 years. Mahlangu

‘Then I Knew I Was Good at Painting’: Esther Mahlangu. A Retrospective,

th

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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.

© BMW AG

BRAND-NEW

SPECIAL ISSUE - PaintExpo

HangOn Launches New Sustainability Concept at PaintExpo to Improve CO2 Footprint At the next PaintExpo edition HangOn will present its new solutions to improve the CO2 footprint of the coating lines.

H

angOn 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

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.

produced are of course important factors, and perhaps the first things

Product release 2024

that come to mind when this question is asked. The type of powder

The new product HQW S, the latest dense hanging HangOn innovation

used is also significant. Factors such as its application process and the

will also be presented during the exhibition: it is a close relative to HQW

amount wasted during production can significantly impact emissions,

D, which the company displayed during PaintExpo last time. Compared

making it a crucial aspect to consider.

to its double-sided and flexible precursor, the new product aims even

The solution: dense hanging

more towards simplicity. Easy to understand and easy to use.

Hanging densely and really filling the line, will result in both reduced power waste and lower energy usage – which will have a direct effect

© HangOn

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For further information: www.hangon.com

BRAND-NEW

SPECIAL ISSUE - PaintExpo

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.

F

rom 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

© Plasmatreat

optimum adhesion be ensured. It is also important that the surface is clean and free of

compressed air and electricity, eliminating

Thanks to this Openair-Plasma application, the

release agent residue, grease or dust.

the need for solvents or huge amounts of

foiling of the battery cell can be completely

Various pretreatment methods have been

gas for flame treatment. Using fast-drying UV

and reliably replaced by painting, resulting in

used in the industry to improve adhesion

coatings in combination with Openair-Plasma

cost and time savings and a higher quality of

properties, such as grinding, sandblasting,

eliminates the need for costly and space-

the final products.

etching, flame and plasma treatment. Plasma

consuming ovens to dry painted components

At the booth, the plasma experts will clearly

technology has significant advantages over

during pretreatment. Plasma pretreatment is

activate and clean the surfaces of various

many conventional processes: it is in-line,

ideal as an environmentally friendly solution

materials, such as PP and PE or aluminum, and

selective and can be applied to the entire

that provides optimum adhesion properties

verify the plasma treatment with various test

surface.

for a perfect paint finish.

methods. The plasma effect can be detected

“The dry Openair-Plasma process completely

Visitors to the Plasmatreat booth at PaintExpo

and the surface energy determined by

eliminates the need for environmentally

will be able to see for themselves the

measuring the contact angle of a water drop,

harmful wet chemical primers. In this way,

effectiveness and functionality of plasma

water spray tests or Plasmatreat’s test inks.

we also reduce the release of VOCs (volatile

surface treatment. Several plasma systems

organic compounds) into the atmosphere,”

will be available for live demonstrations

For further information:

explains Joachim Schüßler, Head of Sales

with different materials. In addition to the

www.plasmatreat.com

Germany at Plasmatreat GmbH.

activation of a plastic automotive component

In addition to reducing VOCs, manufacturers

in a PTU1212 (Plasma Treatment Unit), visitors

can also reduce their carbon footprint by using

will see how a Scara robot is used to precision

plasma surface treatment: the reactive plasma

clean various metal battery cells as a pre-

species are generated by a combination of

treatment for painting with 100% UV paint.

international PAINT&COATING magazine - MARCH/APRIL 2024 - N. 86

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WHERE WE HAVE BEEN

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© Adobe Stock

The most important industry events at your fingertips 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 an ipcm app ®

events of the surface treatment sector.

COLOUR STUDY

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.

