ipcm n. 89 | September - October 2024

The smart journal for surface treatments

ipcm digital on

® Special issue ALUMINIUM 2024

INTERNATIONAL PAINT&COATING MAGAZINE

ISSN 2280-6083

www.myipcm.com 2024

15th Year - Bimonthly

N° 89 - SEPTEMBER/OCTOBER

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CONTENTS SEPTEMBER/OCTOBER 2024

© Eisenmann GmbH

26

© Venjakob

HIGHLIGHT OF THE MONTH

Eisenmann’s New Course: Extensive Portfolio of Technologies, Customised Solutions, and International Presence

Increased Lacquer Adhesion and Possible Savings Thanks to New High-End Coating Process

© Fraunhofer IFAM/Wolfgang Hielscher

© Emboss

66

46

ADVANCEMENTS

FOCUS ON TECHNOLOGY

Metallic and Special-Effect Powder Coatings for Emboss’ Three-Dimensional Cladding Surfaces

05 EDITOR’S LETTER 06 ANALYSIS

Practical Coverage Calculation and the Necessary Overconsumption Factor

14 BRAND NEW 32 ASK JOE POWDER

The “Ask an Expert” Column

34 FOCUS ON TECHNOLOGY

Automation and High Quality: Pulsar Improves Its Coating Process with a New Articulated Robot

76

RESEARCH BREAKTHROUGH

Ultrathin, Hard and Sustainable Non-stick Coating Revolutionises Shaping Processes In Injection Moulding and Die Casting

40 HIGHLIGHT OF THE MONTH

72 ROAD TO 2050

49 50 BRAND NEW 60 HIGHLIGHT OF THE MONTH

80 FOCUS ON TECHNOLOGY

High Recovery Rate with Ultrafiltration Membrane Technology in Electrocoating Processes SPECIAL ISSUE ON METAL ARCHITECTURE AND DESIGN

Low Bake Powder Coatings from KABE-Farben: Quality for Architectural Applications

62 SUCCESS STORIES

The Collaboration Between DHK, ALIT Technologies and Alufinish Ushers in a New Era in Metal Surface Protection

EcoAl® by Alsan - Chrome-Free Passivation in Pretreatment Processes for Powder Painting

Azeta Confirms Itself as a Pioneer in Aluminium Coating Through a New Vertical Line Combined with an Innovative IPS Powder Feeding System

88 HIGHLIGHT OF THE MONTH

ST Powder Coatings Presents the New Green Oasis Range, the Ecological Oasis of the Future

HP series

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

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



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

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

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



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

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CONTENTS SEPTEMBER/OCTOBER 2024

© Kenosistec

90

© Sirio Galv

ADVANCEMENTS

Evolution on Design: Kenosistec’s PVD Technology for Elegant, Durable, and Sustainable Finishes

© Walther Trowal

116

102

FOCUS ON TECHNOLOGY

Raising the Bar of Quality: Sirio Galv’s New Liquid Coating Plant for High-End Furniture and Lighting Accessories

© Delco Trailers

ROAD TO 2050

146

Ice Cream Spoons and Golf Tees: Completely Absorbed by Nature

94 FOCUS ON TECHNOLOGY

Luxe Perfil: The Experts in the Impossible Rely on the New PrimeCoat® A109 Pre-Treatment Product’s High Performance

108 ADVANCEMENTS

EcodePure: the Road to Water Recycling and Zero Discharge

122 SUCCESS STORIES

PAN-DUR Paints Refrigeration Equipment with Dürr’s EcoPaintJet – Without the Need for Masking

126 ROAD TO 2050

Ahead of Regulation for More Environmentally Friendly Coatings

112 SUCCESS STORIES

130 HIGHLIGHT OF THE MONTH

114 SUCCESS STORIES

134 ANALYSIS

ItalMesh Clads the New Burger King in Rovereto with Perforated and Painted Aluminium Panels

RIPOL in Bayreuth: Innovation and Avant-Garde Design

The Evolution of Vernici Caldart: an Italian Success Story Through Fifty Years of Innovation

The Choice: The Ecological Transition and the HangOn Green Effect

SUCCESS STORIES

Delco Trailers Revolutionises Its Trailer Finishing Process with a New Automatic Coating Line

142 HIGHLIGHT OF THE MONTH

Defil Srl: Innovation in Industrial Filtration

150 ROAD TO 2050

Olea FP: a Natural, Sustainable Option for the Paints & Coatings Industry From Waste Stream to High-performance Functional Powders

154 UCIF INFORMS

Corporate Cybersecurity: a Shared Commitment to Digital Security

156 COLOUR STUDY

The Irresistible Charm of Pink

160 MEETING THE INDUSTRY

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EDITOR’S LETTER

Richiedi la versione in italiano a info@ipcm.it

H

ave you ever reflected on the difference between planning and designing, between a project and its development?

It is the same as between dream and reality.

Dreaming, like planning, belongs to a creative, imaginative, detailed, and inspirational phase with unrealistic but visionary traits. It connects the subject with reality, the designer with the issue to be addressed.

Reality, like the design activity, is the construction phase, the realisation of the idea – of the dream, to be more precise – with less vivid colours, with the sacrifice of a few details, and with the necessary compromise between what is feasible and what is not.

In architecture and design, therefore, planning refers to the creative thinking behind a project, the visionary approach intended to guide the subsequent realisation, whereas design refers to the technical process by which an idea is transformed into a tangible product, such as a building or an object.

Bridging the gap between a project and its development requires having all the technologies and materials, including finishes, needed to translate an idea into reality.

This is the most challenging phase for designers, who sometimes lack the necessary technical information on materials and their performance.

That is where CMF (Colour, Materials, Finish) comes in, a field focussing on the chromatic, tactile, and decorative identity of products and environments. Over the years, CMF experts have worked with designers on the one hand and manufacturers of materials and finishes on the other hand, to promote knowledge sharing, training, and collaboration to bring the design world, more inclined to breaking down limits, closer to the industrial one, constantly dealing with technical and scientific limits.

Since its inception in 2010, ipcm® has had the metal architecture sector, including architects and designers, among its preferred targets, providing it with precise information about any innovation in the world of surface finishing materials – in other words, what constitutes the skin of a product, the interface between an object and the environment.

This special Aluminium issue of ipcm® features a series of articles and success stories on the peaks of innovation achieved in the surface treatment of aluminium, a material that is increasingly popular in architecture and beyond.

As in previous years, ipcm® is also a media partner of the most important platform dedicated to the aluminium sector, the international trade fair Aluminium in Düsseldorf (Germany).

We will gladly meet you among the stands to discuss the most significant issues, trends, and developments in the industry.

Alessia Venturi Editor-in-chief Direttore Responsabile

international PAINT&COATING magazine - SEPTEMBER/OCTOBER 2024 - N. 89

05

© ipcm/generated with AI

ANALYSIS

Practical Coverage Calculation and the Necessary Overconsumption Factor Gianmaria Guidi, Germedia Srl – Brescia, Italy

U

gianmaria.guidi@germedia.it

nfortunately, and increasingly often in the coating industry too,

dynamics have favoured economic and financial aspects to the

our society fails to anticipate and avoid the loss of knowledge,

detriment of investment in technical training, taking it for granted that

skills, and expertise levels. In 1974, Kaufman called this

the necessary technical elements were simply ingrained in the common

phenomenon “the obsolescence of skills”, referring to the lack of up-to-

consciousness. The case described below attempts to refocus attention

date knowledge or proficiency a worker needs to continue to perform

on a calculation method that helps define the economic impact of paint

their current or future job properly. More and more often in our

products in a coating project.

professional activities, major problems arise precisely from the failure to compensate for physiological information asymmetries between

Practical coverage or consumption calculation criteria

contractual parties, which can no longer be adequately compensated

Every coating project requires a thorough feasibility analysis

due to a lack of specific technical expertise. In recent decades, market

that considers various factors and constraints, e.g. time-related,

06

N. 89 - SEPTEMBER/OCTOBER 2024 - international PAINT&COATING magazine

ANALYSIS

technological, regulatory and, last but not least, economic. In particular,

measurement tolerances (e.g. +/- 20%). In the execution phase, the

this article analyses paint coverage as a cost item directly affecting the

applicator applies the coating and strives to meet and maintain the

coating project’s economic factor.

set standards, initially measuring the applied wet film thickness (WFT)

To reach a coating treatment’s expected performance and durability

and then checking the final dry film thickness (DFT) achieved after the

as defined in the design phase, it is necessary to achieve and maintain

polymerisation step.

the specified dry film thickness (DFT) value. That ensures the coating

It is important to emphasise that the terminology and acronyms used

acts as a protective barrier, preventing corrosive agents such as water,

to define the desired values are not universal but strictly depend on

salts, and oxygen from reaching the metal surface. Insufficient DFT

the technical regulations adopted by the designer. For example, in

can indeed leave vulnerable areas, exposing the metal to corrosion. In

ISO 2808 and ISO 19840, the acronym DFT may refer to two different

contrast, adequate DFT increases the coating’s resistance to mechanical

measurements, one of which rules out surface roughness after shot

and chemical stress, prolonging its service life and protective action

blasting. These differences are of fundamental importance when

and reducing the need for frequent maintenance and repairs. A

calculating the coverage of a coating treatment.

sound coating project should also use the appropriate terminology coating treatments, nominal quantities translate into actual measures

Consumption and coverage calculation: practical aspects

conditioned by wide tolerances, which are absolutely necessary and

To achieve the specified NDFT, the applicator must calculate the

unavoidable.

coverage of the products that make up the coating system by taking into

to define the desired DFTs, also considering that, in the context of

Terminology and definitions: economic discriminants

account at least the following aspects:  The theoretical coverage of a paint product (fig. 1), considering its

Various international standards can be used to determine the dry or

dry solid by volume (S.V.) and the possible dilution required for its

wet thickness of a coating. This article focuses on dry thicknesses as

application, which increases the value of volatile organic compounds

an objective parameter for qualitatively evaluating the applied cycle.

(VOCs) and decreases the DRV, with a direct impact on the final DFT.

The coating work can be divided into two main macro-phases: design

 The correction factor for shot-blasted surfaces, which takes into

and execution. In the design phase, the designer defines the coating’s

account the fact that part of the paint is deposited within the surface

nominal dry film thickness (NDFT), the required sampling plan, and the

irregularities, creating a so-called “dead volume” (fig. 2). Although such

© Germedia

Figure 1 - Dry paint residue.

international PAINT&COATING magazine - SEPTEMBER/OCTOBER 2024 - N. 89

07

volume is filled by the product, it does not contribute to the effective

influenced by various elements, such as the distance from the surface,

protection of the substrate, as it does not increase the thickness of the

the complexity of the part’s shape, the presence of air currents, the type

dry film covering the exposed areas. Therefore, it is crucial to consider

of atomisation used, and the spray pressure set by the operator.

this correction factor when calculating product coverage, as it directly affects the effectiveness of the protection provided by the coating

Economic impacts and preliminary estimates

treatment. Ignoring the dead volume could lead to underestimating the

Any advance estimate cannot be exact and must be confirmed or

amount of paint required to achieve the necessary degree of protection.

denied after completion of the process. However, since it is necessary

 The necessary overconsumption factor (NOC), representing an

to calculate the economic impact of paint consumption at the quotation

amount of paint product that does not disperse into the environment

stage, it can be useful to resort to computational formulas using

but rather is deposited on the surface to ensure compliance with the

theoretical correction coefficients. If a company is consistent in using

required NDFT values (fig. 3): such overconsumption is not due to the

these formulas and in subsequently verifying the theoretical coefficients

applicator’s lack of skill but is an unavoidable discontinuity in the coating

initially applied, it will be able to reduce its error margins, thus

process. Any application method inevitably generates variations in the

consolidating its position in the market with a high level of qualitative-

thickness of the organic film deposited on the surface. Therefore, a

economic competitiveness.

larger volume of paint must always be applied to ensure compliance with the minimum DFT value defined in the sampling plan.

Theoretical coverage calculation

 The loss factor due to the geometry of the object to be coated mainly

The theoretical coverage of a paint product expressed in square metres

affects spray application operations, but it should be considered that,

(m2) per litre (l) applied is generally determined using the following formula:

to a lesser extent, it can also affect brush or roller application ones, depending on the complexity of the part’s geometry itself.

© Germedia

 The loss factor due to overspray affects spray application and can be

Figure 2 - Non-protective volume.

08

N. 89 - SEPTEMBER/OCTOBER 2024 - international PAINT&COATING magazine

© Germedia

ANALYSIS

Figure 3 - Necessary overconsumption.

DFT = Dry Film Thickness, the required thickness expressed in microns.

On the other hand, a paint product’s consumption expressed in litres

The formula assumes ideal conditions and does not take into account

per square metre applied is determined using the following formula:

factors such as overconsumption, dead volume, or losses due to overspray that may reduce the product’s actual coverage.

Dead volume correction coefficient The correction coefficient for the dead volume (fig. 2) is essential to

Where:

compensate for the loss of paint product that is deposited within

TC = Theoretical Consumption

surface irregularities and, therefore, does not contribute to effective

SV = Solid by Volume, the percentage of product remaining on the

protection.

surface after evaporation of the solvent

This coefficient helps estimate the actual amount of paint required to

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w w w. r a d i a l g r o u p s r l . i t

achieve the desired result.

DFT sampling plan. In this article, specific guidance is given according to

ISO 19840, in accordance with ISO 8503-1, provides guidance on

the geometry of the part to be treated, leaving the reader to adapt the

how to apply this coefficient. Table 1, provided by these standards,

coefficient according to their past and future experience.

simplifies the practical application of this coefficient, allowing the

This factor reflects the actual paint amount deposited on the treated

product coverage calculation to be adapted by considering surface

surface, and although it relates to geometry, it does not directly imply

discontinuities and their associated losses.

the loss of material due to the part’s geometry itself, which will be treated separately. To distinguish these two coefficients, we will use here the acronym NOC followed by the type of object geometry.

Surface profile in accordance with ISO 8503-1

Correction value µm

Fine

10

Medium

25

Coarse

40

 NOC for linear geometry: Linear geometry refers to large, flat-surfaced sheets, profiles, and tubular structures where the spray paint application does not involve frequent direction changes. This application process allows the operator to maintain a constant dispensing position over at least 90% of the surface to be treated. The stripe coating technique is not mandatory, and if used, it should be limited to a maximum of 5% of the total surface area.

Therefore, in the case of a shot-blasted surface, it is necessary to define

 NOC for complex geometry:

its type of surface profile and consequently increase the NDFT of the

Complex geometry refers to sheets, profiles, and tubes assembled to

first layer by the correction value.

form complex structures. In such cases, the spray application of the paint product requires numerous changes of direction, preventing the

NOC correction coefficient

applicator from maintaining a constant dispensing position over more

As this article introduces a new factor to balance the interests of all

than 50% of the surface to be treated. Stripe coating is necessary but

parties involved in a coating project, the following considerations will

should cover a maximum of 15% of the surface.

be based on empirical data collected experimentally during inspection activities (fig. 3). It should be noted that this factor is affected by multiple

 NOC for intricate geometry:

conditions, such as the type of application process, the complexity of the

Intricate geometry refers to sheets, profiles, and tubes assembled to

object geometry, the method used, and the tolerances indicated in the

form intricate structures. In such cases, the spray application of the

© Germedia

© Germedia

Figure 4 - Loss factor due to object geometry.

10

N. 89 - SEPTEMBER/OCTOBER 2024 - international PAINT&COATING magazine

Figure 5 - Loss factor due to overspray.

ANALYSIS

paint product requires numerous and frequent changes of direction,

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preventing the applicator from maintaining a constant dispensing position over the entire surface to be treated. Stripe coat application is therefore necessary and should cover more than 15% of the surface.

Table 2 also provides values for roller and brush application.

Type of surface

Correction value % spray

Correction value % roller / brush

Linear geometry

+15%

+5%

Complex geometry

+25%

+10%

Intricate geometry

+40%

+20%

Actual paint loss correction coefficient The actual paint loss must be related to transfer efficiency (TE), which represents the amount of applied paint that actually reaches the surface to be coated (figs. 4 and 5). Two main factors influence such efficiency: the object’s geometry and the application method. Based on the previous definitions, we will use the term “loss” similarly to the acronym NOC, to differentiate the required correction coefficients (table 3).

Type of surface

Correction value % spray

Correction value % roller / brush

Linear geometry

+10%

+0%

Complex geometry

+25%

+5%

Intricate geometry

+50%

+10%

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 Loss for linear geometry: This refers to large, flat-surfaced sheets, profiles, and tubular structures where the spray paint application does not involve frequent direction changes, allowing the operator to maintain a constant dispensing position over at least 90% of the surface to be treated. Under these conditions, almost all the applied paint is deposited on the surface. However, factors such as the type of atomisation technology, the distance from the surface, the geometry of the workpiece, the presence of air currents, and the delivery

srl

pressure set by the operator can affect the final result.

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

 Loss for complex geometry:

profile, in order to achieve an NDFT of 200 microns with a paint product

This refers to sheets, profiles, and tubes assembled to form complex

(PP) with 80% DRV, the following calculation scheme is suggested as per

structures, where the spray application of the paint product requires

the two examples.

numerous changes of direction and prevents the applicator from maintaining a constant dispensing position over more than 50% of the

Conclusions

surface to be treated. In these circumstances, part of the paint is not

Conducting a thorough preliminary economic analysis is essential

deposited on the surface due to the geometry of the workpiece, which

to ensure durable coating results. The project variables and their

facilitates the dispersion of the applied product. Additional factors, such

correction coefficients should be discussed and agreed upon in specific

as the type of atomisation technology, the presence of air currents,

meetings between the customer and the contractor.

and the dispensing pressure set by the operator, can further aggravate

Corrective factors such as the necessary overconsumption, if not

dispersion.

adequately considered, can have significant economic consequences.

These costs cannot be overlooked in the design phase nor entirely

 Loss for intricate geometry:

attributed to the applicators, assuming unrealistic execution skills. All the

This refers to sheets, profiles, and tubes assembled to form complex

parties involved should consider and concretely agree on the mentioned

structures, where the spray application of the paint product requires

correction factors to meet the required treatment performance

continuous direction changes and prevents the applicator from

standards.

maintaining a constant dispensing position over the entire surface to be treated. In this situation, a significant amount of paint is not

About the author

deposited correctly on the surface due to the highly complex geometry

Dr. Gianmaria Guidi has over thirty years of experience in the industrial

of the workpiece, which facilitates the dispersion of most of the applied

and corrosion protection coating sector. Over the years, he has

product. Additional factors, such as the type of atomisation technology,

specialised in the management of technical-legal disputes and is

the presence of air currents, and the dispensing pressure set by the

regularly registered with the Official Register of Court-Appointed Experts

operator, can further aggravate dispersion.

(C.T.U.) of the Italian Ministry of Justice, further enhancing his previous NACE and FROSIO certifications.

Suggested calculation scheme For computational calculations related to a spray coating project on a

Everything stated and reported here is intended for the benefit of the

structure with linear or intricate geometry and a “coarse” roughness

industry.

EXAMPLE 1

EXAMPLE 2

Project NDFT adaptation scheme

Values in µm

Project NDFT adaptation scheme

Values in µm

NDFT as per design

200

NDFT as per design

200

Dead volume correction factor (for the primer only)

+ 40

Dead volume correction factor (for the primer only)

+ 40

NOC correction factor (linear geometry =15%)

+ 30

NOC correction factor (intricate geometry =40%)

+ 80

Actual paint loss correction factor (linear geometry =10%)

+ 20

Actual paint loss correction factor (intricate geometry =50%)

+ 100

Total NDFT adjusted by the coefficients

= 290

Total NDFT adjusted by the coefficients

= 420

Theoretical and practical consumption and coverage analysis

Theoretical and practical consumption and coverage analysis

Theoretical coverage in m2/l

4.0 m2/l

Practical coverage in m2/l

2.75 m2/l

Theoretical coverage in m2/l

4.0 m2/l

Practical coverage in m2/l

1.90 m2/l

Theoretical consumption in l/m2

0.250 l/m2

Practical consumption in l/m2

0.362 l/m2

Theoretical consumption in l/m2

0.250 l/m2

Practical consumption in l/m2

0.525 l/m2

+ 44.8%

Increase over theoretical consumption

Increase over theoretical consumption

12

N. 89 - SEPTEMBER/OCTOBER 2024 - international PAINT&COATING magazine

+ 110%

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BRAND-NEW

ALIT Technologies Opens Two New Branches in Serbia and Portugal with New ALIT-Service Branches The new ALIT-Service Branches in Serbia and Portugal will bring high-quality paint-stripping services closer to its clients.