T

he international paints and coatings manufacturer Axalta Coating

Starry Night is a strong and contemporary colour with light blue

Systems has recently presented Starry Night, its automotive

and silver flakes that evokes the depths of our universe and space

colour of the year 2024 – marking the 10 anniversary. The colour

exploration, representing bold imaginations and driving to reach new

th

is a dynamic black shade evoking depths of our universe and space

heights. As a dynamic hue, Starry Night transcends classic and modern

exploration. “Black is the second most popular automotive colour

design styles and harmonises with other colours, finishes, patterns and

globally, so we are excited to feature a black shade as our 2024 Global

textures. The company first introduced its Global Automotive Color of

Automotive Color of the Year. Starry Night is a hue where black is bright

the Year in 2015 with Radiant Red. Since then, its global team of colour

and dark is distinguished. The colour of this year is part cosmic and part

experts collaborated annually to introduce a trending and up-in-coming

classic, but all Axalta,” has stated Dan Benton, Senior Manager, Global

shade for the automotive industry.

Color at Axalta.

© Axalta Coating Systems

For further information: www.axalta.com

220 N. 86 - MARCH/APRIL 2024 - international PAINT&COATING magazine

© AdobeStock

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.

A

ccording to colour studies, black and white are not colours. White

materials in which they are made receive beams of light that they partly

is obtained by combining all colours, whereas black is obtained

reflect and partly absorb. Black does not reflect light and, therefore,

by subtracting them – that is, it is the result of the subtractive

has no colour. It is thus considered a non-colour. Yet, it is one of the

synthesis of all the colours of the visible spectrum. As often mentioned

most widely used tints in the most diverse applications, from fashion to

in this column, colours are determined by light and differ according

interior design, from architecture to electronics, from art to literature,

to its wavelengths. We can identify the colours of objects because the

from music to sport and comics, to name but a few, perhaps also thanks

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ART WITHIN SURFACES

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 © Wikipedia

to the Latin nigrum, the accusative of niger, i.e. “black”, “dark”, and, in a broader sense, “gloomy”, “sombre”, “foreboding”, “mournful”. In fact,

Caravaggio’s “Narcissus”, oil on canvas, 1598-99 - Galleria Nazionale di Arte Antica, Rome (Italy).

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

Ixtlilton (“the little black one”), used magical tlital (“black water”) as a remedy for ailments2.

Carl Gustav Jung wrote that black is “the colour of the sunrises, of the

Made from black charcoal and iron ore, black was the first pigment used

principles, of the occlusions in their germinal phase, preceding the

in history: the bison drawn in the prehistoric caves of Altamira (Spain)

luminous and the hopeful explosion of birth”. Indeed, in the Bible, it is

and Lascaux (France) bear witness to this. In Greece, black silhouettes

the primordial colour from which light springs forth. The same concept

on a red background were painted on clay pottery using a sophisticated

is found in Egyptian mythology, according to which the cosmos was

technique. Black was obtained by Roman painters with graphite-based

created from the Nun, the primordial chaos, akin to the Te Bo Ma

powders and pigments made by burning resins or tar, although the use

(“darkness”) of Micronesia and the Dreamtime of Aboriginal culture.

of soot (carbon black) to produce inks was even cheaper. Pliny wrote

Black, therefore, emanates a generating and fertile power, an original

that some painters, to obtain good-quality black pigments, robbed

chaos from which light and life can erupt. In ancient Egypt, it was

graves to collect charred remains, but this practice was obviously

associated with the fertile land left by the Nile after the floods, whereas

forbidden. The black tint for dyeing textiles was obtained from the

among the Maasai of Kenya, it recalled the puffy clouds heralding

vegetal waste of the wine industry, consisting of copper tannates (fouling

rain, becoming a symbol of life and prosperity. From darkness comes

on vats). The name of Nero, the Roman emperor who ruled Rome from

the light: this concept was also evoked by Homer, who described the

54 AD to 68 AD and is (perhaps erroneously) blamed for the great fire

sea’s depths as black and containing latent life, the great reservoir of

that destroyed the city, derives from the Roman cognomen “Nero”

all things, and even by Aztec mythology, in which the god of medicine,

(connected to the Latin nigrum, “black”), probably of Sabine origin and

1

www.linkedin.com/feed/update/urn:li:activity:7001092899694129152

2

https://www.mentinfuga.com/lartificio-del-colore-nero/

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© Surrey NanoSystems

BMW VBX6 is the first BMW model coated with Vantablack®.