T

he chemical paint stripping company ALIT Technologies

paint stripping services in regions not yet covered by its distributors.

has recently proudly announced the opening of its first two

However, the new branches in Portugal and Serbia are just the start

international branches in Portugal and Serbia, under the brand-

of an ambitious expansion project: ALIT Technologies plans to open

name ALIT-Service. The expansion testifies the beginning of a new

many more strategic locations around the world. According to the

chapter for the Italian business, that is willingly to spread its paint

company, its expansion is not only a sign of ambition but also a

stripping services to new global markets.

concrete commitment to supporting economic growth and sustainable

“ALIT-Service represents an innovative and strategic initiative, which is

development in local communities, creating new jobs and providing

set to transform the landscape of industrial paint stripping. What makes

increasingly in-demand services.

our service unique is its bold and personalised approach, exclusively

“With this revolutionary initiative, ALIT Technologies embraces change,

using top products to meet the diverse needs of customers worldwide”,

redefines industry standards and opens the doors to a new and exciting

has stated Loris Rossi, the CEO of ALIT Technologies.

chapter of global success, demonstrating our vision for a future where

With the introduction of ALIT-Service, the company then further expands

innovation and excellence are fundamental pillars,” has concluded Rossi.

its already extensive range of offerings, in order to bring high-quality services closer to its clients. As a matter of fact, the new openings aim to bridge geographical gaps and meet the growing demand for contract

© ALIT

© ALIT

The ALIT Service Portugal team.

14

For further information: www.alit-tech.com

N. 89 - SEPTEMBER/OCTOBER 2024 - international PAINT&COATING magazine

The ALIT Service Serbia team.

BRAND-NEW

Brenntag Acquired Monarch Chemicals The acquisition of Monarch Chemicals will strengthen the market position of Brenntag globally.

B

renntag has recently acquired Monarch Group Holdings, a British distributor of chemicals for several industries, including

Curing ovens

Powder painting booths

paints and coatings.

“The team at Monarch have built a great product and service offering for their broad customer and supply partner base, and we look forward to growing and expanding that offering together. Brenntag gains expertise, infrastructure, as well as expanded liquid and powder blending capabilities with this transaction. With our acquisition strategy, we expand our last mile service operations to bring a broader portfolio of products and value-added services to customers, supported by our regional supply chain services within our global network. With this extended offering, all our customers in the UK can benefit going forward,” has stated Russel Argo, Regional President Brenntag Essentials EMEA. “We take great pride in the level of service and support we can offer our supply partners and customers. Our independence made us flexible, but joining Brenntag, a truly global distributor, will give us the scale and network we can use to grow our business and better serve our customers with a wider range of products and services,” has added

Washing tunnels

Spray paint booths

Innovative solutions

Our structure is organized and flexible and able to satisfy the most demanding requests.

Eurotherm solves every problem concerning painting processes, creating complete lines for the entire process.

Jon Hill, Managing Director of Monarch.

For further information: www.brenntag.com

Shot blasting booths

Customers who turn to Eurotherm are customers who, despite knowing the “painting process”, want to improve production by adopting highly customized technical solutions.

Based in Turin (IT)

95

205

Headquarter

Employees

Plants realized in 2023

Verona (IT) Lyon (FR) Sigmaringen (DE) Brussels (BE) Other locations

© Brenntag

PLANT 1: 4.700 m² of offices, metal work production and painting.

PLANT 2: 5.300 m² for production, preassembling, warehouse and logistics.

Eurotherm S.p.A. T +39 011 98 23 500 | M info@eurotherm.eu Eurotherm France S.A.S. T +33 6 76 72 48 65 | M france@eurotherm.eu Eurotherm Oberflächentechnik GmbH T +49 7571 92795 10 | M germany@eurotherm.eu Eurotherm Benelux Srl T +33 6 47 44 96 27 | M dekergorlay@eurotherm.eu

www.eurotherm.eu

BRAND-NEW

Dürr Will Manufacture a Paint Shop for Coating the Rear Centre Tank of The Airbus A321XLR The upcoming coating system from Dürr will enable Airbus to paint the rear centre tank of the A321XLR aircraft with enhanced energy efficiency and reduced carbon emissions.

T

he German engineering company Dürr has taken on its most

efficiency, Dürr is implementing a component-specific air ducting

significant individual project to date for the Airbus Group’s

system. This system reduces the amount of air needed for conditioning

division, Premium AEROTEC. The project involves constructing a

– thus lowering energy consumption. The energy recovery systems

state-of-the-art paint shop in Augsburg (Germany) for coating the new

will also recycle up to 65% of the energy from the exhaust air, further

rear centre tank of the Airbus A321XLR, crucial for the aircraft’s long-

enhancing efficiency.

range capability, extending its reach by 8,700 kilometres.

The paint shop will be a turnkey system, incorporating cutting-edge

Sustainable pollutant removal

technology to enhance energy efficiency and reduce emissions. Notably,

Premium AEROTEC’s commitment to sustainability is underscored by

it will feature an all-electric exhaust purification system, marking a first

its adoption of Dürr’s Oxi.X RV all-electric exhaust purification system

for Premium AEROTEC’s facilities. This system, based on regenerative

that operates without an open flame, resulting in very low nitrogen

thermal oxidation, promises to significantly minimise CO2 emissions.

oxide emissions. In addition, it is designed to run on green electricity,

Advanced surface protection and energy efficiency

Dürr’s Oxi.X RV system also includes a Sorpt.X CD unit that concentrates

eliminating additional CO2 emissions.

The project will cover the entire coating process, from pretreatment to

the exhaust air streams to enhance economic efficiency, reducing

sealing and painting. The new paint shop will include sealing, cleaning

the volume and increasing the solvent concentration. This allows the

and painting booths, as well as surface and leak testing areas. High

downstream Oxi.X RV unit to be smaller and operate without additional

standards for corrosion resistance and diffusion will ensure that the

heating energy, optimising the cost-benefit ratio.

tank surfaces withstand extreme conditions without corroding.

For further information: www.durr.com

Moreover, to achieve these high standards while maintaining energy

© Premium AEROTEC

The fuel tank integrated into the fuselage of the Airbus A321XLR is the key component in transforming the former short- and medium-haul planes into the new long-haul version.

16

N. 89 - SEPTEMBER/OCTOBER 2024 - international PAINT&COATING magazine

© Dürr

The exhaust air is purified with a flameless Oxi.X RV in accordance with the principle of regenerative thermal oxidation (RTO).

BRAND-NEW

Lechler Tech’s Water-Based Products Following CAM Criteria: Quality and Compliance with Environmental Protocol Requirements Lechler Tech water-based CAM-compliant products offer high performance, reduce environmental impact thanks to low VOC emissions and guarantee quality finishes in compliance with European regulations.

L

echler Tech offers solutions that meet its customers’ needs

• Regulatory compliance: being CAM-compliant means being in line with

without compromising the health of the planet. Choosing water-

current European building regulations (Green Public Procurement),

based products complying with CAM (Criteri Ambientali Minimi

which facilitates access to tenders and contracts.

- Minimum Environmental Criteria) is an important step towards a more

• Compliance with international protocols BREEAM/LEED/WELL:

conscious future. The features and benefits of Lechler Tech’s

compliance with CAM allows accessing LEED/BREEAM/WELL

CAM-compliant water-based products include as follows:

certifications.

• Reduced VOC emissions: water-based products have lower emissions

These water-based products have passed the EN 16516 low-VOC

of Volatile Organic Compounds (VOC), helping improve air quality and

emission test required by IAC GOLD in accordance with EN 16000 and

reducing environmental impact.

are CAM approved, which means they are totally free of HEAVY METALS,

• Safety: water-based products are generally less toxic and safer to

with low or no VOC EMISSIONS, and with controlled VOC CONTENT.

handle than solvent-based products, protecting the health of operators

Lechler Tech’s water-based products guarantee high-quality finishes

and end users.

on a wide range of metal and plastic substrates. They offer remarkable

• High performance: besides ensuring a reduced environmental impact,

versatility, allowing for the creation of glossy, matte, pastel-coloured, and

Lechler Tech’s products provide excellent performance in terms of

even metallic/micalised effects and textures.

durability, resistance, and finishing quality.

© Lechler

For further information: www.lechler.eu

international PAINT&COATING magazine - SEPTEMBER/OCTOBER 2024 - N. 89

17

BRAND-NEW

AkzoNobel’s Redox One Coat Successfully Coated the Shelving Systems of Trestles Redox One Coat from AkzoNobel Interpon is a powder coating designed to protect metal surfaces from corrosion and UV damage, all while streamlining production time and reducing costs.

T

he Czech shelving systems manufacturer

in rain or snow, and since using Redox One

colours we need, but its people are also very

Trestles has turned to international

Coat there have been no complaints,” has

friendly and flexible to work with. The technical

paints and coatings supplier AkzoNobel

stated Daniel Molnár, Procurement Manager

support it provides is certainly one of the

for a quality and durable powder coating,

at Trestles.

reasons why we continue to be one of the

opting for Redox One Coat.

Technically, Interpon Redox One Coat enables

most important manufacturers in the entire

“In the gates and fences sector in particular,

Trestles to reach corrosion protection up

European Union,” has added Daniel Molnár.

there are many companies we compete

to C4M and high UV durability in a single

“Businesses like Trestles need simple, effective

against, most of whom have more experience

coat which requires only a base chemical

solutions to get the job done with high quality

than us. To stand out from the competition we

pre-treatment, while traditional powder

but quickly, easily and at a lower cost. With

need to have the best quality, and since Redox

coatings require a primer layer for corrosion

Interpon Redox OneCoat we’ve removed

One Coat can be applied to both stainless

protection followed by a topcoat for gloss and

the need for a second process for the same

steel and zinc steel, we are able to deliver the

UV protection. In addition, Trestles offers its

job, saving on powder, energy and labour

quality our customers are looking for at the

product in four colours: Anthracite Grey, Jet

and maximizing productivity while delivering

price they are willing to pay. In salt spray tests,

Black, Moss Green and Blue/Grey.

desired quality. It’s helping Trestles to be

Interpon Redox One Coat performed the best

“We are looking to increase our production

competitive in a new market, and further

in protecting our products against corrosion.

and Interpon Redox OneCoat will help us.

improve their business performance,” has

We also tested it on different steel surfaces,

A single coat application will have a positive

added Sanal Limoncuoglu, Commercial

as well as some Beta products we currently

impact on reducing the time and cost of

Director South and East Europe of AkzoNobel

have on trial, with excellent results. We wanted

production and will help keep us competitive.

Powder Coatings.

to be sure the product would perform, even

AkzoNobel not only has the products and

“In a competitive market, Trestles is offering customers a new portfolio of fencing systems, and recognises that quality is key. We

© Trestles

demonstrate this quality with what is visible at first glance - the powder coating system of the Interpon Redox One Coat series from AkzoNobel,” has concluded Pawel Nowak, CEO of Trestles.

For further information: www.interpon.com/us/en

18

N. 89 - SEPTEMBER/OCTOBER 2024 - international PAINT&COATING magazine

BRAND-NEW

Jörg Krames Appointed as New President and CEO for BYK-Gardner BYK-Gardner has appointed its new President and CEO, Dr. Jörg Krames.

T

he global measuring instrument manufacturer BYK-Gardner,

strategy to strengthen BYK-Gardner as the market leader.

headquartered in Geretsried, Upper Bavaria (Germany) and part

“We are delighted to have found a managing director in Jörg Krames

of the ALTANA Group, welcomes its new Managing Director, Dr.

within our own ranks, who not only has excellent professional expertise,

Jörg Krames. As a trained mechanical engineer with a doctorate in

but is already very familiar with the ALTANA Group,” said Dr. Jörg

chemical engineering, Jörg Krames takes over the global management

Hinnerwisch, BYK Executive management and ALTANA Management

of the company with its foreign representatives and around 350

Board member. “With his strong focus on customers, technology and

employees. BYK-Gardner is a leading supplier in the field of measuring

innovation, Jörg Krames is continuing to lead BYK-Gardner on the road

instruments. The testing and measuring instruments objectively assess

to success.”

the quality of colour, gloss and appearance as well as the physical properties of paint and plastic products. Last year, the company

For further information: www.byk-instruments.com

acquired measuring instruments for non-destructive, high-precision coating thickness measurement.

Jörg Krames previously spent 15 years at ECKART, also an ALTANA Group company, as Vice President Global Key Account and responsible for Business Line Management Coatings. Prior to that, he worked for BASF Coatings as Director Key Account in Japan and Germany for leading car brands such as Toyota and Volkswagen.

His main goals are to drive forward the brand perception of the premium measuring instrument manufacturer and to drive forward the digitalization of business processes. Looking ahead to the upcoming

Competence in Shot Blast Technology

generational change, transformation projects and the continuous development of employees are among the focal points of his business

© BYK-Gardner

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

international PAINT&COATING magazine - SEPTEMBER/OCTOBER 2024 - N. 89

390-01/23-4c-GB

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

19

BRAND-NEW

HMG Paints Launched Hydrosol: A New Range of Protective Coatings HMG Paints has recently launched Hydrosol, a new range of hybrid coatings designed for the metal fabrication marketplace. © HMG

T

he first product to launch in this range is Hydrosol QD Primer, an alkyd-based, quick-drying primer designed for ultimate versatility and efficiency. In fact, it improves

adhesion and moisture resistance, while granting good corrosion protection thanks to the incorporation of modified Zinc Phosphate. This primer is ideal for structural steel, chassis and steel fabrications, and can be applied by using either roller, airless or conventional spray methods.

Moreover, the first user who are adopting the Hydrosol QD Primer are identifying several benefits, including increased coverage compared to competitor products and improved efficiency in application. This is thanks to volume solids of Hydrosol QD Primer which stands at 55% in comparison to approximately 40% for competitor equivalents.

“Our new Hydrosol QD Primer represents a significant advancement in protective coatings and is a testament to the work done by our Research & Development team to bring

© HMG

innovations to the market. This product not only meets the high-performance standards our customers expect from us, but also aligns with our commitment to environmental sustainability. It is the first piece of the jigsaw in our Hydrosol brand, with a variety of exciting products set to join this range in the near future,” has stated Paddy Dyson, Marketing Manager of HMG Paints.

The second to be launched will be the Hydrosol Compliant DTM, a Direct-to-Metal that can be applied directly to bare or primed metal surfaces. This technology is PG6/23 11 Compliant and ideal as a single coat primer finish for stillages, skips, containers, agricultural and construction equipment and machinery. It has lower VOCs in comparison to solvent based equivalent products and it is available in a wide range of colours, including RAL & BS. For further information: www.hmgpaint.com

20

N. 89 - SEPTEMBER/OCTOBER 2024 - international PAINT&COATING magazine

BRAND-NEW

Fast & Fluid Management Presented the New X-SMART PRO Automatic Dispenser The new X-SMART PRO Automatic Dispenser from Fast & Fluid Management combines repeatability and durability.

F

ast & Fluid Management has recently presented the new © Fast & Fluid

X-SMART PRO Automatic Dispenser, specifically engineered to provide unparalleled repeatability and with a robust design

which is tailored for demanding environments. By leveraging an advanced piston pump technology, it delivers precise colour dispensing, crucial for achieving consistent results required in various industries.

The automatic paint dispenser enhances the previous X-SMART series with a durable metal case and an upgraded brush, ensuring optimal cleaning operations. In addition, it also introduces additional safety features – including a front door sensor that guarantees operators safety without compromising functionality.

“In the fast-paced world of industrial tinting, precision and durability are not just simple requirements, but the foundation upon which businesses can build their reputation. So, recognising the challenges faced by different locations across the globe, the X-SMART PRO Automatic Dispenser is engineered to deliver both speed and robustness, crucial for maintaining continuous and reliable operation.

Its steel-armoured design ensures it can withstand the rigors of heavy usage, making it an ideal solution for businesses looking to reduce downtime and enhance operational efficiency”, has declared the company.

For further information: https://emea.fast-fluid.com

Sistemi di Profilazione della Temperatura Sistema Ottico

Completo:

Video e Temperatura

a a cos rno!

Guardede nel fo c suc

Forno e spegnimento

Nuovo Software

Profili termici e TUS

Rapporti CQI-9 e AMS2750 rapidi e veloci

Sicurezza:

a à Nnoovvaziiotne e sicurezz In

Semplicità:

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

Hall 6 Booth E53

BRAND-NEW

Condoroil Lands in Stellantis From Turin to Cassino (Italy): the degreaser CONDORINE SG 576 N developed by Condoroil Chemical, already used in the bumper cleaning line of the Stellantis plant in Turin-Mirafiori, has now also been implemented in the Cassino site’s production line, with considerable savings in energy and water consumption.

E

nergy saving, ecology, and low

reduce dragging issues, thus minimising the

The benefits for the customer included as

environmental impact have always been

progressive pollution of post-cleaning rinsing

follows:

key elements for the Stellantis Group.

baths.

 perfect cleanliness of the treated

With this in mind, about a year ago, Condoroil

components;

Chemical began testing its degreaser

A successful project

CONDORINE SG 576 N for integration into the

The project was developed in collaboration

product at room temperature;

final cleaning phases of plastic components.

with the Painting Process Engineering PPE

 lower product consumption;

Materials Approval team at Turin-Mirafiori,

 lower water consumption, including for

where the product is now used in the

rinsing. An 80% reduction in demineralised

CONDORINE SG 576 N is a one-component

cleaning phase of the bumper production

water consumption was observed in the final

low-foam detergent, active even at room

line, confirming the positive outcome of the

rinse phase (from 500 l/h to 100 l/h).

temperature. Its use ensures considerable

preliminary tests carried out. All the quality

energy savings and lower water consumption

requirements imposed by Stellantis for

compared with traditional products. The

product approval were met from the outset,

From Turin to Cassino: implementing CONDORINE SG 576 N

almost total absence of foam and the

as well as the considerable savings predicted

Afterwards, CONDORINE SG 576 N was

innovative features of its formulation also

during the design phase.

presented to the Plastic Unit of the bumper

Product features

 considerable energy savings by applying the

production and coating department at the Stellantis plant in Cassino (Frosinone), where a two-component solution was used that required a working temperature of at least 55 °C, like almost all current plastic degreasers. Now, by working at room temperature, they achieved considerable savings without any compromise on the quality of results. The implementation of this product in the Cassino plant was possible thanks to the Process Improvement team, which played a vital role in the early start-up phases and continues to closely monitor the regular production process.

For further information: www.condoroil.com

© Condoroil Chemical

22

N. 89 - SEPTEMBER/OCTOBER 2024 - international PAINT&COATING magazine

Moreno Zuccarelli, Condoroil’s Industrial Coating Sales Manager, with Achille Di Sano, Stellantis Alfa Romeo Cassino’s Bumper Production and Coating Manager.

BRAND-NEW

Gema Moved its Facility to Gossau to Increase Production Capacity

Your Leaders in Zero Liquid Discharge

The new Gossau-based facility features expanded production areas, advanced testing labs and eco-friendly systems, allowing Gema to enhance its manufacturing capabilities and increase production capacity.

T

he powder coatings application systems

customer application laboratory with advanced

supplier Gema has recently relocated to

coating lines, enabling more effective and practical

a new facility in Gossau (Switzerland). This

coating tests.

move underscores the company’s commitment to

Demonstrating its commitment to sustainability,

advancing manufacturing capabilities and boosting

Gema’s new location is equipped with photovoltaic

production capacity.

systems for energy generation and a brine/water

The new Gossau facility boasts spacious office

heat pump system for heating, highlighting the

environments, state-of-the-art meeting rooms and

company’s dedication to environmentally friendly

modern technological infrastructure. It features

practices.

Industrial Wastewater Treatment

a high-bay warehouse and expanded production areas, enhancing operational efficiency. Additionally,

For further information:

the facility includes a sophisticated test and

www.gemapowdercoating.com/en/

Simple Principle

© Gema

Effective Result Leading companies rely on vacuum distillation systems for the sustainable treatment of industrial wastewater.

Do you want to benefit from a zero liquid discharge production with VACUDEST aswell?

Just contact our Experts!

www.h2o-de.com

BRAND-NEW

KANSAI HELIOS Further Expands as a System Supplier in Italy KANSAI HELIOS Italy and Weilburger Coatings Italia continue their successful course together.

A

fter KANSAI HELIOS announced the successful acquisition of

The company has been focusing on expanding its infrastructure with

Weilburger Coatings in May 2024, Weilburger Coatings Italia and

projects like the implementation of new warehouses, enhancing both,

KANSAI HELIOS Italy have started to identify and leverage initial

storage and logistics capabilities. This expansion supports their strategic

synergies. This strategic integration not only expands the production

goal of serving diverse industries including houseware, stoves and

capabilities in Italy but also reinforces KANSAI HELIOS’s position as

heating appliances, railway vehicles, the eyewear industry, small items

a system supplier on the market. With local production of both –

and zippers, aluminium packaging, and coil and foil sectors.

industrial powder and liquid coatings – the company's expertise and

Weilburger Coatings Italia is committed to quality and sustainability,

service offerings are now stronger than ever. Additionally, the strategic

holding certifications such as ISO 9001-2015, ISO 14001-2015, and ISO

locations of the production units and the enhanced storage facilities

45001-2018. With the acquisition of Weilburger Coatings Italia, KANSAI

in Bergamo ensure greater flexibility and more efficient supply chains.

From now on KANSAI HELIOS Italy and Weilburger Coatings Italia will combine their expertise and strengths to serve the Italian market with a unified approach.

Over the past few years, KANSAI HELIOS Italy has experienced significant growth through strategic investments and continuous improvements on its powder coatings production locations in Riese Pio X (Treviso) and Tezze sul Brenta (Vicenza). The company expanded its production capabilities by adding new production lines and upgrading existing facilities with state-of-the-art equipment. Advanced systems are being implemented to enable paperless production and full product traceability, enhancing both, efficiency and sustainability. Focusing on innovation and sustainability, KANSAI HELIOS Italy is developing new products such as low-temperature cure powders and formulations using recycled or natural raw materials. Their unwavering commitment to excellent customer service is evident in their efforts to ensure maximum product availability, short delivery times, and continuous technical assistance. With 22 different quality approvals, KANSAI HELIOS Italy became a preferred partner for the industry.

Weilburger Coatings Italia has also made significant strides in recent years, driven by strategic investments and ongoing improvements.

The company specializes in industrial liquid coatings and operates from a state-of-the-art production site in Sotto Il Monte, Bergamo.

The headquarters of Weilburger Coatings Italy in Bergamo.

24

N. 89 - SEPTEMBER/OCTOBER 2024 - international PAINT&COATING magazine

BRAND-NEW

HELIOS is significantly expanding its presence in Italy. The strategic

with its experts for liquid coatings together with the well-known sales

alignment of the two companies will not only expand the presence of

representatives for liquid coatings from KANSAI HELIOS, who will move

KANSAI HELIOS in Italy, it also broadens the production capabilities

to Bergamo. This means that the usual contacts will remain.”

and most of all, strengthens its position as a system supplier. Now,

By joining forces and focusing on their core businesses, KANSAI

with two central hubs, KANSAI HELIOS offers a comprehensive range of

HELIOS Italy and Weilburger Coatings Italia are set to improve

industrial coatings: the Bergamo site for liquid coatings and the Treviso

performance by leveraging synergies and maximizing efficiency. The

and Vicenza sites for powder coatings, architectural coatings, and car

integration of Bergamo’s production site into the KANSAI HELIOS

refinishing.

network offers, for example, extended warehouse options, enabling

Bine Pangršič, Managing Director of KANSAI HELIOS Italy, assures: “We

the relocation of goods from the Piacenza hub to Bergamo and thus

want to fully utilize the expertise of the Weilburger Coatings team for our

closing the offices there.

customers and confidently place our industrial coatings business in the

Zoran Boras, Managing Director of Weilburger Coatings Italia, adds:

hands of our colleagues in Bergamo. Weilburger Coatings Italia will thus

“The strategic locations of our production units and the well-developed

become the hub for industrial liquid coatings in Italy - also for KANSAI

warehouses at all sites provide a solid foundation for future growth.

HELIOS products, which of course will be retained. Weilburger Coatings

This setup allows us to maintain greater flexibility and higher storage

Italia will only take over the trading part and act as a local service partner

capacities in the long term, with the opportunity for further expansion in the future. This move, set to be completed by March 2025, aims to keep day-to-day business unaffected, ensuring no impact on deliveries.

Additionally, the proximity of the warehouses to production facilities offers seamless logistics and quicker response times.”

The expanded capabilities and enhanced service offerings underscore the company's dedication to being a full system supplier aligned with customers’ wishes and needs. Italy remains one of the strategic markets for the KANSAI HELIOS Group, and this acquisition further extends the offer and strengthens the approach as a system supplier.

By joining forces with Weilburger Coatings, KANSAI HELIOS is now stronger than ever on the Italian market, providing a robust platform for innovation and growth.

About KANSAI HELIOS Italy and Weilburger Coatings Italia The two companies are one of the major suppliers of integrated coating systems, including liquid, powder, cataphoresis technologies, gelcoats as well as adhesives and sealants. Together they run three production sites in Italy. For powder coatings one in Riese Pio X (Treviso), with a production of around 7500 tones of thermosetting powder coatings and one in Tezze sul Brenta (Vicenza) with a production of around 2500 tones of thermoplastic powders. The liquid coatings production is located in Sotto Il Monte, Bergamo, where around 2500 tons of coatings are produced. Both companies are members of KANSAI HELIOS, which is part of KANSAI PAINT, one of the world's leading manufacturers of paints, varnishes and coatings.

For further information: © Weilburger Coatings Italy

www.kansai-helios.it and www.weilburger.it

international PAINT&COATING magazine - SEPTEMBER/OCTOBER 2024 - N. 89

25

HIGHLIGHT OF THE MONTH

Eisenmann’s New Course: Extensive Portfolio of Technologies, Customised Solutions, and International Presence Interview with Matthias Haarer, Managing Director of Eisenmann GmbH – Böblingen, Germany

Alessia Venturi, Editor-in-Chief of the ipcm® magazines, interviewed Matthias Haarer, Managing Director of Eisenmann GmbH, whose name has always been associated with customised, efficient solutions and the highest quality in industrial coating technology.

E

isenmann is a rapidly growing company. Since the GmbH was

What does the brand Eisenmann represent today?

founded in October 2020, the number of employees at its

“The brand Eisenmann represents customised, efficient solutions, and

headquarters in Böblingen (Germany) has risen from 100 to 190.

the highest quality in industrial coating technology. We offer a worldwide

In addition, there are 40 employees in its branches in Puebla (Mexico) and South Carolina (USA).

At its headquarters in Böblingen, the company pools all its core competencies: research & development, engineering, project management, quality assurance, service, and sales. Eisenmann also operates a technical centre with 8,000 square meters for pre-assembly, logistics, spare parts storage, and research & development. Via business partners (licensees) in China, India, and Spain, and own subsidiaries in Turkey, Italy, USA, Mexico and Saudi-Arabia, the German company maintains reliable business relationships in these markets.

Eisenmann GmbH plans to achieve a total operating performance of over 100 Mio. Euro in 2024, counting on a broad product portfolio and customer base in different industrial field, from the automotive (historically, the company’s core business) and wheels industries to the agricultural and construction equipment, down to the general industry as far as coating of metals and plastics by using dipping, powder and wet application techniques is concerned.

Mr. Haarer, can you offer our readers a concise portrait of Eisenmann GmbH? “The 2020 founded Eisenmann GmbH is focused on the successful further development of its business unit Paint & Assembly Systems with more than 1,000 patents which include all key products such as E-Shuttle 200 & 300, Vario-Shuttle XL, Vario-Loc, Vario-Mover (AGV), E-Cube and over 2,000 painting systems installed all over the world, of which around 90 are attributable to the alloy wheel sector, a field in which Eisenmann has been a pioneer”.

Modular, energy-efficient dry separation system E-Cube.

26

N. 89 - SEPTEMBER/OCTOBER 2024 - international PAINT&COATING magazine

proven and extensive portfolio of coating systems in the metal,

HIGHLIGHT OF THE MONTH

automotive, and wheels industries, including conveyor technology for

design, it is tailored to the customer’s requirements and is therefore

final assembly.

unique. They vary in their complex interplay of process steps and the

Having over 2,000 painting systems installed worldwide means that

conveyor systems adapted to them. All our products and solutions are

more than 60 million car bodies have been equipped in the PT-ED area

based on the experience we have gained from a wide range of projects

with Eisenmann patented technologies, like the conveyor systems for

in different industries around the world. And it is on this expertise that

dip coating of the E-Shuttle series or the rotating dip system for higher

we will continue to focus on in the future”.

payloads, VarioShuttle XL. With the new course of the company, we are able to support our customers worldwide with reliable service and spare

Company culture: how can you define that of Eisenmann?

parts management (24/7). The aim is to ensure that the systems retain

“Transparency and corporate responsibility, appreciation and tolerance,

their value for as long as possible, so that our customers can reliably

commitment and genuine practice, boldness, openness to something

achieve their individual production targets and the highest quality. Our

new, resource-consciousness, and sustainability in focus: these are

expertise also includes the analysis of modernisation measures and

Eisenmann corporate values. Today, more than 230 employees work

the creation of innovative and sustainable retrofit concepts for existing

every day to ensure the success of our clients. Highly specialised

systems”.

designers combine their many years of engineering experience with fresh ideas from highly qualified young talents. As a result, our product

What does it mean to customise a paint shop?

range and services are continually evolving. Our operations have been

“Customers requirements are extremely variable, even within the same

characterised by agility and the ability to innovate, as well as reliability

industrial field. Each painting system is based on individual planning and

and ambitious collaboration within the team.

© Eisenmann GmbH

© Eisenmann GmbH

quality and quantity, as well as on production processes and health aspects: precision, positioning accuracy, effectiveness, speed, and ergonomics are becoming increasingly important. A clever combination and safe co-operation between man and machine are indispensable and common practice today.

That’s why we are working on reliable concepts for new systems and – also very important – ideas for retrofitting or converting existing paint shops.

Based on a standardised software architecture with uniform operating concepts, we enable the use of robots and application technologies from leading manufacturers.

Our expertise covers all process and applications technologies for:  Seam sealing from bottom;  Seam sealing from top;

Matthias Haarer, Managing Director of Eisenmann GmbH.

 Insulating spray;  Cavity preservation;  Material handling”.

But living our values in our working

cataphoretic dip coating (PT/E-Coat), for

What is Eisenmann focus when

environment also contributes to customer

example VarioShuttle XL, E-Shuttle 200, and

developing new technologies?

satisfaction and a good working atmosphere.

E-Shuttle 300;

“Economic and ecological sustainability, as

We work constructively together, keep our

 Conveyor systems for the whole coating

well as a focus on energy efficiency, are crucial

promises, and meet our deadlines. This has

process, like the VarioMover (Automated

drivers for all developments. Beside this, we

resulted in a high level of loyalty among our

Guided Vehicle), VarioLoc, Monorail systems,

want to offer flexibility, user-friendliness, and

employees and trusting relationships with our

classic skid conveyor systems, Power &

easy-integration of the different systems. This

partners and suppliers. This is something we

Free-Systems for different payloads (Inverted

is why we have founded the new Robotics BU.

are proud of”.

Power & Free, circular and spindle conveyor)

Automotive paint shops are massive

for effective and individual usage in general

installations packed with painting technologies,

Can you briefly outline Eisenmann

industries / metal industries as well as the

and are energy- and resource-intensive.

product portfolio & services?

automotive industry;

Energy-wise, the painting stage is the

“Our technologies provide consistent quality

 Various drying systems (most compact and

most intense when it comes to the whole

standards throughout the whole process, from

resource-saving: E-SmartOven);

manufacturing process of a car body.

pre-treatment to final assembly. What sets us

 E-Cube, RE-Cube /Dry separation system for

Among the various technologies we

apart is our solution-oriented and customer-

collection and disposal of overspray;

have developed in this regard, it is worth

centric approach, which is always geared

 Solutions and application technology for

mentioning the new dry separation system

towards changing market requirements. Our

automated handling.

RE-Cube, which uses pyrolysis for a cost-

aim is to develop permanently relevant system

 The new founded business unit Robotics

and energy-effective dry separation of the

concepts that can be optimally integrated into

adds to this wide range of technologies”.

overspray.

The changeover from wet separation to dry

existing processes and open new potential in painting for our customers.

What is the new business unit Robotics

separation of the overspray was already

Our product portfolio includes:

about?

pushed by energy issues. Now that dry

 Conveyor systems for pre-treatment and

“There are high expectations on product

separation is well proven and widely used,

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N. 89 - SEPTEMBER/OCTOBER 2024 - international PAINT&COATING magazine

HIGHLIGHT OF THE MONTH

we developed the new RE-Cube system from the

aware of our responsibilities and try to design our

expertise gained with the two generation of our

products in a way that reduces harmful emissions

proprietary E-Cube technology. RE-Cube stands

and conserves resources such as electricity and

for REcycling Cube and that is the key point. It is a

water. All key ideas and technical approaches that

cube with a shell of sheet metal and only the filter

can improve the energy and resource balance are

parts inside the cube are made of card box. The

based on the firmly anchored sustainability concept

idea behind is to pyrolyze the card board cube in a

ATLAS that is observed by our employees.

pyrolysis oven at 450 °C, using the heat generated

ATLAS stands for Advanced Technology for Low-

by this process for other areas of the paint shop, for

emission Application and Sustainability. We do

example to heat up the ovens or the PT tanks. This is

not want to just place a slogan for sustainability,

a CO2 neutral process, since you eliminate the need

we really want to live this programme in terms of

for logistics and transportation and you balance the

product categories. An easy example of this is the

CO2 emitted during the pyrolysis with the CO2 saved

drying technology in an automotive paint shop. We

for heating up other stages of the painting process. It

have developed very efficient smart ovens, able to

is circular economy at its best!”

adapt the drying process to the type of car body entering the oven. We call these ovens “smart”

You mentioned ATLAS, Eisenmann

because, in combination with our smart conveyor

sustainability concept to improve the energy

technologies, like the VarioLoc or the Vario Mover

and resource balance. Can you explain this

(our own AGV system), they do have the intelligence

approach in details?

to direct the warm air individually and precisely to

“A paint shop is very resource-intensive. We are

the respective components of the car body by means

© Eisenmann GmbH

Eisenmann’s headquarters in Böblingen, Germany.

Headquarters: Via Marchesina, 53, Trezzano sul Naviglio (Ml) Italy Phone and WhatsApp: +39 375 6395301 info@spexparts.com www.spexparts.com

© Eisenmann GmbH

Pyrolysis-capable RE-Cube as part of the E-Cube system.

of an optimised control of the swivel nozzles. There are many other

concept: the careful use of valuable natural resources not only

examples of technologies developed by Eisenmann that comply with the

determines our actions in the development of our technologies. It is

ATLAS approach. In the PT/ED area with the patented Vario-Shuttle XL,

also important to us to consistently realise these goals when designing

a rotating conveyor system for dip coating, even heavy bodies of up to

a modern working environment that optimally meets our needs and

2,000 kg can be coated with consistently high flexibility, manoeuvrability

also provides an adequate presentation framework for our customers’

and efficiency. This meets a new common demand from our customers,

investment projects.

which are manufacturing car bodies becoming bigger and bigger every

We are building a new pre-assembly hall of about 7,000 sqm that will

day, in line with the SUV and E-Mobility trend. It is funny, but electrical

accommodate logistics, testing devices and equipment, the R&D area,

car bodies are sometimes heavier than those of traditional cars!

and the pre -assembly of our own proprietary products. Besides the

To sum up, ATLAS is not just theory put on a web-page: it is a concept,

pre-assembly hall, a new headquarter building of around 3,500 sqm will

we live it and our products realise it”.

accommodate from 250 up to 300 employees.

As I said, this step emphasises somehow the positive development of

As last question, can you set out briefly what the prospects of

our new company; sometimes, we need to remind ourselves that it is

the company are?

not just four years that we are back in the business, we did not start

“Eisenmann is currently planning a new building and will move to its

from scratch: with a new headquarters we combine the heritage and

own premises in the neighbouring town of Gärtringen in 2026. This step

the future. The investment for the new building will amount to 20 –

emphasises the stable growth of Eisenmann GmbH.

30 million Euro. The new location in Gärtringen also offers scope for

A new building offers us the greatest possible flexibility in terms of

future expansion. We would like to continue to develop as an attractive

modern and energy-efficient construction. We go back to the ATLAS

employer in the region and to create additional jobs”.

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N. 89 - SEPTEMBER/OCTOBER 2024 - international PAINT&COATING magazine

Ravarini Castoldi & C. srl ELETTROSPRAY® via E. De Nicola, 18 - I-20090 Cesano Boscone (MI) Italy - tel.+39 0255210608 www.ravarinicastoldi.it - dive@ravarinicastoldi.it

ASK JOE POWDER

The “Ask an Expert” Column Kevin Biller

kbiller@chemquest.com

overspray into your virgin powder feed will affect fluidization. This increase in fines and coarse particles may require adjustments to your fluidization process. How do you avoid this problem? The best strategy is to use high-quality powder coating from a reputable powder manufacturer. The most reliable suppliers have well-controlled grinding processes that yield relatively narrow PSDs. Narrow PSDs deliver high first-pass transfer efficiency and hence less overspray to contend with.

A secondary factor that contributes to poor fluidization is moisture.

“Wet” powder is very difficult to fluidize and transport through a powder application system. High levels of moisture are usually due to poor storage and handling of powder coating inventory. Powder should be stored in an air-conditioned environment and open bags/containers should be avoided. In addition, you should be careful to avoid introducing “cool” powder into a warmer, moister environment. The cool powder will act as a desiccant and absorb the ambient moisture. It is Dear Joe,

wise, as you move powder from storage to the application area, to allow

What makes one powder fluidize better than another?

it to acclimate to the ambient application environment before opening

Jason Smith

the package.

Denver, Pennsylvania

Thank you for the question. Best regards, Joe

Hi Jason, This is an excellent question. For a powder coating to perform well,

Hello Joe,

many physical and chemical properties must be aligned. Fluidization

We currently are planning on using cold-rolled 304 stainless

performance is one of the critical physical properties necessary to

square tubing for our instrument housings, and the tubing

successfully apply a powder coating. Fluidization involves incorporating

comes slightly oxidized and slightly pitted. We are looking

a volume of air into a quantity of powder to prepare it to be transported

to provide the customer a finish for the housing that looks

from the feed hopper to the application gun. This mixture of air and

professional and prevents it from going back to the way we

particles not only helps transport the material but also enhances the

received it.

delivery of electrostatic charge to the individual particles as they exit

We were looking at possibly painting, powder coating, polishing,

the spray gun. Particle size distribution (PSD) is the primary factor that

or plating the housing, but I am leaning towards powder

influences fluidization. Powder coatings are comprised of a range of

coating as a cost-effective means to protect the housing. The

different-sized particles, from about 1.0 micron upwards to around

environment the instrument will be in ranges from -40°C to

100 microns. The best fluidization occurs within the heart of this range,

+100°C and is occasionally dusty, oily, and near sea water (not

typically 20-60 microns. Fines (< 10 microns) tend to agglomerate and

touching or emerged). Given that the tubing is 304SST, I know

impair fluidization. Coarse particles (> 100 microns) are difficult to

adhesion is the big problem. Can you recommend the proper

fluidize because of their relatively high mass. Hence, the best fluidizing

way to prepare the surface of a 304SST material? Details on the

powder coatings possess tight particle size distributions. This means a

type of degreaser to the type of grit (non-ferrous) or chemical

minimal level of fines and also a minimum of coarse particles.