Audrey Hepburn in the movie “Breakfast at Tiffany’s”.

meaning “strong” and “valiant”, further confirming that, even in ancient

Black in the world of art

times, black did not have an entirely negative connotation.

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

Black in the Middle Ages

palette or the shapes of sculptures, from Flemish painters Jan Vermeer

At the height of the Middle Ages, black became the colour of Hell, where

and Rembrandt to Caravaggio, who used it with masterly skill to create

darkness reigns, and the symbol of the devil. Black animals, such as the

the backgrounds of his indescribable paintings, up to Édouard Manet,

raven, were penalised for this. However, according to colour historian

who, in his 1863 oil painting “Olympia”, was able to make the black of

Michel Pastoureau, something good was still seen in black since, in the

the cat on the right and the face of the servant girl stand out against the

same period, it also became the colour of humility, temperance, and

black background of the canvas by creating a unique “black on black”

dignity. Benedictine monks wore a black tunic, which became the subject

effect. In contemporary art, we cannot fail to mention Anish Kapoor, one

of a religious dispute with Cistercian monks, accused of excessive pride,

of the most important sculptors today, who has been at the centre of

as evidenced by their white robes: the Cistercians replied that the black

much controversy for having acquired Vantablack®, the blackest black

worn by the Benedictines was the colour of the devil, death, and sin,

pigment ever made, produced by British company Surrey NanoSystems

whereas their white symbolised purity and innocence.

and composed of carbon nanotubes. It absorbs up to 99.965% of

A little later, black became the preferred colour for courtiers’ clothes

the visible spectrum radiation and it was developed originally for

and a symbol of luxury, as clearly shown in many portraits of the time.

military purposes, as it was intended to coat stealth aircraft, built with

It retained the reputation of “fashionable colour” until the 16 century.

technologies that make them “invisible” to radar. Kapoor described it in

Although it remained associated with witchcraft and mourning practices,

these words: “It is so black that you almost cannot see it, and it is so dark

its position evolved: now respectable and luxurious, it became a royal

that you lose awareness of space, so much so that you are driven to rely

colour until the mid-17th century. And, with the invention of printing,

on something you do not know in your inner reality.” BMW coated the

which used black ink on white paper, it became a part of everyday life, in

body of one of its car models, the BMW VBX6, with Vantablack® for the

the same way the smartphones’ black screens are today.

first time in 20193.

th

In the 19 century, black became the symbol of the smoke of the first th

factories and automobiles – a world difficult to imagine in colour, which

When the soul is dark

we are in fact more inclined to visualise in black and white. It then

Black clothing has made history, not only in fashion – Coco Chanel

became a symbol of political extremism in the 20th century, linked to a

is credited with the invention in 1929 of the “little black dress” that

grim historical period: suffice it to recall the black swastika of the Nazi

Audrey Hepburn made timeless – but also in sport, music, and comics,

flag, the colour worn by the paramilitary corps of the Italian National

sometimes with surprising implications. For example, the black jersey

Fascist Party, and the black flag symbol of anarchy.

awarded to the last rider to cross the finish line of the Giro d’Italia 3

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https://www.ipcm.it/en/open/ipcm/2019/59/146-147.aspx

ART WITHIN SURFACES

does not have the negative meaning one might expect. It originated,

extent the negative connotations of black still affect our everyday life,

as is often the case, from a particular sports story: Giuseppe Ticozzelli

even at an unconscious level. I was walking two large dogs, one black

was a fairly well-known footballer with an immense passion for cycling

and one brown. Although the former is more docile and friendly, the

who, in 1926, decided to race some stages of the Giro d’Italia as an

people I met only paid attention and cuddled the brown dog, completely

independent. Since he did not have a team with official colours, he

ignoring the black one.

chose to compete with the black jersey with a white star on the chest

Perhaps, although black is now largely legitimised, it still unsettles us

of his then-football team, Casale. The jersey worn by “Tico” served as an

deep down... and this, too, is part of the intriguing, eternal fascination of

inspiration when the Giro d’Italia resumed after the Second World War

this non-colour.