(i.e., silane), to the primer type so that UV and sea salt corrosion

If you employ a reclaim system to capture and recycle oversprayed

will not affect the housing for up to 10 years would be greatly

powder, this can be a factor in fluidization. The best-suited particles are

appreciated.

preferentially deposited on the parts you coat. And as you can surmise,

I look forward to your reply,

the fines and coarse particles populate the overspray. Reintroducing

Christopher Filoon, Pennsylvania

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N. 89 - SEPTEMBER/OCTOBER 2024 - international PAINT&COATING magazine

Hi Christopher,

run through the entire cleaning/passivation/coating/

This is an excellent question, and it is very wise

curing process and perform the following tests:

to explore all your options before committing to

Simple “X” crosscut dry adhesion. Cut a 40 mm by

a new process. Powder coatings are a very good

40 mm “X” into the coating with a sharp blade. Apply

finish for stainless steel if the process is designed

a strong tape such as 3M 2517 or Permacel #99

and maintained properly. The key is in the cleaning

and pull sharply. The coating should exhibit no

and metal pretreatment process that precedes

loss of adhesion. A similar test can be done with

application of the powder. The process you should

a “crosshatch” as described in ASTM D3359. This

consider for powder coating starts with media

entails a perpendicular series of cuts that create

blasting. A high-quality medium such as aluminum

a grid. Nevertheless, the simple “X” crosscut test

oxide will suffice. Follow the blasting with a well-

is usually sufficient to determine if adhesion is

controlled alkaline degreasing step to remove

acceptable.

any residual oils, process fluids, and handling

Hot water immersion adhesion. Place the coated

contaminants. It is also important to keep your blast

samples evaluated in the adhesion test described

media clean. Next, I suggest a passivation step to

above into a 75°C water bath for 24 hrs. Remove and

remove any iron-based residues on the stainless

allow them to dry, then recheck tape adhesion. The

surface, as well as the possible presence of residual

coating should show little or no loss of adhesion.

sulfides. Trace amounts of either contaminant can

I would confirm these test results with a 500-hrs Salt

act as sites for subsequent corrosion. Passivation

Fog test (ASTM B-117). Place the scribed test parts

of stainless steel typically involves immersing

in the corrosion chamber and evaluate every 250

the part in a nitric acid bath, although nitric acid/

hrs. Most powder coatings pass 1,000-hrs Salt Fog

sodium dichromate or citric acid solutions can also

resistance, and 500 hrs is what I consider a minimum

be used. The concentration of acid can range from

benchmark.

20-50% by volume. ASTM A380 describes standard

Good luck with identifying a finishing technology that

practices for passivating stainless steel.

provides the necessary cost/performance balance.

After thoroughly drying the parts, it is wise to powder

Best regards,

coat the passivated surface as soon as possible.

Joe

Chemically pretreated surfaces have a finite shelf life before they begin to degrade. Using a highquality powder coating precludes the need for a primer coating. Meeting the durability required in the environments you describe requires the powder coating to be applied at a reasonable thickness as specified by the powder coating supplier; 6580 microns are usually sufficient for an outdoor application. It is also critical to ensure that the coated parts see enough temperature and time to complete the cure to the powder coating chemistry. When a powder supplier quotes a recommended bake, they are referring to the time at or above the stated temperature that the part has reached. It is therefore important to factor in the heat-up time needed to reach the bake temperature. As for ensuring acceptable coating performance in the field, I can recommend a couple of practical tests. I suggest that you prepare a few test pieces that have been

© ipcm

FOCUS ON TECHNOLOGY

Automation and High Quality: Pulsar Improves Its Coating Process with a New Articulated Robot Ilaria Paolomelo ipcm®

Pulsar, a Polish company specialising in the production of safety devices and accessories for alarm systems, was experiencing some problems with its products’ coating quality. To solve these issues, it decided to switch from a manual to an automatic application system by relying on Lesta. The coating robot supplied by this Italian company enabled Pulsar to obtain uniform finishes, improve process repeatability, and minimise manual touch-ups. This change significantly boosted its productivity, allowing it to handle a daily production of up to 2,000 product sets, with a 400% increase in capacity.

I

n the modern industrial context, coating is a crucial phase that affects not only the aesthetics of products but also their degree of protection and durability over time. Often, when companies need to

install a new coating system, they are faced with a fundamental choice between two application methods: manual and automatic. Each brings specific advantages and challenges that can significantly affect the efficiency and overall quality of the end products.

Manual coating offers a high degree of control and adaptability but strongly depends on the operator’s skills and experience. This process makes it possible to work on complex details and flexibly handle unpredictable variables, such as uneven surfaces or changing environmental conditions. However, it may present limitations regarding uniformity and repeatability of results, increasing the risk of defects and variability in the quality of finishes.

On the other hand, automatic coating systems are designed to operate efficiently, ensure greater accuracy and repeatability of results, reduce processing times, and minimise human error. They are particularly advantageous in large-scale production environments, where consistent

FOCUS ON TECHNOLOGY

© ipcm

© ipcm

© ipcm

From left to right: Components entering the pre-treatment tunnel; The atomising process; Components after the pre-treatment cycle.

results and speed are essential to maintain competitiveness and meet

manufacturer of accessories for alarm, access control, and video

quality requirements.

surveillance systems. Pulsar’s product range is broad and diverse

Pulsar faced this decision, too. Until 2017, it operated with a manual

and includes enclosures, power supplies, PoE devices, fire protection

coating plant equipped with two booths, but despite the efficiency of

systems, transformers, and accumulators. The company has quickly

the plant, the results’ quality was not up to expectations: problems

extended its presence to European and Asian markets, consolidating

with finishing uniformity and quality were compromising the company’s

its position through a constant commitment to excellence. “Thanks

operational efficiency and ability to meet the high standards demanded

to a strategy focused on quality and innovation, we have been able

by its customers.

to expand into new markets and maintain a leading position,” states

To solve these critical issues, Pulsar chose to automate the coating

Pulsar’s CEO, Krzysztof Tatara.

application phase by relying on Lesta (Dairago, Milan, Italy) for the

Today, with over 200 employees and a production site of 8,000 m²,

supply of a new, six-axis articulated coating robot. Installed within a

Pulsar stands out as a modern and dynamic company, capable of

single coating booth, this works in synergy with the reciprocators: the

responding flexibly to the global market’s needs. Its success is the result

robot applies paint on the difficult-to-reach surfaces of parts, such as

of a carefully curated production cycle in which every stage is designed

hollow spots, whereas the two reciprocators, each equipped with three

to ensure high quality standards. “Pulsar uses only the highest quality

guns, coat the flatter surfaces. This innovation has enabled the Polish

materials and subjects each product to rigorous controls during all

company to overcome the limitations of the manual process, achieving

manufacturing stages, from sheet metal processing to coating and from

higher levels of quality and more consistent finishes.

the electrical components’ production and installation to final assembly,”

Pulsar: innovation and quality in the production of safety and video surveillance accessories Since 1994, Pulsar (Łapczyca, Poland) has established itself as a leading

adds Tatara. “In particular, coating is one of the most important steps in our workflow, as it provides each metal part with essential protection.

For Pulsar, the finishing cycle plays first of all a functional role and only secondarily an aesthetic one.”

international PAINT&COATING magazine - SEPTEMBER/OCTOBER 2024 - N. 89

35

The coating cycle and the booth’s special feature

After pre-treatment, the operator unloads the workpieces, which

The coating process is designed to ensure the highest quality and

then undergo a masking process necessary to prevent certain parts

durability of the finished parts while maintaining high production

from losing conductivity. They are then placed on special trolleys and

efficiency. “The components are manually loaded by the operator

transported to the new coating area. “Our products’ hanging precision is

onto the monorail conveyor and taken to the pre-treatment tunnel,

crucial as even a shift of a few millimetres can affect their final finishing

where they undergo a degreasing phase, necessary to remove oils and

quality. Therefore, the operator uses laser trackers to position the

surface residues from the previous processing stages, combined with

components correctly on the hooks,” indicates Szczepanik.

passivation with iron salts to form a protective layer;

The system, equipped with a laser barrier for automatic part contour

a rinse with mains water and further rinse with demineralised water.

detection, optimises all the paint application operations. The

That is sufficient for Pulsar products intended for indoor use, such

components are transported into the coating booth at a speed of 1

as home security systems, which do not require advanced corrosion

metre per minute, where the coating process is divided into two stages.

protection,” notes Łukasz Szczepanik, Sales Manager at Indufinish, the

At first, the six-axis articulated robot supplied by Lesta applies the

plant engineering company that supplied the coating system.

coating in hollow, difficult-to-reach areas using its advanced technology

“The special feature of the pre-treatment tunnel lies in the tanks made

to paint concave surfaces. Subsequently, six reciprocator-mounted guns

of polypropylene, which provides numerous advantages over steel. It

supplied by PUT Wagner-Service Polska apply the powder on the outer

is characterised by its high resistance to corrosion, a decisive factor

surfaces of the components, which are mostly flat.

in industrial environments where moisture and chemicals can easily

“This plant’s key peculiarity,” illustrates Indufinish’s Sales Manager, “is

deteriorate steel. Finally, the improved thermal insulation offered by the

that the robot and the reciprocators coexist in one booth. Unlike other

polypropylene contributes to the greater energy efficiency of the system

systems where the robot only performs a pre-finishing function, here

by maintaining stable temperatures and reducing heat loss,” adds

it is an integral part of the application phase.” Manual post-finishing is

Szczepanik.

performed if necessary, but thanks to advanced robot programming,

© ipcm

The pre-treatment tunnel tanks made of polypropylene.

36

N. 89 - SEPTEMBER/OCTOBER 2024 - international PAINT&COATING magazine

© ipcm

Within the same booth, powders are applied first with the Lesta robot and then with six Wagner guns mounted on reciprocators.

FOCUS ON TECHNOLOGY

this is now rarely required. “The coating booth is designed to enable rapid colour

© ipcm

changes thanks to the use of a cyclone that facilitates the reuse of residual powders. At Pulsar, we have an average of five colour changes per week as 80% of production is painted white and the remaining 20% black, grey, and red,” says Tatara.

At the end of the application phase, the parts enter the curing oven for about 20 minutes, and after cooling down, the operator unloads them from the hooks, removes any masking device, performs quality controls, and prepares the products for shipment. Despite the compact size of its coating plant, Pulsar can now process up to 2,000 sets of products, each consisting of two elements, in a 16-hour working day. In some circumstances, the plant can handle up to 5,000 smaller sets.

Reasons behind this choice Pulsar recently undertook a major renovation of its coating plant. Although the system had been installed in 2017, some challenges related to finishing quality had emerged over time. “The manual system we had in place, although initially effective, was beginning to show some limitations,” explains Pulsar’s CEO. “Differences among our operators caused undesirable variations in the quality of the final products, especially in different shifts. We could not allow this to affect our reputation. That is why we decided to make a technological leap: on the advice of Indufinish, which

A P P R O V E D

LECHLER TECH WATER-BASED PRODUCTS: HIGH QUALITY FINISHES ON A WIDE RANGE OF METAL AND PLASTIC SUBSTRATES.

www.lechler.eu

Lesta provided a coating robot to optimise the application phase.

© ipcm

After the application phase, the components pass through a storage buffer before entering the curing oven.

© ipcm

Components exiting the curing oven.

we had already approached to install the coating system, we decided

the key to solving several quality issues and making the process

to invest in a robot not only to improve our coating results but also

smoother and less dependent on manual labour. Indeed, it has

to increase our production capacity. Indeed, thanks to the installed

optimised production and even improved the working conditions

technology, this has increased by more than 400%.”

within the company. “Reducing our employees’ exposure to dust was

Conclusions

a priority,” emphasises Tatara. “Now, our operators mainly deal with robot programming rather than coating, which makes their work less

“After a visit to Pulsar’s plant to analyse the reported problems, it soon

burdensome.”

became clear that a significant part of the manual operations could

Pulsar’s CEO also expresses great satisfaction with Lesta’s advanced

be optimised with a coating robot. I pointed out an automated system

technology and Indufinish’s continued support: “We can only be pleased

could replace many of the manual tasks, improving the efficiency and

about our collaboration with Lesta and Indufinish. The technology

quality of the coating process,” says the Sales Manager of Indufinish. “We

provided by Lesta lived up to our expectations, and Indufinish’s constant

then organised a meeting with Igor Kania, Lesta’s sales representative

support was instrumental in addressing and solving every challenge that

for the Polish market, and it was immediately apparent that a robot

arose along the way. We are very satisfied with the results achieved. We

could solve the problems encountered.”

are confident that this partnership with Lesta and Indufinish will enable

Although initially not planned, the robot’s implementation became

us to continue to grow and meet our customers’ needs.”

38

N. 89 - SEPTEMBER/OCTOBER 2024 - international PAINT&COATING magazine

RISE UP for the BETTER Small and Large EFFECTive REVOLUTIONS

CURIOUS? Let's rise up and explore the TOOL

Merck Srl Electronics | Surface Solutions Via Monte Rosa 93 | 20149 Milano MI | Italia

PMsalessupportIT@merckgroup.com tel. 00 800 72771666 surface-portal.merckgroup.com/IT/it

© SG Projects

HIGHLIGHT OF THE MONTH

High Recovery Rate with Ultrafiltration Membrane Technology in Electrocoating Processes Federica Alberti SG Projects – Voghera (Italy)

federica.alberti@sgprojects.it

SG Projects is the partner company of Solecta that deals with the distribution of their painting and products in Italy, guaranteeing continuous customer support and representing a rapid intermediary ready to solve any problem that may be detected on the ultrafiltration lines. The following is an overview of the advantages offered by ultrafiltration membranes for the electrophoretic process and a quick guide to perform effective maintenance operations.

40

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HIGHLIGHT OF THE MONTH

T

he core part of the industrial painting process is the cataphoretic

capacity is the ‘specific filtrate capacity’. It depends on the type of

bath, where a layer will be deposited by electrodeposition on

paint used and must be determined from case to case by way of

the items to be painted. At the end of this step, coated items will

measurement. The specific filtrate capacity is also influenced by the

be rinsed with ultrafiltrate (the liquid part of the paint bath, purified of

paint recirculation system, i.e.:

pigments, with a similar process of RO but with different cut-off).

 Pressure

Ultrafiltration is a pressure-driven membrane process capable of

 Temperature

separating solution components on the basis of molecular size and

 Solids concentration

shape. Under an applied pressure difference across an ultrafiltration

 Cross flow

membrane, solvent and small solute species pass through the

 Carry-over from pre-treatment.

membrane and are collected as permeate, while larger solute species

It is necessary to adapt the replenishing material to the use of

are retained by the membrane and recovered as a concentrated

ultrafiltration.

Retentate.

To be more specific, in the paint process it is necessary to rinse the

In electrocoat paint systems, the ultrafiltration permeate contains

surface of the plated parts with water first, and then rinse with pure

water and paint solubilizer. The Permeate is used in the paint line rinse

water. Wastewater contains mainly harmful chemicals such as epoxy

section. This recycling method provides a closed loop rinse system for

resin, paint, vegetable oil, carboxylic acid, butanol and pigments.

recovering paint solids (drag-out). The Permeate can also be diverted to

When the painted part is taken out from the electrocoating tank, it

drain, in order to reduce conductivity of the paint.

needs water to wash off the residual liquid paint on the surface, thus

The degree of paint recovery depends on the quantity of rinsing water

producing electrophoretic paint wastewater.

which is supplied to the electro-dip coat painting bath. This quantity

The electrical coating in the wastewater represents 30% of the paint

corresponds to the quantity of filtrate. The filtrate capacity referred to

used. Adopting an ultrafiltration membrane device will form a closed

the membrane cartridge surface area at a certain paint recirculation

circulation route, allowing to re-use both the paint and the water.

© SG Projects

The ultrafiltration process.

international PAINT&COATING magazine - SEPTEMBER/OCTOBER 2024 - N. 89

41

© SG Projects

A sample scheme of an electrocoating process with ultrafiltration membranes.

The advantages of ultrafiltration systems

for multiple other industrial sectors. The recovery rate has significantly

Ultrafiltration may provide advantages in terms of paint recovery, the

increased and the processing cost has been reduced by 30%.

control of the chemical parameter of the coating and the balancing of the conductivity in the tank. As the electrophoresis process goes on,

The maintenance of the ultrafiltration membranes

the content of the water, the cosolvent and the inorganic ions in the

After several operational hours, the e-coat process may be subject to a

electrophoresis solution in the metal tank increases, affecting the quality

flux rate decrease. Therefore, a recovery procedure might be required.

of the painting process. The ultrafiltration technology can retain polymer

Several factors from the normal operations of the electrophoretic

coatings and pigments, remove excess water and other impurities in the

plant can affect the permeate output deriving from the ultrafiltration

electrophoresis solution, extend the use-time of the coating solution

membranes, such as the type of paint employed, the percentage of

and improve the quality of the paint.

solids, the operational temperature, the conductivity and pH of the

The ultrafiltration membrane technology offers then the following

tanks, the paint flow and the inlet pressure to the membranes, as well as

advantages for the treatment of the wastewater deriving from the

the drop and drag-in contamination from the pre-treatment tunnel, just

electrophoretic painting process:

to mention a few.

 It has good retention effect, providing a clean and transparent filtrate

After the start-up, the ultrafiltration flux rate will decline to a steady-

after the treatment;

state flow within some days: this steady-state flow will be considered

 The automatic system control is simple and easy to use, guaranteeing

the baseline for your system. However, when the system declines to

safety during operations;

~70% of the steady-state flow, it is time to clean it. A delay in cleaning

 The space-saving equipment has a rigorous structure and a low-

can lead to irreversible fouling. Care should be taken to maintain the

energy consumption;

recommended flow rate for your particular system. On paint, it is

 The large water output is suitable for the recovery of cathode and

recommended to maintain a pressure differential of 2,0 - 2,3 bar, with a

anode electrophoretic paint;

minimum outlet pressure of 0,7 bar.

 It possesses a good anti-pollution ability and long-term operations will

Because the number of variables affecting the proper performance of

not affect the water production.

the ultrafiltration system, it is important that a detailed log is kept and

As a matter of fact, the ultrafiltration membrane technology has played

maintained on a regular basis. This will ensure that potential problems

a major role for the electrophoretic painting process of car bodies,

could be avoided and the cause of the flux decline be determined more

luggage accessories, electrical appliances and several metal components

accurately and eliminated as a potential or recurring problem.

42

N. 89 - SEPTEMBER/OCTOBER 2024 - international PAINT&COATING magazine

HIGHLIGHT OF THE MONTH

Here are the most common problems and the related solutions: Shutdowns When an unplanned shutdown occurs, the paint must not stand

EnvironmEnt SuStainablE GrEEn

idle in the ultrafiltration system: if it is allowed to stand idle for too long, the membranes may become fouled beyond recovery. So, during shutdowns, it is necessary to immediately drain and flush the system with fresh D.I. or R.O. water (permeate if available) and a chemical cleaning procedure shall be started before the system shutdown.

Additions to the paint Moreover, when resin, pigment, solvents or solubilizers are added to the paint, they should be added slowly and according to the recommendations of the provider. Furthermore, the additions should not be made near the intake of the ultrafiltration pump.

8–10 October 2024, Düsseldorf booth 3H60

© SG Projects

wastewater recycling

VACUUM EVAPORATORS • > 90% WATER RECYCLING • REDUCTION OF DISPOSAL COSTS • ZERO LIQUID DISCHARGE • ZERO EMISSIONS • EASY MAINTENANCE • FULLY AUTOMATIC

An example of ultrafiltration technologies.

www.saitaimpianti.com

© SG Projects

© SG Projects

An example of an ultrafiltration system and a scheme of the process.

Sediments and agglomerates

Paint stability

Paints always contain some minor percentage of destabilized paint

A healthy paint consists of dispersed paint particles that carry optimum

particles, which will cause sediment or agglomerate formation in system

electrical charges to repel each particle from others, inhibiting the

areas of zero flow. Because some 10 g of agglomerates can ruin an 8”

formation of agglomerates. The unstable paint may lose these electrical

Element, all necessary pre-filtration procedures must be carried out to

charges because one or more of the following conditions:

avoid sediments and/or agglomerates from reaching the ultrafiltration

 Inadequate solubilizer levels causing the paint pH to move out of

modules.

range;  Contaminants (such as iron) reacting with the solubilizer or paint;

Paint fouling

 Bacteria consuming the solubilizer or otherwise disturbing the paint

One of the main reasons of unsatisfactory performance and flux

solubility;

decline is related to paint fouling. Paint fouling occurs when the stability

 Flow rates too low to sweep away the fouling layer at the surface of

or solubility of the paint allows agglomeration of the paint particles

the membrane;

and the membrane surface becomes obstructed with these ‘gummy’

 Severely low flow rates resulting in settling, loss of electrical charge

agglomerates. So, the permeate passes through the membrane with

and agglomeration;

more difficulties.

 Improperly introduced replenishment feed material;  Introduction of occluded air into the paint, through vortexing at the pump, etc…

44

N. 89 - SEPTEMBER/OCTOBER 2024 - international PAINT&COATING magazine

The new way of CONVERSION COATING Dosing and nebulization system for the conversion coating of metal and aluminium parts Drizzling consists of a dosing panel for automatically managing the demineralized water coming from a feed tank and the amount of passivating chemical product, in order to apply an optimally concentrated solution on the material to be treated. The use of special atomizing nozzles and compressed air enables it to produce and evenly distribute a light mist of chrome-free solution.

WANT TO SEE IT IN ACTION? Visit us at stand 3H42 8 – 10 October 2024 Messegelände Düsseldorf, Germany

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

SAFE

EFFECTIVE

FLEXIBLE

Electric circuit fully insulated from liquids for greater safety

The solution that is sprayed is always fresh and dosed in-line

Suitable to treat different types of metal components

www.alit-tech.com

ADVANCEMENTS

Increased Lacquer Adhesion and Possible Savings Thanks to New High-End Coating Process Andreas Michalske VENJAKOB Maschinenbau GmbH & Co.KG - Rheda-Wiedenbrück, Germany andreas.michalske@venjakob.de

Modern fittings combine form, function and design. The challenge for manufacturers is to meet individual color and design preferences while at the same time ensuring durability and abrasion resistance. Sooner or later, the finish may suffer damage in certain areas, especially under heavy duty use. Together with three technology partners, Venjakob -specialized in customized finishing lines, provides a solution that offers far-reaching economic and ecological benefits.

W

herever there is a demand for chrome-plated fittings with a

Fittings, for example in bathrooms and kitchens, which are subject to

stylish surface design in a colored, metallic, smooth or glossy

heavy use, must be robust and corrosion-resistant.

look, coating plays an important role. Depending on the

“Metallization alone is not enough to achieve long-lasting adhesion of the coating to the material surface,” says Andreas Michalske, sales

intensive.

engineer at Venjakob.

© Venjakob

material to be coated, the process can be very complex and resource-

Innovative and resistant surface finishes for metal and plastic components without the use of heavy metals using the HIGH END COATING (HEC) process. The environmentally friendly coating process offers improved technical properties, passes the stringent requirements of the relevant industry tests and offers attractive looks with an almost unlimited choice of colors and gloss levels.

46

N. 89 - SEPTEMBER/OCTOBER 2024 - international PAINT&COATING magazine

ADVANCEMENTS

Venjakob presented the patented coating process at this year’s Paint

ADVANTAGES OF HEC-PROCESS

Expo in Karlsruhe/Germany, the world’s leading trade fair for coating technology.

Up to 70 percent savings - without any loss of quality For the fittings industry, the high-end coating process (HEC) could be the solution to many challenges. This involves a special pre-treatment in a

•

industrially inspected, tested and proven

high-vacuum system. The surfaces of metal and plastic parts are given an antistatic functional layer with increased surface tension.

This simplifies the subsequent coating process. Pre-cleaning the surface with ionized air is completely sufficient. “In the subsequent coating

•

compliance with standards of the fittings, hardware and automotive

process, we can manage with layer thicknesses of between 12 and 25 µm. Paint consumption is reduced by up to 70 percent.

industries

The components treated in this way have a high-quality appearance and pass all the necessary tests,” explains Michalske. It is important to know that the fittings industry places higher demands on components than the automotive industry, for example. There is a so-called boiling

•

one-coat system, without adhesion promoter or additional primer

test, in which the components are placed in a boiling medium to test how long they remain intact or do not release any harmful substances.

Components in the automotive industry only need to “boil” for one hour.

In the German fittings industry, 100 hours are required.

•

can be integrated into existing series processes

Less effort for better results The high-end coating process is completed in just a few steps. The components are pre-treated in a special HEC high-vacuum process

•

no clean room conditions necessary

•

paint material savings of up to 70%

•

no disposal costs

•

replaces passivation and phosphating

•

no additional chemicals or water

and a specially generated vacuum plasma. They are then removed and fed to the coating system for coating. The high-vacuum pre-treatment replaces passivation and phosphating, thus reducing the number of pretreatment steps. There is no edge alignment or edge build-up during the subsequent coating process. The high-end coating process offers many other advantages and can also be integrated into existing series processes.

About Venjakob Venjakob, founded 1963 and family owned in third-generation, is one of the world’s leading manufacturers for finishing lines. The company develops individual solutions for the entire production line, including

required

pretreatment, coating, drying and automation technology, as well as exhaust air purification plants. All from a single source and individually tailored to the needs of users from a wide range of industries. Venjakob is headquartered in Rheda-Wiedenbrück, Germany, and employs 380 people worldwide. Further production facilities: Venjakob Umwelttechnik

•

environmentally friendly, free from chrome and heavy metals

GmbH & Co. KG in Sarstedt, Germany and Nutro Inc. in Strongsville, Ohio, USA.

international PAINT&COATING magazine - SEPTEMBER/OCTOBER 2024 - N. 89

47

10

TH

“Everything About Chemistry!”

27-29 November 2024 Istanbul Expo Center turkchem.com.tr Organizer:

Supporters:

Official Airline:

Media Partner:

THIS FAIR IS ORGANIZED WITH THE PERMISSION OF TOBB (THE UNION OF CHAMBERS AND COMMODITY EXCHANGES OF TURKEY) IN ACCORDANCE WITH THE LAW NO. 5174

© ipcm / generated with IA

SPECIAL ISSUE ON METAL ARCHITECTURE AND DESIGN

50 BRAND NEW 60 HIGHLIGHT OF THE MONTH

Low Bake Powder Coatings from KABE-Farben: Quality for Architectural Applications

62

SUCCESS STORIES

The Collaboration Between DHK, ALIT Technologies and Alufinish Ushers in a New Era in Metal Surface Protection

66 FOCUS ON TECHNOLOGY

Metallic and Special-Effect Powder Coatings for Emboss’ Three-Dimensional Cladding Surfaces

72

ROAD TO 2050

76

RESEARCH BREAKTHROUGH

EcoAl® by Alsan - Chrome-Free Passivation in Pretreatment Processes for Powder Painting

Ultrathin, Hard and Sustainable Non-stick Coating Revolutionizes Shaping Processes In Injection Moulding and Die Casting

80 FOCUS ON TECHNOLOGY

Azeta Confirms Itself as a Pioneer in Aluminium Coating Through a New Vertical Line Combined with an Innovative IPS Powder Feeding System

88 HIGHLIGHT OF THE MONTH

ST Powder Coatings Presents the New Green Oasis Range, the Ecological Oasis of the Future

90 ADVANCEMENTS

Evolution on Design: Kenosistec’s PVD Technology for Elegant, Durable, and Sustainable Finishes

94 FOCUS ON TECHNOLOGY

Luxe Perfil: The Experts in the Impossible Rely on the NewPrimeCoat® A109 Pre-Treatment Product’s High Performance

102 FOCUS ON TECHNOLOGY

Raising the Bar of Quality: Sirio Galv’s New Liquid Coating Plant for High-End Furniture and Lighting Accessories

108 ADVANCEMENTS

EcodePure: the Road to Water Recycling and Zero Discharge

112 SUCCESS STORIES

ItalMesh Clads the New Burger King in Rovereto with Perforated and Painted Aluminium Panels

114 SUCCESS STORIES

RIPOL in Bayreuth: Innovation and Avant-Garde Design

international PAINT&COATING magazine - SEPTEMBER/OCTOBER 2024 - N. 89

49

BRAND-NEW

SPECIAL ISSUE ON METAL ARCHITECTURE AND DESIGN

AkzoNobel Boosts Durability of Low-E Powder Coatings with New Interpon D2525 AkzoNobel strengthens carbon reduction commitment with superdurable range of low-energy powder coatings.

A

rchitectural customers can now take advantage of a

(150 °C compared with a standard curing temperature between 180 °C

superdurable low-bake powder coating developed by AkzoNobel,

and 200 °C) – cutting energy consumption by as much as 20% – or it can

which helps to protect building surfaces in more challenging

be cured up to 25% faster than conventional powders, allowing for more

environments.

products to be coated in less time and improving the efficiency of the

Having launched a standard durability option in 2023, the newly

coating line. As well as supporting customers in reducing their carbon

introduced Interpon D2525 Low-E range has been specifically designed

emissions, it will help AkzoNobel achieve its own ambition of reducing

to withstand conditions in more extreme and challenging locations.

carbon emissions across the value chain by 50% by 2030.

Backed by an Environmental Product Declaration (EPD), it can also

It’s ideally suited to any architectural or industrial metal surface, both

improve longevity in standard environments.

exterior and interior, such as facades, windows, pergolas, fencing,

Using industry-first technology introduced by the company in the

railings, metal office equipment and doors. Key features include

standard durability option last year, the new range can be cured at

excellent levels of durability to protect colour integrity and performance.

temperatures as low as 150 °C – while still delivering the supreme levels

Interpon customers can also receive help with calculating the benefits of

of quality and performance demanded by customers in the buildings

using its Low-E products, with regards to energy and carbon savings or

and construction sector.

productivity increases.

“This latest innovation reflects our commitment to listening to customers

The company’s architectural powder coatings feature on some of the

and providing them with a range that combines several benefits – such

world’s most famous buildings, including The Shard and Westminster

as longer durability and lower cure – but without compromising on

Abbey in London, UK; the Bird’s Nest stadium in Beijing, China; and La

aesthetics,” says Bob Dirks, Global Segment Manager for Architecture

Sagrada Familia in Barcelona, Spain.

at AkzoNobel’s Powder Coatings business. “It also supports the need for a collective responsibility towards a more sustainable future and highlights our commitment to sustainability throughout the value chain.”

For further information: www.interpon.com/gl/en/products/

Interpon D2525 Low-E can either be cured at a lower temperature

architectural/interpon-d-low-e

© AkzoNobel

50

N. 89 - SEPTEMBER/OCTOBER 2024 - international PAINT&COATING magazine

BRAND-NEW

SPECIAL ISSUE ON METAL ARCHITECTURE AND DESIGN

GSB International at the ALUMINIUM 2024 The GSB International Association will participate in the upcoming edition of ALUMINIUM (Düsseldorf, October 8-10, 2024) at booth 3F70-03. © GSB

Q

uality assurance of coatings is of great importance to the aluminium industry. Regardless of the product, the surface is always what catches the eye. Of course, special attention is paid to quality assurance

whenever a surface is particularly exposed to outdoor influences and is intended to maintain an impressive appearance for a long time.

This is precisely the case when it comes to facades. The buildings are typically constructed to be used for many decades. Depending on the location, they are exposed to various environmental influences. On the shorelines, the salt water of the sea can increase the corrosiveness of the environment. Regions with many hours of sunshine per year have high levels of UV intensity. But not only the environment has an effect, the usage of the building also plays a role.

Swimming pools, for example, are cleaned with aggressive cleaning agents.

At this point, it is clear that the list of possible stress factors can be continued endlessly.

With its quality assurance system for the coating of aluminium in the architectural sector, GSB International - the leading quality association for surface coatings in the fields of aluminium and steel - takes these external influences into account and thus ensures a stress-free work experience for architects, building owners and planners.

Everyone who is interested in GSB’s extensive quality assurance or has detailed questions about coating is very welcome to visit the experts from GSB at the ALUMINIUM 2024 in Düsseldorf. At booth 3F70-03, the GSB team is looking forward to great conversations about coating. And that’s not all. At the booth, a coating plant will be on site to allow all visitors the opportunity to experience the powder coating process.

For further information: https://gsb-international.de/en/

BRAND-NEW

SPECIAL ISSUE ON METAL ARCHITECTURE AND DESIGN

New Advanced Powder Coating System for PRATIC’s Aluminium Pergolas and Awnings PRATIC has chosen to rely on IMEL’s expertise to install a new state-of-the-art coating system that ensures high-quality performance for the powder coatings on aluminium pergolas and awnings.

P

RATIC S.p.A., part of the STELLAGROUP, a global leader in the

water in the pre-treatment stages, maintaining the baths in optimal

production of pergolas and awnings with refined design and

condition and reducing water consumption, with nearly zero discharge

architecture, has implemented an advanced powder coating

into the sewer network.

system at its manufacturing facility in Fagagna (Udine), realized by IMEL

Thanks to its high level of automation and the integration of certain

S.p.A. The coating system has been designed to ensure high performance

modules from the i4paintshop® platform, the system is able to

in terms of durability, offering remarkable versatility in pre-treatment and

automatically managing various coating cycles based on the parts’

coating cycles, with a high degree of automation. The system is optimized

codes and assigned priorities. The system ensures automatic data flow

for energy efficiency and integrates a sophisticated depuration plant that

management, complete process traceability, constant monitoring of

allows for the recovery of wastewater.

energy consumption, and efficient maintenance scheduling. Additionally,

The line is distinguished by the use of high-quality equipment, a compact

with the digital reading of data from each component of the system, it is

design that optimizes space, and attention to detail—hallmarks of

possible to optimally manage quality and reduce waste, in compliance

PRATIC’s projects. The system includes a pre-treatment tunnel with

with Qualicoat standards.

separate chambers, made entirely of AISI 316 stainless steel, which allows

The high coating performance and rigorous process control have enabled

localized treatment and minimizes contamination of the baths, making it

PRATIC to obtain the prestigious QUALICOAT SEASIDE certification, which

suitable for the use of any chemical agent.

attests the compliance with the most stringent international standards

The drying and curing ovens, positioned next to each other, are properly

for aluminium treatment and coating quality. This certification ensures

insulated and equipped with doors that ensure optimal thermal

maximum paint adhesion and excellent resistance to corrosion caused by

maintenance, helping to reduce fuel consumption. The coating plant is

atmospheric agents.

also equipped with two Gema Magic Cylinder booths, each equipped with

Through this collaboration, IMEL has met a new challenge in high-

14 guns powered by a spray system that uses dense phase pumps and a

end industrial coating treatments, demonstrating its competence and

fast colour change system.

innovative capabilities.

A key element of the system is its eco-friendliness: 97% of the wastewater is recovered thanks to a complex depuration system based on mechanical vapor recompression. This innovative process allows for the reuse of

© PRATIC

52

N. 89 - SEPTEMBER/OCTOBER 2024 - international PAINT&COATING magazine

For further information: www.imelspa.com

© Flavio Graffi

Plastic Vernici Caldart: professional paint for Carbon Fiber.

Metal

New TIXO Clear and TIXO Filler.

Superior quality for carbon fiber surfaces.

The Tixo line redefines the finishing of carbon surfaces, both glossy and matte.

Specifically designed for this material, TIXO products offer extraordinary thixotropy and fullness, allowing for the application of considerable thicknesses with excellent levelling and impeccable aesthetic appearance. Thanks to their high resistance, these UHS paints reduce the number of coats required, ensuring faster and more efficient processing. The exceptional gloss and scratch resistance of TIXO paints elevate quality standards to a superior level.

Discover all Vernici Caldart products designed for Automotive on our website.

Metal

Plastic

www.vernicicaldart.it

BRAND-NEW

SPECIAL ISSUE ON METAL ARCHITECTURE AND DESIGN

In its Annual Vibes Colour Journal, Axalta Launches the Latest Colour Trends for Architecture and Design The 2024-2025 colour trends have been presented by Axalta in its latest Vibes Colour Journal: nature and technological aspirations come together under the name of Architectural Fusion.

This duality inspires creativity and evokes a blend of calm and new beginnings.

In addition, Vibes magazine’s case studies also show that building materials coated with Axalta products are as varied and diverse as modern, global societies. Axalta’s technology portfolio addresses the nature of these diverse materials, such as metal substrates, combining them with an exhilarating colour experience.

“As we present the latest edition of Vibes, we are thrilled to showcase the vibrant intersection of colour, creativity, and innovation, in architectural design. Our curated themes - Earth Unity, Human Evoke, Tech Vision, and Vivid Vibe - reflect a harmonious blend of nature, technology, and human connection, offering designers an inspiring palette of colours and finishes. Each page of Vibes is a testament to Axalta’s commitment to pushing the boundaries of design, fostering a deeper connection with our environment, and embracing the endless possibilities of the future,” has stated Sally Put, Editor of Vibes colour journal and Head of Marketing Communications at Axalta EMEA. Vibes 2024 presents the following colour trend themes:  Earth Unity: Humanity’s connection with nature and the universe.

Shades such as amethyst crystal, ochre, stone and clay are reminiscent of forests and wild berries.  Human Evoke: Emphasising emotional connections. Lighter tones are reminiscent of shell patterns, with hints of stone, precious metals and emotive red.  Tech Vision: Ambitious and curious, technology enthusiast. Colours include straw yellow, pink, green, blue and purple,

A

reflecting innovation and scientific exploration. xalta Coatings has launched the latest edition of Vibes, the

 Vivid Vibe: A palette that celebrates hopeful creativity. It

magazine through which the company annually offers architects

acknowledges the world as it is while striving for a brighter future.

and designers a guide to the latest trends, exploring colour and

Imagine colours that evoke memories, stimulate the imagination and

texture in the built environment. The latest trends have been gathered

inspire creativity in design.

under the theme ‘Architectural Fusion,’ blending the essence of nature with technological aspirations and emotional depth.

Axalta’s new colour trends capture the connection to nature while embracing a technology-driven future, helping architects and designers in their creative endeavours.

54

N. 89 - SEPTEMBER/OCTOBER 2024 - international PAINT&COATING magazine

For further information: www.axalta.com/vibes

BRAND-NEW

SPECIAL ISSUE ON METAL ARCHITECTURE AND DESIGN

WEG Mexico Has Obtained the Quality Certificate from the Global Organisation QUALICOAT The QUALICOAT certificate ensures that products from WEG Mexico meet the highest quality standards.

T

he Mexican subsidiary of the global electric-electronic equipment company WEG has recently obtained the QUALICOAT certificate, after inspections conducted by recognised experts and tests performed by accredited laboratories according to ISO

17025 standards. The QUALICOAT seal is a product certification scheme developed by the homonymous global organisation based in Zurich (Switzerland) and specialised in certificates committed to maintaining the quality of painting and coating for aluminium and its alloys for architectural applications. The organisation defines comprehensive quality requirements and monitors their compliance by authorised plants worldwide, ensuring that products meet the highest quality standards and providing buyers the assurance that they will receive a highquality product that offers long-term value and consistent quality.

For further information: www.weg.net

WE TURN YOUR FORMULATIONS INTO OUTPERFORMULATIONS.

Discover the WOW in know-how! At Coating Additives, we don’t just embrace innovation – we embrace you with the power of digital transformation in the coatings and inks industry. Join our COATINO Campus with customized learning journeys and insightful webinars to enrich your industry knowledge and experience. www.coatino.com/campus

© WEG

BRAND-NEW

SPECIAL ISSUE ON METAL ARCHITECTURE AND DESIGN

ANDRITZ Starts up New Surface Treatment Line for Aluminium Strip at AMAG International technology group ANDRITZ, specializing in the manufacture of innovative plants, equipment, systems, services, and digital solutions for a wide range of industries and end markets, has successfully completed the delivery, installation, and start-up of the new continuous surface treatment line and integrated wastewater treatment plant at AMAG rolling GmbH in Ranshofen, Austria.

T

he modern line with exclusively electric

quality surface treatment of a wide range of

contribution to a sustainable future and help

heating and advanced digitalization

hot-rolled and cold-rolled aluminium strips

its customers achieve their sustainability

strengthens AMAG’s position as a

up to five millimetres thick.

goals. ANDRITZ is a global market leader in

leading specialist for high-quality aluminium

Electric heating of the process with green

all four of its business areas – Pulp & Paper,

surfaces and supports the company’s

energy and integration of a state-of-the-

Metals, Hydropower and Environment &

sustainability goals.

art wastewater treatment plant contribute

Energy. Technological leadership and global

The 115-meter-long plant was built on

to environmentally friendly production.

presence are cornerstones of the group’s

a greenfield site. ANDRITZ’s equipment,

Advanced digital solutions and modern data

strategy, which is focused on long-term

especially the highly efficient spray pickling

analysis methods are used to increase the

profitable growth. The publicly listed group

system, enables AMAG to perform high-

quality and productivity in surface treatment.

has around 30,000 employees and over 280

An autonomous coil transport system, also

locations in more than 80 countries.

electrically powered, enhances the efficiency of the entire production process.

ANDRITZ METALS

“Realizing this project together with ANDRITZ

ANDRITZ Metals is – via the Schuler Group

has been a very good decision,” says Florian

– one of the world’s leading suppliers of

Stadler, Managing Director of AMAG rolling

technologies, plants and digital solutions in

GmbH.

metal forming.

“The collaboration between our teams

The product portfolio also includes

has again been excellent as in previous

automation and software solutions, process

projects, resulting in the timely completion

know-how and service. In the metals

of commissioning. With this new line we can

processing segment, the business area offers

further enhance the quality of our products

innovative, sustainable and market-leading

and at the same time take another step

solutions for the production and processing

towards decarbonization.”

of flat products, for welding systems and

ANDRITZ GROUP International technology group ANDRITZ

furnaces with its own burner solutions, as well as services for the metals processing industry.

offers a broad portfolio of innovative plants, For further information:

solutions for a wide range of industries and

www.andritz.com

end markets. Sustainability is an integral

© AMAG

The new ANDRITZ surface treatment line for aluminium strips at AMAG is heated with green energy and features advanced digitalization for high quality and productivity.