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

© AdobeStock

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.

The New Zealand national rugby team wears a black jersey.

Has black really redeemed itself?

Although, nowadays, black also evokes positive aspects, we

© ipcm

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

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RESEARCH BREAKTHROUGH

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.

S

cientists from the University of Surrey

Chroococcidiopsis cubana as a biocoating,

extreme environments, like droughts and

in Guildford (United Kingdom) have

researchers immobilised the bacteria in a

after high levels of UV radiation exposure.

recently presented Green Living Paint,

mechanically robust biocoating made from

This makes them potential candidates for

an innovative biocoating containing oxygen-

polymer particles in water, which was fully

Mars colonisation,” has added Simone Krings,

producing bacteria capable of capturing

dried before rehydrating. They observed that

the lead author and a former postgraduate

carbon dioxide (CO2) that could be used in

the bacteria within the biocoating produced

researcher in the Department of Microbial

extreme environments such as space stations.

up to 0.4 g of oxygen per gram of biomass

Sciences at the University of Surrey.

“With the increase in greenhouse gases

per day and captured CO2. Continuous

“Our research grant from the Leverhulme

measurements of oxygen showed no signs of

Trust enabled this interdisciplinary project.

concerns about water shortages due to rising

decreasing activity over a month. In contrast,

We envision our biocoatings contributing to a

global temperatures, we need innovative

researchers conducted similar experiments

more sustainable future, aligning perfectly with

environmentally-friendly and sustainable

with the bacterium Synechocystis sp., another

the vision of our Institute for Sustainability,

materials. Mechanically robust ready-to-

cyanobacterium usually found in freshwater.

where both Dr Hingley-Wilson and I are

use biocoatings, or ‘living paints’, could help

Unlike its desert counterpart, it was unable to

fellows,” has concluded Joseph Keddie, a

meet these challenges by reducing water

produce oxygen within the biocoating.

professor of soft matter physics in the School

consumption in typically water-intensive

“The photosynthetic Chroococcidiopsis

of Mathematics and Physics at the University

bioreactor-based processes” has stated

have an extraordinary ability to survive in

of Surrey.

in the atmosphere, particularly CO2, and

Suzie Hingley-Wilson, a senior lecturer in bacteriology at the University of Surrey.

Biocoatings are a type of water-based paint

© University of Surrey

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

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Image of Cyanobacteria in a biocoating.

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MEETING THE INDUSTRY

COVERED by ipcm®

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.

T

he Surface Treatment global business unit of BASF’s Coatings

activities for aluminium, Chemetall is positioned to develop technologies

division, operating under the Chemetall brand, celebrated the

faster and more efficiently resulting in transformative innovations in the

opening of its new Global Aluminum Competence Center in

field of anodising and pretreatment of this special substrate.

Giussano (Italy). The state-of-the-art facility will strengthen the position of

“The new global Aluminum Competence Center will allow us to bring

Chemetall as a global supplier of solutions for the surface treatment of

new surface treatment solutions to the market faster. The centralisation

aluminium substrates.

of our research and development activities for aluminium will result in

The Aluminum Competence Center was established to bundle the

pioneering technologies that solve the challenges of our global customers,

comprehensive competences of Chemetall in the area of surface

provide solutions for their needs and most of all deliver long-lasting

treatment of aluminium in one place. After the intensive analyses of

sustainable value,” has stated Frank Naber, Senior Vice President of

existing capacities, development priorities as well as customer and market

Chemetall.

requirements, the existing Chemetall site in Giussano was identified as

“The Aluminum Competence Center at our Giussano site is a strategically

the best option. With the centralisation of the research and development

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.