56

equipment, systems, services and digital

part of the company’s business strategy and corporate culture. With its extensive portfolio of sustainable products and solutions, ANDRITZ aims to make the greatest possible

N. 89 - SEPTEMBER/OCTOBER 2024 - international PAINT&COATING magazine

BRAND-NEW

Europolveri Powder Coatings Became a Point of Reference in the Architectural Sector Europolveri leverages its forty years of experience to offer three powder coatings series specifically developed for aluminium applications in the architectural and design sectors.

O

ver the years, powder coating treatments

for architectural elements, furniture and design

have become increasingly more important.

items. In this context the role of powder coatings

As a matter of fact, they represent now a

derives from the fact that it gives the possibility of

fundamental choice for architects and designers

choosing from a wide range of products with an

looking for high-performing and captivating finishes

ever-increasing level of specialisation, making it one of the key elements that contributes to the final

© Europolveri

result of a project, not only in formal aesthetic terms but also in terms of functionality and duration.

For over forty years thanks to their technology, applicability, specific characteristics and variety, the powder coatings from Europolveri have represented a point of reference for the surface treatment of several types of objects.

The ArchitecturalPlus series – Qualicoat (class 1 and 2) and GSB certified – is composed by products specifically developed for the world of architecture, formulated to enhance the effects of powder coatings on aluminium components for doors and windows, window frames and curtain walls.

It includes a wide range of colours in a smooth, wrinkled and textured finish, according to the specific needs of the customers.

The range ArchitecturalFlex represents the latest novelty proposed by Europolveri, a solution for coil coating that meets the specific requests of bending resistance and of low thickness applications.

The series ArchitecturalLignum, made of sublimation products and powder on powder products, offers the customers the possibility to reproduce the warm finishes of wood on the panelling and on the aluminium profiles.

For further information: www.europolveri.it © Europolveri

BRAND-NEW

SPECIAL ISSUE ON METAL ARCHITECTURE AND DESIGN

ESTAL Analyses the Impact of the New Industrial Emissions Directive on Aluminium Surface Treatment ESTAL has analysed the new Industrial Emissions Directive (IED), which came into force last August, introducing significant changes in the field of surface treatment of metals to reduce industrial emissions.

E

STAL, the European Association for Surface Treatment on

Where the processes are not homogeneous, the new Environmental

Aluminium, which aims to promote the interests of its member

Management Systems will have to include indicative benchmarks on these

companies - more than 400 anodizing and coating companies

parameters.

throughout Europe - has been analysing the publication of the latest

The Surface Treatment of Metals and Plastics Best Available Technique

European Directive on industrial emissions.

Reference Document (STM BREF), which will set the permitting basis

This new Industrial Emissions Directive (IED) was published in the Official

for the members of National Associations involved in ESTAL, will be

Journal of the European Union on the 15 of July and entered into force

among the first to be published under the new IED. This means that

on the 4th of August 2024. It consists of a series of amendments to the

the STM BREF, currently under review, will be implemented with these

previous Directive IED 2010/75/EU, for which a consolidated text is now

requirements, more stringent than the ones in previous BREFs published

available1. The revision introduces several changes aimed at reducing

under the original 2010 Directive. The ESTAL STM BREF Working Group

industrial emissions, two of which are very important for ESTAL. First,

has been involved in the review process, which started two years ago.

competent authorities are now required to establish the strictest

Surface treated in batch anodising lines or batch chemical conversion

achievable emission limit values using Best Available Techniques (BAT)

lines being difficult to calculate and processes not being homogeneous,

from the BAT-associated Emission Levels (BAT-AELS), whereas in the

ESTAL considers not feasible to define quantitative resource efficiency

past it was only about not exceeding them. Second, when industrial

requirements but considers appropriate to ask each conversion

processes are homogeneous across the EU, permits must include binding

coating and anodising line to have its own improvement plan, tailored

quantitative performance limit values for water consumption, waste

to its specific situation, so that all plants contribute to the objective of

generation, resource and energy efficiency, as appropriate.

protecting the environment.

th

1

https://eur-lex.europa.eu/legal-content/EN/ALL/?uri=CELEX:02010L0075-20240804

For further information: www.estal.org

© AdobeStock

58

N. 89 - SEPTEMBER/OCTOBER 2024 - international PAINT&COATING magazine

LIQUID HIGHTECH Perfectly encased, perfectly protected Sometimes it is what is on the outside that counts. Our zinc flake systems are suitable for all screws and bolts and hug every thread perfectly. Premium quality that protects against corrosion, sets defined coefficients of friction and withstands a range of mechanical stresses. However, we are not satisfied with the best and are constantly on the lookout for new solutions and innovations – for every problem, for every challenge.

High cathodic corrosion protection Complex fastenings no problem Cross-linking at low curing temperature

www.doerken.com Dörken Coatings GmbH & Co. KG . Wetterstraße 58 . D-58313 Herdecke . Telephone 02330 63243

HIGHLIGHT OF THE MONTH

SPECIAL ISSUE ON METAL ARCHITECTURE AND DESIGN

Low Bake Powder Coatings from KABE-Farben: Quality for Architectural Applications Edited by KARL BUBENHOFER AG Gossau SG, Switzerland

pulver@kabe-farben.ch

As part of its ongoing research and development efforts, KABE-Farben has recently introduced POLYFLEX® PES-140-SD-NT, a comprehensive low-bake series of highly weather-resistant powder coatings designed for architectural and other applications

F

or nearly 50 years, KABE-Farben has been synonymous with quality and technological innovation in the field of powder coatings. The KABE-Farben’s Qualicoat-certified powder

coatings set benchmarks and reflect its continuous pursuit of the highest performance.

Pioneering work in low bake curing for certified facade applications Almost 15 years ago, the company achieved a significant milestone: with its first low bake powder coating system for facade applications, certified according to Qualicoat class 1, it redefined standards. Its POLYFLEX® PES-165-NT system (Approval number P-0937) continues to impress with an extraordinary curing window starting from 10 minutes at 160 °C and its phenomenally fast curing capability at higher temperatures. This innovation underscores company’s early focus on developing in new technological areas to maximize both the quality and efficiency of its products.

Continuous development for the highest demands In recent years, KABE-Farben has continued to invest in the development of low bake polyester powder coatings, specifically for facade applications.

The range has been significantly expanded with various gloss levels and surfaces, all with low bake properties. Specially developed versions for outgassing substrates are particularly noteworthy. Thus, the company offers not only tailor-made solutions for the complex requirements of modern architectural projects but also properties for high application security in other areas.

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HIGHLIGHT OF THE MONTH

Setting new standards in Qualicoat Class 2

weather resistance but also outstanding processing properties,

This year, KABE-Farben proudly presents POLYFLEX® PES-140-SD-NT, a

good storage stability, and superior surface characteristics.

comprehensive low bake series of highly weather-resistant powder coatings

The company is particularly proud of its unique, smooth, matte

for architectural and other applications, all certified according to Qualicoat

system POLYFLEX® PES-140-SD-NT-GU smooth Corona Matt with

class 2. Compared to conventional facade quality, Qualicoat class 2 is

a gloss level around 10 gloss units (60°), which is also certified

characterized by significantly enhanced UV and weather resistance, resulting

according to class 2. This innovative, unique system offers not only

in longer durability —perfectly aligning with a sustainable focus. The product

outstanding aesthetics but can also be cured from 160 °C.

line includes a variety of surfaces, including smooth surfaces in different gloss

Pearl-metallic variants with excellent durability are also available

categories and finely textured finishes.

for all mentioned surfaces, providing additional aesthetic options

The curing windows start from 10 minutes at 160 °C object temperature,

and further enhancing the visual impact of any projects.

which is unique in the market. At higher temperatures, the powder coatings further exhibit very short curing times.

Future-oriented powder coating solutions

These innovative polyester powder coatings offer not only excellent UV and

KABE-Farben stands for technological progress and highest quality in powder coatings. Its continuous innovative strength and commitment to excellent products make it the ideal partner for

© LOSYS GmbH

demanding architectural and various other applications. Trust in its team’s expertise and be inspired by its highly weather-resistant low bake powder coatings — for results that impress. Incidentally, the company has also been offering an extensive low bake portfolio for interior applications for many years.

In KABE-Farben’s product range, it is possible to find the following Qualicoat-certified low bake powder coatings:  Class 1 – Standard Facade Quality - POLYFLEX® PES-165-NT smooth Corona silk gloss – Approval number P-0937 - POLYFLEX® PES-165-NT smooth Corona silk matt – Approval number P-1979  Class 2 – Highly Weather-Resistant Facade Quality - POLYFLEX® PES-140-SD-NT smooth Corona silk gloss – Approval number P-2079 - POLYFLEX® PES-140-SD-NT smooth Corona Satin matt – Approval number P-2078 - POLYFLEX® PES-140-SD-NT-GU smooth Corona matt – Approval number P-2053 - POLYFLEX® PES-140-SD-NT fine structure Corona silk matt/matt – Approval number P-2056.

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61

SUCCESS STORIES

The Collaboration Between DHK, ALIT Technologies and Alufinish Ushers in a New Era in Metal Surface Protection The design company DHK implemented a new plant for the pre-treatment of aluminium components equipped with the DRIZZLING system from ALIT Technologies Spa, which atomises a passivating solution prepared in realtime based on the dilution ratio set through the control panel.

T

he Belgian company DHK, manufactures and markets terrace

It is lightweight, fully recyclable, easy to work with, and has excellent

covers, custom pergolas, canopies, window sills and aluminium

corrosion resistance characteristics when adequately pre-treated.

© DHK

thresholds, as well as supplying aluminium profiles, sandwich

panels, steel, PVC and polycarbonate profiles and a comprehensive

The pre-treatment of aluminium surfaces

range of accessories for building structures for architectural use.

Pre-treating an aluminium surface means performing a series of

It has outlets in Genk and Chatelineau (Belgium) and in Luxembourg, but

chemical processes to transform it and make it an ideal substrate for

at its Chatelineau site the company has a new and modern line for pre-

anchoring the layer of paint that will be applied to it. The combination

treating and powder coating the metal surfaces it brings to the market.

of the chemical treatments carried out, added to the paint product

Aluminium, in particular, is the material provided by DHK par excellence,

applied, will make the coated component resistant to atmospheric

as it offers several advantages that make it perfect for architectural

corrosion and thus usable in the architectural sector. That is precisely

use, especially in exterior structures not subjected to heavy loads.

what DHK’s modern pre-treatment and coating line does: Aluminium

SPECIAL ISSUE ON METAL ARCHITECTURE AND DESIGN

parts are hooked onto an overhead conveyor, pass through a spray tunnel where they are degreased, pickled and passivated and are finally transferred to the coating area for the application of the powder paint.

“Initially, the aluminium workpieces are spray degreased and pickled by the combined effect of the acidic pickling agent ALFIDEOX 82/3 and the degreasing additive ALFISID 14. In the subsequent tunnel segments, the parts are rinsed with mains water and then with demineralised water. At this point, their aluminium surfaces are perfectly free of oils and grease, deoxidized and, therefore, reactive and ready for the subsequent passivation treatment.

Passivation is a key stage during which polymerbased adhesion promoters and titanium-based corrosion inhibitors are chemically anchored to the surfaces. In this case, we use ALFICOAT 748, a QUALICOAT and GSB-approved product that has passed the strictest tests in the industry, including 10-year outdoor exposure testing.

Usually, this is applied by dipping or spraying, but DHK uses an absolutely innovative and effective application technology,” has explained sales engineer Ludwig Liesens, the pretreatment division manager of Alufinish GmbH – the company supplying the pre-treatment products. “

The DRIZZLING system provided

by ALIT Technologies Spa The pre-treatment plant is equipped with a DRIZZLING system, which atomises a solution of ALFICOAT 748 prepared in real-time based on the dilution ratio set through the control panel.

The DRIZZLING technology instantly mixes the chemical product with demineralised water in-line and then sprays that mixture on the aluminium components, creating a sort of mist that settles on their surfaces to passivate them.

“The great advantage offered by DRIZZLING is that the chemical solution is always freshly prepared and, therefore, extremely reactive and free of contaminants dragged from previous steps.

© ALIT Technologies Spa

The entrance of the pre-treatment tunnel at DHK site.

SUCCESS STORIES

SPECIAL ISSUE ON METAL ARCHITECTURE AND DESIGN

© ALIT Technologies Spa

© ALIT Technologies Spa

The control panel of the DRIZZLING system provided by ALIT Technologies Spa and the atomiser.

no longer required. The solution is prepared instantly and atomised

Excellent passivation results with minimum consumptions

on the surfaces. Chemical analysis of the liquid in the tank is no

“There are two ramps with eight atomising nozzles in total. The flow

longer necessary precisely because there is no longer a tank. In

rate of the solution is about 160 liters/hour; the consumption of

short, the management of the process is remarkably streamlined and

the ALFICOAT 748 chemical is about 0.5 kg/hour. The quality of the

the footprint of the system is smaller than that of traditional spray

passivation results is excellent. The titanium deposit is regularly

technologies,” has continued Liesens. “Installation was swift: two spray

checked and is well within the ranges set by supplier Alufinish GmbH.

bars were mounted one opposite the other inside the tunnel, whereas

The combination of Alufinish GmbH’s chemical product and ALIT

the mixing and control panel was installed outside it. As a plug-and-play

Technologies Spa’s DRIZZLING application system is perfect and will

system, it was ready to be used within a few hours. The technicians

soon be implemented in other aluminium pre-treatment plants. I would

from ALIT Technologies assisted the customer during the start-up

like to thank Thibaut Braibant and Jean-Marie Jenicot from DHK for

phase and trained the plant operators.”

the collaboration in the purchase, start-up and management of the

Traditional passivation tanks and energy-intensive spray pumps are

company’s paint shop and for their trust in us,” has concluded Liesens.

For further information: www.alit-tech.com

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FOCUS ON TECHNOLOGY

SPECIAL ISSUE ON METAL ARCHITECTURE AND DESIGN

Metallic and Special-Effect Powder Coatings for Emboss’ Three-Dimensional Cladding Surfaces Alessia Venturi ipcm®

© Emboss

Powder coating, with its evolving colour, decorative, and aesthetic effects that imitate natural surfaces and improve both the appearance and the functional performance of the treated components, is increasingly the preferred choice of architects and designers for finishing architectural elements, such as metal cladding. That is also thanks to the collaboration and joint experimentation between metal panel manufacturers and powder coating manufacturers. In this article, we recount the professional partnership between Emboss Panels, a specialist in the production of metal panels with three-dimensional effects, and TIGER Coatings, which supplies it with special-effect, matte and flat matte, metallic, and anodised-like powder coatings to enrich its products’ sculpted surfaces.

FOCUS ON TECHNOLOGY

A

cladding system is like a skin that protects, decorates, and

metal panels with striking decorative effects. Emboss serves architects,

enhances the underlying material and its shapes. Cladding can

designers, installers, distributors, and end users who want to customise

be used to accentuate the modernity of a building or room, to

their projects with exclusive, attractive-looking panels. Its innovative

curb, contain, and screen light for specific visual effects, to protect an

manufacturing process allows deforming metal sheets to ultimately offer

area or isolate it thermally and acoustically, to enhance aesthetics and

three-dimensional surfaces with vibrant, multiform effects.

beauty, and to improve the sustainability and durability of a structure or

“At its foundation, our company was focused on technical design,” says

component. Thanks to its versatility in terms of shapes, materials (it can

Cesare Zilio, the engineer who established Emboss, “as it was originally

be made of wood, metal, or composites), and finishes, cladding is one of

a design studio specialising in metal façade cladding. Over the years,

the most powerful tools for architects and designers to create exclusive,

however, we have increasingly dealt with the production aspects of

distinctive structures with a soul.

metal cladding sheets, developing the concept of panels with three-

“Sculptured surfaces for architecture”: this is the evocative definition that

dimensional effects. Experimentation with various manufacturing

Emboss (Tezze sul Brenta, Vicenza, Italy), a manufacturer of decorative

techniques has gradually led us to define an efficient and innovative

panels for architecture and interior design founded in 2018, gives of

process for producing 3D metal panels used for façade cladding, interior

its products. This company represents the combination of different

cladding, and suspended ceilings.”

souls into a refined and exclusive solution for exterior and interior

Although such machining processes creating 3D effects through sheet

cladding, as it has designers and craftspeople work together to create

metal deformation are already enough to make Emboss’ metal panels

© Emboss

© Emboss

international PAINT&COATING magazine - SEPTEMBER/OCTOBER 2024 - N. 89

67

SPECIAL ISSUE ON METAL ARCHITECTURE AND DESIGN

combines craftsmanship and industrialisation. This workflow offers an extremely attractive, unique, and exclusive solution for architectural

numerous opportunities: it is possible to process solid, perforated, or

cladding, the paint products applied on them certainly contribute

expanded metal sheets in aluminium, galvanised steel, stainless steel,

to further enhancing these effects. “Finishes must emphasise what

brass, copper, and zinc-titanium (an alloy whose surface, under the

Emboss has added to the simple metal sheet. They should also be as

action of the weather, becomes covered with a thin, self-protective layer

smooth as possible, as the tactile effect is already inherent in the three-

that gives it a naturally ageing and aesthetically pleasing appearance,

dimensionality we give to the metal,” explains Zilio. “Since we prefer to

Ed.),” indicates Zilio.

use powder coatings, we choose to work with an industry leader, TIGER

“Despite being a young company, we are able to supply finished panels

Coatings, not only for the quality of its powders but also for its technical

ready to be installed, not only formed and coated but, if necessary, also

support service, its laboratory’s assistance for testing and validation, and

folded and framed. Ideally, Emboss’ three-dimensional panels should

its willingness to experiment and formulate products with customised

be specified directly by designers: by conceiving a project with this type

colours and effects.”

of cladding from the outset, both the aesthetic performance and the

Surfaces with a soul

production costs can be optimised in terms of sheet division, modules, finishes, and so on.”

“Emboss’ sculptured surfaces are decorations created with an

Emboss offers several standard patterns, as well as the possibility to

exclusive production technique: each model is carefully designed and

customise the effects to make each project original and exclusive.

mechanically reproduced with a plastic deformation technique that

“Our portfolio includes standard patterns such as Bumps, an organic

© ipcm

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FOCUS ON TECHNOLOGY

water effect; Carapax, an organic effect similar to the previous one but with a denser pattern; Branch, a branching pattern that ensures continuity among panels; Line, with elegant linear stripes; Quilt, a soft, quilted effect; and Sand, with a wavy pattern reminiscent of dunes. At the same time, we place great importance on customisation. We give our customers the opportunity to create personalised designs, and this greatly enhances our offer,” states Cesare Zilio. “Emboss’ main strength is to have investigated lean manufacturing technologies to offer tailor-made solutions at attractive costs and even for small batches.”

All Emboss panels can be made in solid or perforated metal and decorated with different technologies, from anodising to powder or liquid coating, from electro-colouring to polishing and satinfinishing. Thanks to these multiple combinations of substrates, effects, decorations, and cladding functions, Emboss’ panels are a very versatile decorative solution: they can be used both for exterior architectural applications such as façade cladding and roofing and for indoor applications such as false ceilings or wall cladding.

Solid sheet metal panels are typically used for complete roofing systems, whereas perforated or expanded metal ones can be used to create transparencies and interplays of solids and voids, for example, in solar shading and ventilation systems.”

Powder coating: multiplying the decorative effects available “Processing all types of metal sheets opens up the possibility of using different surface finishes to enhance each three-dimensional effect in its specific design context. We range from polished steel to satin-finished steel and from pre-anodised aluminium to coated aluminium, which makes up a large part of our volumes. For Emboss’ products, coating is a very flexible and useful finishing solution because it provides a vast range of colours, gloss levels, and special effects. Its only limitation is that it diminishes the metal surfaces’ gloss degree and cannot maintain the mirror effect, which is important for some patterns. Still, with TIGER’s experimentation and technical support, we can offer an excellent compromise between colour, effect, and gloss,” explains Cesare Zilio.

“Working in the metal industry, I was familiar with TIGER and the quality of its products even before Emboss was established in 2018.