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As a lightweight metal with high availability, aluminium plays an important

© Chemetall

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

Aerial view of the new Chemetall Global Aluminum Competence Center in Giussano (Italy).

remarkable success in areas such as neutral cleaners and plastic recycling. In close collaboration with our global technology teams and

© Chemetall

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

Alessia Venturi, ipcm® Editor-in-Chief, moderating the technical conference on future megatrends of the aluminium industry.

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

The gala dinner in the wonderful frame of the Sala del Cenacolo.

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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.

H

annover. “Geopolitical tensions, climate change, stagnating

cross-sector energy solutions. For European companies in particular,

growth, high prices for energy and a shortage of skilled workers

HANNOVER MESSE will thus create a bulwark against the impending

mean that cost discipline and efficiency are currently the

de-industrialization of Europe,” says Köckler. “Our exhibitors will show

dominant themes in companies. At the same time, artificial intelligence

that competitive industrial production is possible in Europe. However,

is leading to profound changes in the worlds of work in industry. In

this will require a regulatory framework that promotes innovation and

addition, business leaders and trade associations are warning of a de-

entrepreneurship.”

industrialization of Europe,” says Dr. Jochen Köckler, CEO of Deutsche

The solution lies in the interplay of automation, digitalization and

Messe AG, describing the environment in which this year’s HANNOVER

electrification, broad cross-industry and cross-border cooperation,

MESSE takes place.

and a clear political course. Köckler: “With the lead theme ‘Energizing

“HANNOVER MESSE is more important than ever this year, because

a Sustainable Industry’, 4,000 exhibitors, high-caliber representatives

the economic environment has rarely been so volatile. In Hannover,

from politics and industry, and with Norway as the partner country,

technologies and solutions will be presented to enable industry to

HANNOVER MESSE 2024 is the ideal platform for this.”

produce on a competitive and sustainable basis. The trade fair will be

More than 300 economic delegations are expected to attend the

all about intelligent and carbon-neutral production, AI, hydrogen, and

trade fair, first and foremost the Chancellor of Germany, Olaf Scholz,

© Deutsche Messe

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MEETING THE INDUSTRY

who will open HANNOVER MESSE together with the Prime Minister of

hydrogen and fuel cell industry will be showcasing their solutions in

Norway, Jonas Gahr Støre. In addition, the President of the European

Hannover. This makes HANNOVER MESSE the world’s largest and most

Commission, Ursula von der Leyen, and the German Minister of

important trade fair for the topic of hydrogen.

Economics, Robert Habeck, will use the world’s leading trade fair for

Köckler: “Hydrogen offers enormous opportunities as the green energy

industry to exchange ideas with representatives of the industrial sector.

carrier. However, the current pace of roll-out and scaling up is too slow.”

“If Europe is to retain substantial and sustainable production and

Developing a hydrogen economy now requires bold political decisions

investment, then the amount of red tape must be urgently reduced, for

to be taken in the regulatory area, intensive research and development

example through faster planning and authorization procedures,” Köckler

for rapid implementation, and the development of the necessary

appeals.

infrastructure for scaling up. This is the only way that viable business

“Visitors to HANNOVER MESSE are looking for guidance on how they can

models will be able to become established. “At HANNOVER MESSE,

use automation, artificial intelligence, renewable energies or hydrogen

we will be demonstrating what is technologically feasible, and creating

in a meaningful way. This is precisely the expertise that the exhibitors at

the framework for discussions between representatives of politics and

HANNOVER MESSE can provide,” says Köckler.

industry, hopefully allowing decisions to be taken on a specific road map

The exhibiting companies include global tech giants such as Accenture,

towards a functioning hydrogen economy,” says Köckler.

AWS, Bosch, DELL Technologies, Google, Microsoft, SAP, ServiceNow, such as Beckhoff, GP Joule, ebm-papst, Ericsson, Festo, Turck, Harting,

Partner Country Norway: a powerhouse for energy and digitalization

ifm, igus, LAPP, Pepperl+Fuchs, Phoenix Contact, Rittal, Schunk, SEW-

Norway is using the global stage offered by HANNOVER MESSE to

Eurodrive, Wago, WIBU and Ziehl-Abegg plus renowned research

present itself as an innovative and reliable energy partner, among other

organizations such as the Fraunhofer-Gesellschaft and the Karlsruhe

things. The motto of the partner country is “Norway 2024: Pioneering

Institute of Technology (KIT) and more than 300 industrial startups.

the Green Industrial Transition”. This underscores Norway’s ambition

Schneider Electric and Siemens as well as SME technology leaders

Artificial intelligence: the next level of industrial digitalization

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.

For more than a decade now, HANNOVER MESSE has been the most

At the “North Sea Energy Hub” conference on 23 April, politicians

important trade fair for the digitalization of industry. Artificial intelligence

and experts from Norway and Germany will discuss the transition in

is now taking industrial digitalization to the next level by revolutionizing

energy policy, with a focus on general political conditions as well as

industry, making processes more efficient and adding value. By using

technological developments and applications. Köckler: “In Europe,

AI, companies will be able to shorten development times while saving

Norway is a powerhouse for energy and digitalization. Which means it

resources and energy.

fits in perfectly with HANNOVER MESSE.”

“The speed at which AI solutions are finding their way into industry is breathtaking. Companies need to invest now and, above all, introduce

European Union: strong economic alliance

their employees to the opportunities offered by AI, otherwise they will

Two months before the European elections, the European Union will be

get left behind by the competition,” emphasizes Köckler. “AI is the key to

presenting itself as a strong economic alliance at HANNOVER MESSE.

competitiveness and sustainability in industry.”

Ursula von der Leyen, President of the European Commission, will get

Specific applications will be on show at HANNOVER MESSE: robots

the program started with a speech at the opening ceremony on 21

that can be controlled by voice, machines that automatically recognize

April. The EU program during the trade fair includes the “Investing in

defects; or systems that cut downtimes through predictive maintenance.

European Industry” conference on 22 April, at which representatives

Köckler: “In the near future, generative AI will be able to design

of industry will be able to discuss with EU politicians topics such as the

machines. This will lead to fundamental changes in engineers’ job

Green Deal.

profiles – a subject that will also be discussed at HANNOVER MESSE.”

When will the hydrogen economy arrive?

For further information: www.hannovermesse.de/en

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

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MEETING THE INDUSTRY

COVERED by ipcm®

© ipcm

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.

C

oatings have been a valuable ally for centuries in enhancing the

On Thursday, 8 March, at the Stangalini Point of Lechler Trade

technical and functional characteristics of substrates, improving

S.r.l. (located in Via Pier Lombardo 230 in Novara, Italy), this paint

their aesthetics and making them attractive through a variety of

manufacturer inaugurated its first Color Design Lab to be even closer to

special-effect finishes. However, the technical requirement to faithfully

its customers and streamline its analysis and design processes, as this

reproduce an exact colour point or effect regardless of the type of

innovative platform is designed to enable the company’s team, colour

surface to be coated is often not easy to fulfil. For example, light refraction

experts, and customers from multiple industries to connect and work

changes the visual perception of tints on products made of different

together to identify and develop the most suitable finishes for even the

materials and with different shapes: this must always be considered and

most ambitious projects. The event also provided a unique opportunity

thoroughly addressed when selecting and designing coatings.

to explore design and colour perception topics.