Our collaboration, including the supply of TIGER paint products and the joint search for the best finishes for our 3D panels, started about two years ago. Today, we have an exclusive partnership for both standard finishes in RAL colours and special-effect finishes, such as, for example, those from its outdoor-specific TIGER Drylac® Series

www.fatisrl.com 0039 031 655688 | info@fatisrl.com Via Carlo Porta 14 - 23861 - Cesana B.za (LC) - Italy

SPECIAL ISSUE ON METAL ARCHITECTURE AND DESIGN

68, which we find particularly interesting due to its super matte effect.

TIGER Drylac® Series 68 and 3D Metallics

We also use coatings from its 3D Metallics series, all super durable class

“The matte and flat matte anodised-like colours of TIGER Drylac® Series

2 products. Finally, TIGER also supports us in developing customised

68 are particularly suitable for Emboss’ products because they enhance

and exclusive finishes, including, for example, in NCS colours, which are

the play of light and shadow created by our 3D patterns,” notes Cesare

then produced in small batches upon customer approval. Emboss is not

Zilio. “They emphasise the sheet’s convexity, accentuating its three-

a powder specialist, but we do receive requests for the most diverse

dimensional effect. In addition, their super durable and highly weather-

finishes: our products are special, so their finishing requirements are

resistant formulation makes them ideal for finishing cladding panels for

also special.

outdoor applications.”

“In particular, for powder application on exterior cladding and façade

TIGER Drylac® Series 68 includes numerous matte or flat matte smooth

panels, we rely on the expertise of Pintarelli Verniciature (Trento, Italy)

finishes whose application is not limited to aluminium but can also

and its certified pre-treatment and coating cycles, whereas for interior

be extended to steel and galvanised steel. They offer high colour

applications, we also rely on other contractors. Emboss always provides

consistency and homogeneity among batches, and they are super

its contractors with the product code of the powder to be used (colour

durable paints with GSB and/or QUALICOAT certifications, offering

and chemical class) or, in some cases, purchases the required powders

resistance for up to 10 years in Florida.

directly from TIGER.”

TIGER Drylac® Series 68 3D Metallics also consists of GSB Florida 3-year © ipcm

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FOCUS ON TECHNOLOGY

and/or QUALICOAT class 2 certified super durable polyester coatings and combines the performance and one-coat application of the Series 68 with the high gloss and depth of effect typical of metallic liquid paints, turning each panel into an exclusive element.

Powder coatings’ unrivalled versatility “Recently, we have also started assessing the use of liquid paints, starting with a pigmented clear coat for pre-anodised aluminium with a mirror-like finishing,” says Cesare Zilio. “This would allow us to mantain a glossy appearance combined with colour, a special effect not obtainable with powders. At the same time, however, the advantages of powder coatings, such as the degree of customisation, uniformity, repeatability of finishes and colours, their inherent sustainability, and the one-coat application process, remain unrivalled and make this solution our preferred choice.”

© ipcm

OptiCenter® All-in-One OC11 Double your efficiency!

The system with OptiSpray All-in-One pump technology and double OptiSpeeder powder hoppers (DualSpeeder) enables the handling and preparation of two independent colours one after the other for ultra-fast colour changes or in parallel for simultaneous coating from both OptiSpeeder powder hoppers.

Cesare Zilio, founder of Emboss.

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

ROAD TO 2050

EcoAl® by Alsan - Chrome-Free Passivation in Pretreatment Processes for Powder Painting In an era marked by growing environmental awareness and sustainability concerns, industries are continually seeking innovative ways to reduce their carbon footprint. One such advancement that has gained traction is the shift towards chrome-free passivation in the pretreatment process before powder painting.

C

hrome-based treatments have long been a staple in the industrial realm for passivating metal surfaces

before coating. Chromium (VI) compounds, particularly hexavalent chromates, have been favoured for their corrosion resistance and adhesion-promoting properties. However, the environmental and health hazards associated with hexavalent chromium have led to stringent regulations and a collective drive to find more sustainable alternatives.

In response to the limitations and risks of traditional chromate-based methods, chromefree passivation has emerged as a safer and © ALSAN

more ecologically responsible alternative. The

Figure 1 - EcoAl® 20 is a titanium-based chrome-free passivation which creates a protective layer on the metal surface with excellent corrosion resistance and adhesion promotion.

primary aim of this approach is to ensure a high-quality surface finish while minimizing the environmental impact.

Benefits of chrome-free passivation  Environmental preservation: chrome-free passivation substantially reduces the release of toxic substances into the environment, contributing to the preservation of ecosystems and minimizing pollution. This aligns with the overarching goals of sustainable industrial practices.  Human health protection: the elimination of hexavalent chromium from the process safeguards the health of workers involved in the treatment and painting processes, reducing the risk of exposure-related illnesses.

© ALSAN

Figure 2 - Some examples of EcoAl® 20 implementation.

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 Regulatory compliance: REACH tighten regulations regarding hazardous substances, chrome-free alternatives meet all of REACH

Get more from water

requirements.  Resource efficiency: chrome-free passivation processes require lower energy consumption and fewer chemical inputs, leading to increased efficiency, reduced operational costs and carbon footprint.  Performance and quality: contrary to misconceptions, chrome-free passivation does not compromise the quality of the treated surface.

Chrome-free alternatives offer comparable corrosion resistance

Turn key solutions for industrial wastewater treatment

and adhesion properties, ensuring a high-quality finish for powder

Design and manufacturing of plants and chemicals for industrial wastewater treatment

painting.  Innovation and reputation: embracing eco-friendly practices like chrome-free passivation can enhance a company’s reputation and promote innovation. Businesses that prioritize sustainability are more likely to attract environmentally conscious clients and partners (Fig. 1).

Chrome-free passivation from Alsan: EcoAl®20 EcoAl® 20 is a titanium-based chrome-free passivation which combines titanium compounds and selected polymers to create a protective layer on the metal surface with excellent corrosion resistance and adhesion promotion.

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

EcoAl® 20 can be applied by immersion, cascade or spray. The conversion layer obtained with the EcoAl® 20 allows excellent results on adhesion and corrosion resistance to be obtained with all types of paints and specifically grants great protection against filiform corrosion. With EcoAl® 20, proper conversion layers could be quickly achieved, just with a short time of contact (around 10-60 seconds), depending on the application method.

The EcoAl® 20 technology is easily adaptable to each process line, including also a fully automated system that guarantees the control of each of the working parameters. In Figure 2 some examples of EcoAl® 20 implementation are shown.

EcoAl® 20 was firstly approved by QUALICOAT in 2003 (A-013).

Since then, it has been successfully installed worldwide in both horizontal and vertical lines. Ecoal® 20 is the Qualicoat approved chrome-free pretreatment, leader in the Spanish, Moroccan and Mexican markets. It is estimated that, under QUALICOAT certification, more than 120.000.000 square meters of extruded aluminium are treated with EcoAl® 20 every year around the world. EcoAl® 20 has recently been further recognised by obtaining the prestigious license from GSB International, certifying its compliance with the stringent quality standards of GSB AL 631-2 for chemicals used in aluminium pretreatment (Fig. 3).

Beware of imitations, buy the original!

info@waterenergy.it

www.waterenergy.it

ROAD TO 2050

SPECIAL ISSUE ON METAL ARCHITECTURE AND DESIGN

Conclusion The adoption of chrome-free passivation EcoAl® in the pre-treatment

EcoAl® 20, that are designed to meet the most demanding environmental

process before powder painting is a significant stride towards ecological

challenges.

excellence in the aluminium industry.

Over the decades, Alsan has proactively taken responsibility for creating

By shunning the use of hazardous hexavalent chromium compounds,

sustainable solutions that not only meet today’s quality standards but

businesses can not only improve their environmental stewardship

also set the benchmark for the future. Every improvement implemented

but also contribute to cleaner and safer production processes. The

in its products reflects its long-term vision, which is centred on the

shift to chrome-free alternatives is a testimony to the innovative

sustainability of the aluminium industry. This commitment was

spirit of industries as they seek to balance quality, performance, and

highlighted by the company’s strategic decision, four years ago, to

sustainability in their operations.

establish its own technical advisor and warehouse in Poland, enhancing

In the year of Alsan’s 50th anniversary, the company reaffirms more than

its ability to serve and respond to the European market with agility

ever its commitment to sustainability and respect for the environment.

and expert insight (Fig. 4). This move has allowed it to forge closer

These pillars are essential to ensure the future of our planet and the

connections with Alsan’s clients and partners, promoting practices that

legacy of generations to come. Its dedication to quality and excellence is

respect and enhance our environment, thereby ensuring a lasting legacy

reflected in the continuous development of products, such as

for future generations.

© ALSAN

Figure 3 - EcoAl® 20 was first approved by QUALICOAT in 2003 and has recently gained further recognition by obtaining the prestigious license from GSB International. © ALSAN

Figure 4 - It is estimated that, under QUALICOAT certification, more than 120.000.000 m2 of extruded aluminium are treated with EcoAl® 20 every year around the world.

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TIGER Trend Colors 2024

PLUM NOIR

As a powerful deep purple PLUM NOIR evokes the darkness of the universe and takes us back to where the mystery of life began.

The flat matte finish can be used as a design element in a range of contexts, creating a spellbinding atmosphere with unique depth for a broad array of applications.

© iStockphoto

www.tiger-coatings.com

RESEARCH BREAKTHROUGH

SPECIAL ISSUE ON METAL ARCHITECTURE AND DESIGN

Ultrathin, Hard and Sustainable Non-stick Coating Revolutionises Shaping Processes In Injection Moulding and Die Casting Klaus Vissing Fraunhofer Institute for Manufacturing Technology and Advanced Materials IFAM – Bremen, Germany klaus.vissing@ifam.fraunhofer.de

The new UltraPLAS coating developed by Fraunhofer researchers has proven to be a ground-breaking solution to the challenges of primary forming processes. This advanced release and easy-to-clean coating is applied as a gradient layer using a cold plasma process and is suitable for materials such as tool steel, stainless steel and aluminium. The unique physical properties of UltraPLAS enable perfect moulding of even nano-scaled and reflective surfaces. By reducing the number of post-processing steps and renouncing external release agents, the application is classified as highly economical.

H

ow can high-quality and sophisticated tool surfaces be coated

Materials IFAM investigated this question together with partners in

in such a way that production is improved, and cleaning

the “GlossyCast” and “UltraTrenn” projects funded by the Industrielle

processes are significantly delayed or simplified? Researchers

Gemeinschaftsforschung IGF. The aim of the research projects was

at the Fraunhofer Institute for Manufacturing Technology and Advanced

© Fraunhofer IFAM/Wolfgang Hielscher

to reduce the demoulding forces and the formation of deposits while

RESEARCH BREAKTHROUGH

permanently withstanding the specific stresses of zinc high-pressure die casting and plastic injection moulding.

Specifically, the injection moulding of technical plastic parts requires solutions to reduce demoulding forces and the formation of deposits.

This applies to the production of components with high-gloss surfaces

LOCAL ASSISTANCE

or highly defined microstructures, such as plastic lenses, decorative trims or connectors with high dimensional accuracy. Similarly, in zinc high-pressure die casting, deposits on the mould surface as well as deposits of release agents and lubricants prevent the production of high-quality, glossy zinc castings. This results in considerable costs for

1 OPERATOR REQUIRED

post-processing of the cast parts. Irrespective of this, the application of release agent alone can account for up to 20 percent of the cycle time, meaning that there is considerable potential for savings if release agents are not required anymore.

UltraPLAS enables outstanding coating properties

SELF-LEARNING ROBOT

To meet the aforementioned requirement-profile of ultra-smooth, optical surfaces (Ra < 25 nm) within the projects, the coating itself must be smooth and structureless. In order to achieve this, the cold plasma process, the so-called PE-CVD process (plasma enhanced chemical vapor deposition), was used. By building up a gradient layer, this process enables excellent layer adhesion to the product body on the one hand and exceptional non-stick properties with excellent physical characteristics on the product side on the other.

The coating produced in this way is characterized, for example, by a high modulus of elasticity (28 - 32 GPa) and a high density (1.5 g/cm³).

This results in a Mohs hardness range of 5.5, which is therefore on par with glass or enamel. Characteristically, as a non-stick coating, it also has a low surface energy (< 28 mN/m) with low polarity (< 1.5 mN/m).

This behaviour is supported by the fact that the Fraunhofer researchers have succeeded in producing the UltraPLAS coating with a particularly thin layer thickness of less than 100 nm. This even proved to be necessary in the GlossyCast project to provide a good

Increase productivity push your quality to the max

non-stick effect. In addition, the thin, structureless layers allow both nanoscale surface structures, e.g., for the nanoimprint process, and mirror-gloss surfaces to be perfectly reproduced.

Sustainable quality and economical production guaranteed Extensive practical tests carried out as part of the projects at various industrial companies have shown that demoulding forces and the formation of deposits are reduced in the field of injection moulding.

OFFIZIELLER PARTNER FÜR DEUTSCHLAND

Opening photo: UltraPLAS enables perfect reproduction of mirror-finish surfaces. Release-coated tool (left) with injection-moulded element.

www.Lesta.it

SPECIAL ISSUE ON METAL ARCHITECTURE AND DESIGN

It has also been shown that the reduction in adhesion forces reduces

casting quality, reducing production costs and making production more

the total demoulding forces. As a result, the demoulding temperature

environmentally friendly.

can be increased, and the amount of friction reduced.

As the cast products are manufactured without release agents, the pre-

In contrast to the state of the art, the coatings can be removed both

treatment time for electroplating is reduced and material consumption

effectively and gently using plasma technology so that, if necessary, a

is lowered. The manufactured components have the desired roughness.

new coating can be applied several times without any loss of quality.

Due to the smoother surface, bright copper plating can be dispensed

This is particularly interesting for high-gloss tool surfaces, as it eliminates

with, which leads to savings in materials, time and wastewater. Reducing

the need for time-consuming polishing or ultra-precision machining.

the layer thickness of copper (cyanide) and bright nickel by 50 percent

It has also been shown that the direct production of high-quality zinc

each led to further savings in materials and time.

die-cast surfaces using casting technology can significantly increase economic efficiency.

Background information on the development process

By significantly improving the surface quality of the cast parts, costly

The development of UltraPLAS was preceded by the PLASLON non-stick

and time-consuming mechanical post-processing steps such as blasting,

coating, which is characterized by high hardness (Mohs hardness 4.5

grinding, and polishing can be simplified or even avoided altogether. In

- 5.5) and excellent temperature resistance up to 230°C. This property

addition, the individual process steps of electroplating can be shortened

profile has made PLASLON a popular PFAS-free easy-to-clean coating

or reduced.

for cookware. Through continuous innovation and the development

The development of this durable UltraPLAS release coating for zinc

of products such as UltraPLAS and PLASLON, our institute makes

die casting stands for a significant advance in foundry technology. The

a significant contribution to improving production processes and

possibility of cutting release agents opens new potential for improving

promoting sustainability in the industry.

RESEARCH PROJECT The following projects have been funded by the Federal Ministry of Economics and Climate Protection as part of the program for the promotion of joint industrial funding (IGF) based on a decision by the German Bundestag.

GlossyCast • Funding reference IGF 22003 N • Innovation in zinc die casting - Production of mirror-glossy cast surfaces through release agent-free production • Duration: 01.02.2021 - 31.01.2024 • Project partner: Fraunhofer Institute for Manufacturing Technology and Advanced Materials IFAM fem Research Institute UltraTrenn • Funding reference number: IGF 22597 N • Non-destructive, ultra-thin release coatings with layer thicknesses below 100 nm for reliable demoulding and postprocessing of micro-moulded parts • Duration: 01.10.2022 - 30.09.2024 • Project partner: Fraunhofer Institute for Manufacturing Technology and Advanced Materials IFAM University of Paderborn.

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CUSTOMIZED SOLUTIONS CIRCULAR ECONOMY & GREEN APPROACH ECO-FRIENDLY CHEMICALS NANOTECHNOLOGICAL CONVERSION COATING

ONE STEP METAL PRETREATMENT

WATER PURIFICATION AND RECIRCULATION

PAINT STRIPPERS

CHEMTEC’S technologies are designed to have a very limited environmental impact, to reduce consumption of resources and for a greater operational simplicity.

CHEMTEC develops customized solutions that aim to maximize the customer’s satisfaction.

DISCOVER MORE ON

WWW.CHEMTEC.IT

FOCUS ON TECHNOLOGY

SPECIAL ISSUE ON METAL ARCHITECTURE AND DESIGN

© ipcm

Azeta Confirms Itself as a Pioneer in Aluminium Coating Through a New Vertical Line Combined with an Innovative IPS Powder Feeding System Monica Fumagalli ipcm®

Based in Muro Leccese, in the Salento region of Apulia (Italy), Azeta Srl was one of the first businesses in this area to specialise in the processing and surface treatment of aluminium and the first to patent, in the 1990s, a wood-effect coating applied with a liquid-on-powder cycle on this material. It is also the first company in the Italian aluminium industry to have recently installed an automatic vertical powder coating plant by Euroimpianti for profiles combined with Wagner’s latest powder feeding and control device, the IPS system, to increase its production capacity and reorganise its workforce more effectively.

I

n Italy, the first documented use of aluminium in construction dates back to 1897, when architect Raffaele Ingami used it for cladding the dome of the church of San Gioacchino ai Prati di Castello in Rome.

It was only a few years before the beginning of the 20th century, which would have gone on to be called “the century of aluminium” because of the growing importance of this metal in the most diverse applications, thanks to its characteristics of lightness, ductility, lustre, and corrosion resistance, as well as, in more recent years, the possibility of recycling it completely.

The Ruggeri Group specialises in the casting, extrusion, and coating of aluminium profiles, particularly for the door and window industry.

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FOCUS ON TECHNOLOGY

In the space of a few decades, aluminium went from

© ipcm

being employed exclusively for jewellery production to widespread use in construction, especially for roofing, in the metallurgical industry at the service of World War I, and even in the nascent aeronautical sector: from 1908, the rigid structure of Zeppelin airships was made of this material, as were some parts of Charles Lindbergh’s Spirit of St. Louis aircraft that made the first transatlantic flight in 19271.

Precisely these innovative solutions for the aeronautical and, later, automotive sectors inspired the use of aluminium in architecture as well, which was actually already widespread in the United States, whose skyscrapers and single-family houses, from the Chrysler Building to the experimental Aluminaire House, the first house built entirely in metal, soon became reference models for the Italian construction sector, where the use of aluminium finally came into its own in the 1950s. However, it was only in the 1970s, following the energy crisis and the increased demand for thermal insulation in homes, that this material began to spread in the world of door and window frames, previously the exclusive preserve of wood, especially becoming a constituent element of double windows, characterised by a

The area with the aluminium profile loading bench in the coating department.

second frame added to improve the thermal insulation of a wooden one. Following the rapid technological development of this industry, special surface treatments capable of giving

© ipcm

aluminium profiles greater resistance to atmospheric agents and attractive aesthetic effects, such as anodising, powder coating, and decoration by sublimation, soon began to become widespread.

“I was one of the first entrepreneurs to introduce aluminium profiles in southern Italy precisely in the years when this material’s qualities were also beginning to be recognised in the window and door industry,” says Salvatore Ruggeri, Azeta Srl’s founder and the current chairman of the Group that has grown around it, as well as a well-known figure not only in the business world but also in the Italian political one, thanks to his past as a parliamentarian. “That is why we chose to specialise in the processing and surface treatment of aluminium: in 1995, we installed the first coating plant capable of applying wood-effect products with a liquidon-powder cycle patented by us. Today, we are one of the best-known and most-awarded aluminium hubs in Southern Italy. For the surface treatment of extrusions, we work with a horizontal coating plant. However, driven by the need to improve and automate production as much as possible,

The outside of the 10-stage pre-treatment tunnel.

https://dsdra.web.uniroma1.it/sites/default/files/Materiali%20e%20 strutture%2012.pdf

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SPECIAL ISSUE ON METAL ARCHITECTURE AND DESIGN

From left to right:

© ipcm

© ipcm

Each booth is equipped with 4 opposing reciprocators.

The monorail conveyor in the foreground and the drying and curing oven in the background.