However, Lechler has succeeded in making the repeatability of colours

“Opening our Color Design Lab in Novara is a turning point for Lechler,

and finishes on any substrate, be it plastic, plaster, wood or metal,

an excellent opportunity to explore the depths of colour design. This

one of its strengths. The company offers a wide range of technical and

state-of-the-art space not only enables us to encapsulate our vast

colour solutions with dedicated water- and solvent-based systems for all

selection of resources and customised consultancy services for specific

sectors, including decorative, industry, habitat, refinish, and yachting.

projects in one place, but also allows our customers to engage with

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our finishing experts and directly access samples and mock-ups, thus

values of companies. The day ended with a convivial aperitif, during

making their decision-making process faster and more effective,”

which participants had the opportunity to exchange thoughts and ideas,

explains Claudia Salomoni, Marketing Manager Industry at Lechler.

further consolidating the importance and value of Lechler’s new Color

During the visit, Lechler’s experts and highly qualified staff were open

Design Lab.

to explaining in detail the many functions of the new space, highlighting

“The inauguration of the first Colour Design Lab is a milestone in colour

how it can be a valuable ally in creating distinctive and successful

and finish design for Lechler, as it offers experts and customers an

projects.

unprecedented tool to explore, create, and realise projects that reflect

Following the welcome speech and the presentation of the space,

their vision and identity in a unique and surprising way. In the near

the event continued with the participation of a few experts, including

future, we plan to open more in the most relevant areas of Italy to

renowned colour psychologist Dr Lia Luzzato, who gave a speech

expand these opportunities even further,” states Salomoni.

entitled “Finishing, colour, and effect”. Through interesting case studies and an overview of the evolution of the discipline, Luzzato analysed

For further information: www.lechler.eu

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

Scan the QR code to watch the video of the event

successful examples, Maestri, too, demonstrated the crucial importance of colours and finishes in creating spaces that reflect the mission and

© Lechler

© ipcm

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© Deutsche Messe

MEETING THE INDUSTRY

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.

F

rom January 19 up to and including April 8, 2024, it is once again

The paint devices manufacturer from Bietigheim-Bissingen, together

possible to apply for the Stuttgart surface technology prize DIE

with partners from the paint and automotive industry, had developed a

OBERFLÄCHE. Participation individuals and organizations that have

completely overspray-free wet painting system.

played an innovative role in shaping the surface technology industry, or other industrial areas related to surface areas related to surface

Award ceremony at the Surface Technology Germany trade fair

technology are invited to take part in the competition.

In addition to Metzner, the interdisciplinary and independent expert jury

In addition to sustainability, the three-member jury also evaluates the

also includes Martin Riester (VDMA Surface Technology) and Michael

degree of innovation of the technology or application as an enabling

Hilt (Research Association for Pigments and Coatings e.V.). The Stuttgart

technology and the industrial feasibility.

surface technology prize DIE OBERFLÄCHE is awarded every two years

“Every component inevitably interacts with its surface. This is why

and will be presented for the ninth time in 2024. The award ceremony

surface technology plays a key role in the degree of innovation and

will take place on June 4, 2024 at the specialist forum of the international

progress in numerous industries. We want to promote and recognize

trade fair Surface Technology Germany trade fair in Stuttgart.

this,” says juror Martin Metzner, Head of the Electroplating Department

All necessary documents for the application as well as further

at the Fraunhofer Institute for Manufacturing Engineering and

information are available at: www.ipa.fraunhofer.de

whether in in electroplating, painting technology, thermal spraying

Automation IPA. First place in the Surface Technology Award at THE SURFACE 2022 went to Dürr Systems AG.

For further information: www.surface-technology-germany.de/en/

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Questa testata è associata a

Eos Mktg&Communication srl www.eosmarketing.it - info@eosmarketing.it www.myipcm.com - info@ipcm.it Redazione - Sede Legale: Via Pietro Mascagni, 8 - 20811 - Cesano Maderno (MB) - Italy Tel. +39.0362.503215 - Fax. +39.0362.1794768

EDITORIAL BOARD Prof. Massimiliano Bestetti:

Prof. Stefano Rossi:

Department of Chemistry, Material and Chemical Engineering, Politecnico of Milan – Section of Applied Chemistry and Physics

Material Engineering and Industrial Technologies, University of Trento - Product Design

Prof. Paolo Gronchi: Department of Chemistry, Material and Chemical Engineering, Politecnico of Milan – Chemical Engineering Section

Dr. Fulvio Zocco: Environment and quality

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