The machine for cleaning the hooks without chemicals.

we recently decided to experiment with a new type of plant, a vertical

aluminium supply chain.” Today, the Ruggeri Group, which employs

powder coating system for profiles designed and installed at the end of

over 170 people, consists of Ruggeri Service Spa, the foundry producing

2023 by Euroimpianti (Valeggio sul Mincio, Verona, Italy) combined with

extrusion billets; TO.MA. Spa, specialising in aluminium extrusion and

Wagner’s latest-generation powder feeding and management plant, the

manufacturing extrusions for the door and window frame, architecture,

IPS system.”

and industrial sectors; Azeta Color Srl, offering hundreds of solutions

The Ruggeri Group: a complete aluminium supply chain

for finishing aluminium with both liquid and powder paints, from RAL colours to wood-effect coatings with the already mentioned Woodall

Founded in the early 1970s thanks to the entrepreneurial initiative of

process as well as the Lignall, PAZ (powder-on-powder), and sublimation

its current president, the Ruggeri Group, which takes its name from

ones; and Azeta Metalli Sas, marketing and distributing aluminium

him, is now a consolidated reality consisting of 4 companies, each

profiles and sheets, window and door accessories, and aluminium

specialising in a crucial processing phase of the extrusion supply chain.

processing machinery and equipment. “The Ruggeri Group’s companies,

“When I think back to when I started my business,” comments Ruggeri, “I

therefore, cover the complete chain of transformation, processing, and

cannot deny that I was faced with several difficulties but also successes

marketing of aluminium extrusions,” Ruggeri confirms, “meeting the

and satisfactions. I began by selling iron mouldings. When the first

highest product quality standards while fully respecting our surrounding

aluminium profiles with special effects began to circulate, I became

area and the environment. Suffice it to say that we can currently

interested in them, immediately realising the considerable potential of

produce billets on demand in 6060 alloy with a recovered material

this material. In 1975, with two other partners, I founded Azeta Metalli

content of 87%, which places us in class A for recycled/recovered

Sas, launching the painted aluminium profile, which did not exist on the

content according to the parameters of REMADE certification2.”

market at the time. This was met with increasing success. Therefore, afterwards, we patented Woodall, the first powder-on-liquid application

Woodall: the first wood effect on aluminium

process to obtain the wood effect on aluminium, which also spread

Probably due to the long-standing tradition of woodworking and coating

to northern Italy with a powder-on-powder technology. In 1999, we

in the Italian door and window industry, aluminium has been slow to be

began to see the need to produce profiles ourselves, creating a new

recognised in this country as a valid alternative to elements made of this

factory devoted to extrusion and simultaneously enhancing our coating

natural material. Perhaps, however, this very reason was also at the root

activities by building an additional hall for them. By this time, production

of the success of Woodall, the process Azeta patented in 1995.

volumes had reached 500 t/month and were increasing steadily. In 2006, we finally opened our own foundry, thus setting up a complete

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2

https://www.remadeinitaly.it/remade/

FOCUS ON TECHNOLOGY

© ipcm

Based on the idea to combine the strength and

points out: “The system designed and installed by

durability characteristics of metal with the warm

Euroimpianti is the first installed in our factory for

and natural aesthetics of wood, it blends well

vertical profile coating. We have always worked with

with different architectural styles, especially in

horizontal coating plants, but this vertical machine

homes where wood is a central element. “Further

immediately proved to bring significant advantages

advantages of coated aluminium elements compared

over the others. Before choosing Euroimpianti as

to wood,” Ruggeri emphasises, “include lower

the supplier of this technology, we assessed other

maintenance requirements thanks to high corrosion

options, but its solution convinced us with its high

resistance, better thermal insulation thanks to

automation performance, which would allow us

the techniques implemented (such as thermal

to reassign our staff to other departments, and

cutting, which improves insulation and avoids heat

its increased capacity in terms of coated volumes,

dispersion), lightness to facilitate installation and

around 15 t/day, which would finally enable us to

reduce the overall load on architectural structures,

meet the needs of a market requiring increasingly

and last but not least, environmental friendliness, as

higher quantities. A further benefit of vertical coating

aluminium is 100% recyclable.”

relates to the positioning of the heaviest profiles,

The first vertical coating plant for profiles Continuous production growth and new market

which, by standing vertically, do not run the risk of bending, as can occur in horizontal plants, thus

PASSION FOR MASKING SOLUTIONS

significantly reducing scrap rates.”

requirements convinced the Ruggeri Group’s

The main features of the coating plant

management to start an expansion project involving

“Every plant designed by Euroimpianti,” indicates

its foundry, whose surface area will be doubled, its

Gianluca Baruffaldi, CEO at Euroimpianti Group, “is

coating department, integrated with the new vertical

configured and customised according to the number

profile coating plant, and its packaging division. The

of aluminium profiles to be coated and the special

work is scheduled for completion between January

requirements of each specific workflow. The system

and February 2026. Fabrizio Ruggeri, Salvatore’s

installed at Azeta boasts state-of-the-art technology,

son, who is joining his father at the company’s helm,

extreme reliability, and high production capacity,

info@global-mask.com www.global-mask.com

SPECIAL ISSUE ON METAL ARCHITECTURE AND DESIGN

and it was the subject of an ad hoc study in terms of energy and thermal savings. It starts with a 10-stage pre-treatment tunnel. Every detail of the tunnel, such as segment length, tank characteristics, and interaxle spacing, is designed according to the requirements of Qualicoat and AAMA chemical treatment cycles. The last passivation stage is equipped with the Nebula system, ensuring that the workpieces are sprayed with a solution of consistent chemical quality while reducing water consumption. The machine has a chemical dosing, mixing, and control unit, an operating system with a touch-screen control panel, and spray bars with atomising nozzles.

After pre-treatment, the monorail conveyor takes the components to the drying oven designed so that heat can be recovered from the parts as they cool.”

The diamond-shaped booths The 2 coating booths belong to the Diamond series, whose name is inspired by their diamond-like shape. © ipcm

Wagner’s state-of-the-art IPS powder centre.

“What makes this application booth stand out is undoubtedly its geometry: thanks to the perfect symmetry of its structural components, profiles with any shape and cross-section can be coated with maximum performance,” states Antonio Cimenes, sales agent for the Veneto-based company. “It comprises a powder-coated metal structure that provides support and containment for a series of symmetrically opposed dielectric sheets. 4 reciprocators per side, specially angled gun bodies, and a linear conveyor path during coating ensure flexibility and control of application parameters. The side sheets delimiting the application area feature a software-controlled rotating movement that promotes powder recovery and facilitates and speeds up colour change operations. Cleaning inside the booth is fully automatic thanks to the dust extraction and recovery system consisting of a high-efficiency cyclone separator and a self-cleaning cartridge filter that intercepts dust particles not removed by the cyclone. The floor also consists of a rotating dielectric sheet that is automatically cleaned. The line is completed by a device that allows cleaning the hooks without chemicals.” Among Azeta’s main powder suppliers is Pulverit Spa, whose history began at the same time as the Apulian company.

© ipcm

SuperCenter EVO.

The vertical plant and the IPS powder management system: a winning combination “This is the first vertical coating plant to adopt Wagner’s innovative IPS powder management system in the italian

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FOCUS ON TECHNOLOGY

aluminium industry,” emphasises Michele De Cesaris, Area Manager-Powder Coating at Wagner. “At the same time, we also supplied Azeta with our classic SuperCenter EVO powder centre, the first designed to be in line with Industry 4.0 parameters and already tried and tested with countless vertical coating systems: the SuperCenter EVO and the IPS plant work perfectly with each of the 2 booths.”

On the other hand, this combination has ensured considerable advantages: “The IPS powder centre increases productivity, guarantees high quality standards, streamlines operations, and reduces colour change times consistently. The powder feeding system is revolutionary, as it is based on the concept of working with a pressurised tank, without the use of pumps (Venturi or pinch), fully meeting the definition of high density. It is equipped with a twofold fresh powder feeding system, allows powder preparation by ultrasonic sieve, vibration, and fluidisation, and features special systems for accurate gun dosing. Its integrated sensors for weight, flow, pressure, and level and its fully automatic colour change system guarantee high productivity and cost efficiency, as the application remains consistent over time – over 2,000 hours without adjustments to the application parameters and therefore without routine maintenance. Thanks to this new powder centre, Azeta can better manage paint consumption and spray fan patterns, thus improving coating performance, the most critical aspect for the Apulian company. “IPS also features the highest level of automation of colour change operations without human intervention, with centralised control of all process steps and real-time detection of powder consumption.”

© ipcm

The chemical-physical treatment plant processing the pre-treatment tunnel’s waste water.

SPECIAL ISSUE ON METAL ARCHITECTURE AND DESIGN

© ipcm

The demineraliser with ion exchange resins installed by Saita.

© ipcm

From left to right, Fabrizio Ruggeri, Gianluca Baruffaldi, Euroimpianti Group's CEO, Azeta Srl’s president Salvatore Ruggeri, and Antonio Cimenes from Euroimpianti.

The chemical-physical waste water treatment plant

aluminium profiles, further increasing our production capacity and

The line is also equipped with a wastewater treatment plant for the

coating quality,” concludes Salvatore Ruggeri. “Even though the

pre-treatment tunnel, developed by Saita Srl of Limena (Padua). "The

investment was significant, it is the result that matters. We are also

water treatment system we installed at Azeta," says Carlo Enrico Martini,

satisfied with the partners we chose: Euroimpianti and Wagner’s teams

Sales Manager of Saita, "is a traditional chemical-physical plant with a

demonstrated not only excellent skills but also a remarkable ability to

capacity of 2,000 liters per hour, where the diluted water discharged

adapt to our needs and even go the extra mile, as in the case of the

from the washing stages is treated continuously, while the concentrated

second powder centre that Wagner provided us with to avoid issues

wastewater is stored in a balancing tank and dosed into the same

with a system that had never before been tested with vertical coating

purification system. Demineralised water is produced and recovered in

technology. As a result, we have tripled our production capacity,

a closed loop within the washing tunnel tanks by a demineraliser with

reduced the number of shifts, and relocated our employees to other

ion-exchange resins in a dual-line system with a capacity of 10,000 liters

departments with different tasks.” That is going to confirm Azeta’s

per hour."

strategic role in the aluminium coatings sector: “The wood effect now

Conclusions

has a large market, and we are currently developing a coating with the same effect on PVC. We are constantly looking for solutions to meet the

“Thanks to this new coating line, we will be able to consolidate our

demand for profiles with the most unusual effects: our history started

position as a supplier for the door and window frames industry

there, and we will continue to pursue this path. We believe that Azeta’s

and become an increasingly important player in the field of coated

future lies in this pioneering approach.”

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© ST Powder Coatings S.p.A.

HIGHLIGHT OF THE MONTH

SPECIAL ISSUE ON METAL ARCHITECTURE AND DESIGN

ST Powder Coatings Presents the New Green Oasis Range, the Ecological Oasis of the Future Enrico Dall’Igna ST Powder Coatings S.p.A. - Montecchio Maggiore (Vicenza), Italy enrico.dalligna@stpowdercoatings.com

In order to support sustainability, ST Powder Coatings has launched Green Oasis: the new range of powder coatings is based on polyester resins containing a combination of recycled raw materials and/or with part of the components deriving from renewable sources.

I

t is ever-increasing the number of consumers and companies placing

the negative impact on the environment. Our time requires innovative

great value on environmental compatibility. So, they are selecting

solutions which guarantee the liability of our planet, preserving it for

powder coatings for their projects, as these solutions are already

future generations.

considered ecological because of their zero-emissions. However, it is

The objective must then be to minimise harmful emissions in the

not exactly so: conventional powder coatings are composed by more

environment without compromising the quality, competitiveness and

than 50% of resins obtained from oil and natural gas derived from

standards of the finished product. Therefore, the company has asked

underground fields.

itself: can it optimise its production processes and reduce its ecological

It is precisely for this reason that ST Powder Coatings aims to constantly

footprint, maintaining or improving quality and reducing the carbon

select products and manufacturing options that are useful for reducing

footprint at the same time?

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HIGHLIGHT OF THE MONTH

The new Green Oasis powder coatings range

(rPET or recycled polyester) is a material obtained

The research and development laboratory of ST

mostly from the recycling of PET bottles and, to a

Powder Coatings has always focused on technical

lesser extent, from industrial polyester or clothing

innovations that are not only beautiful to look at, but

waste.

that also benefit people and the environment, offering

Looking forward to a truly functioning circular

an added value. Its efforts led to the creation of a first

economy, ST Powder Coatings has developed a solid

series of powder coatings with raw materials with

and reliable process to produce powder coatings

components deriving from renewable sources already

starting from this recycled polymer, maintaining their

in 2012 – an absolute novelty at the time. Based on

very high quality unchanged.

the experience gained, the company is now able to

from the recycling of waste materials. It comes

present the new Green Oasis powder coatings series,

Green Oasis series R

available in three configurations, two of which, the R

Green Oasis series R uses innovative polyester resins

and PLUS series, will soon be available on the market:

synthesised not only with traditional field gas but,

 P SERIES: based on polyester resins containing

above all, with ecological bio-gas: it means that the

recycled materials;

sources of the essential raw material to produce the

 R SERIES: based on polyester resins with part of the

powder coatings is food, agricultural and forestry

components deriving from renewable sources;

waste. In this way, the unwanted is transformed into

 PLUS SERIES: based on polyester resins containing a

a high-quality raw material. High quality that can

combination of recycled raw materials and with part of

be found unchanged in the new range of powder

the components deriving from renewable sources.

coatings.

Some of these powder coatings are available with the option of a low curing temperature, to further

Green Oasis series PLUS

reduce the environmental impact by reducing energy

Green Oasis series PLUS combines the advantages

consumption.

of the R and P series in a single solution. The PLUS

Green Oasis series P

series brings the content of raw materials deriving from renewable and recycled sources to a maximum,

Green Oasis series P uses recycled PET-based

offering the best contribution in reducing the

components in its production cycle. Recycled PET

ecological footprint.

COMPLETE SOLUTIONS FOR HANGING AND MASKING © ST Powder Coatings S.p.A.

www.rostirolla.it

© Kenosistec

ADVANCEMENTS

SPECIAL ISSUE ON METAL ARCHITECTURE AND DESIGN

Evolution on Design: Kenosistec’s PVD Technology for Elegant, Durable, and Sustainable Finishes Edited by Kenosistec Srl Casarile (Milan), Italy

antonio.angolemme@kenosistec.it

PVD technology takes a front row seat on the stage of design industry finishes with its exceptional aesthetic, functional and sustainable properties. Kenosistec provides designers with the opportunity to create distinctive, durable, and environmentally friendly products through its ability to customise PVD systems and meet specific customer requirements.

P

hysical Vapour Deposition (PVD) is a biocompatible surface

possibilities. Thanks to its versatility, this technology has numerous

engineering technique that allows depositing thin layers of

applications, from taps and fittings to furnishing accessories, from

material on various substrates such as metal and alloys, plastics,

jewellery and cutlery to watchmaking and packaging.

glass, ceramics, polymers, and semiconductor materials. PVD forms

Kenosistec Srl has developed advanced solutions to meet the needs of

coatings with specific properties that improve the aesthetic and

the design market, contributing to the increasingly widespread adoption

functional characteristics of products, including resistance to abrasion

of PVD. “In this field, Physical Vapour Deposition technologies open up

and thermal shock, thus lengthening their service life. In the design

new possibilities for creating customised works with the most diverse

sector, where aesthetics and functionality must always go hand in hand,

finishes and colours. This coating process is particularly appreciated

PVD stands out as a key resource offering almost unlimited creative

for its adaptability: PVD finishes can be deposited on a wide range of

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ADVANCEMENTS

an optimal choice for anyone seeking versatility, quality, and precision,”

Kenosistec: innovation and leadership in the PVD industry

explains Antonio Angolemme, Head of Sales at Kenosistec.

Founded in 2005, Kenosistec has become a leader in the Italian

different substrates, unlike other deposition methods. That makes them

technology landscape by specialising in the production of

The benefits of PVD: high finishing quality

customised PVD systems. Belonging to the Angelantoni Industrie

One of the main reasons for the increasing use of PVD in the design

Group, this company has consolidated its position thanks to its

sector is the exceptional quality of the finishes obtained. PVD coatings are

ability to offer tailor-made solutions for sectors ranging from

resistant to scratches, wear, and corrosion, making the treated products

eyewear and automotive to architecture and furniture accessories.

durable even in environments such as bathrooms, where contact with

“It is precisely in the design and furniture industry that Kenosistec

water and chemicals can deteriorate the surfaces of taps and fittings.

plays a critical role thanks to the versatility of PVD, which is also

Moreover, this coating technique allows applying a wide range of colours,

widely used in the production of handles, furniture feet, sinks,

enabling designers and architects to follow current market trends. “Gold,

mixers, appliances, taps and fittings, showers, accessories such as

bronze, black, and chocolate brown are currently very popular in the

towel rails, and lighting systems,” states Angolemme.

furniture industry, but the colour possibilities are almost endless. That makes PVD a preferred choice for distinctive, customised solutions. Thanks to this technology, parts can be produced with ad hoc designed colours,

© Kenosistec

which is ideal for objects with an exclusive character,” says Angolemme.

“PVD finishes are glossy and uniform and give every product a refined, high-end appearance.”

An environmentally sustainable solution In addition to its aesthetic and functional advantages, PVD also stands out for its reduced environmental impact. Unlike other coating processes that may generate toxic waste or require the use of polluting chemicals, this is considered ‘green and clean’ as it does not use solvents, does not release harmful substances at the end of the cycle, and allows for deposition even at low temperatures, helping reduce energy consumption and greenhouse gas emissions. Precise thickness control also minimises the consumption of coating material, contributing to greater production efficiency. Finally, thanks to the long service life of PVD coatings, products finished with this technology ultimately need fewer replacements, thus reducing waste and resource consumption over time. This sustainable approach complies with the European REACH and RoHS regulations, making PVD a safe and responsible choice for companies that want to reduce their environmental impact.

Examples of available cutlery finishes.

IT‘S THE PROCESS THAT BECOMES YOUR SOLUTION.

We supply you with individualized finishing lines.

venjakob.com

SPECIAL ISSUE ON METAL ARCHITECTURE AND DESIGN

“Our Hi.P.Po. and CHROME+ technological innovations have been driving

Kenosistec can also be considered the ideal solution for customers

this evolution, offering solutions that not only meet current market

wanting to take their first steps into the world of PVD but do not

needs but are also ready to respond to future challenges.”

have the possibility of buying a system. It offers a flexible and highly specialised contract coating service ensuring excellent quality

The contribution of the Hi.P.Po technology

and technical support at every stage. That allows finishing one’s

One of Kenosistec’s most significant innovations to support this

components with PVD to test the reaction of the market before

industry is the Hi.P.Po. (High Productive Powered Sputtering Cathode)

acquiring a plant, but it is also suitable for companies that already have

technology, consisting of a next-generation sputtering source designed

one and are facing sudden or temporary production peaks.

for large-scale production. Compared to conventional planar cathodes,

PVD is going to play a vital role in the future of design, and Kenosistec

Hi.P.Po. ensures a 10 times higher deposition rate, greater consistency,

is at the forefront of this journey, offering services and technologies

and reduced energy consumption by more than a third. It also allows

that enable the creation of beautiful, durable, and environmentally

materials such as nitrides and carbides to be deposited, offering a wide

friendly products. With the expansion of PVD applications and the

range of colours and finishes to meet all the demands of today’s design

continuous development of new solutions, the possibilities for the

world.

design industry are almost endless – and Kenosistec is ready to make the most of them.

CHROME+: chrome coating on plastic CHROME+ is another example of Kenosistec’s innovation capacity.

This unique, patented two-layer technology allows applying chrome coatings on plastic without galvanic processes. The resulting glossy and satin finishes meet the rigorous standards of the automotive industry but can also be used in fields such as home appliances and furniture accessories.

Kenosistec's Casarile facilities: a dual -purpose in-house Coating Service After years of developing PVD finishes to support our partners and help

© Kenosistec

them remain competitive, we have expanded our services to offer PVD treatments directly to the industry. However, our primary goal remains to educate the market and promote PVD as a key player in surface finishing. “We are working hand in hand with an industry willing to innovate, develop, or expand its finishing solutions. Our Coating Center will also co-develop new solutions, introduce new products, reduce time to market, and everything that the industry needs to deepen and enhance its skills in PVD." PVD technology is constantly expanding, from new finishes for unexplored markets to new solutions, e.g. Hipims, for meeting growing production requirements. However, the process adopted is what makes the difference. Through process study, it is possible to achieve perfect efficiency and repeatability and lend special properties to the substrate.

Kenosistec offers assistance and guidance for customers approaching this technology, contributing to establishing a method. In particular, Cleaning Coating Testing is the turnkey service through which this company can take care of the preliminary study to verify the feasibility of a process, design and produce a PVD system, and finally, install and commission the machine, also guaranteeing assistance throughout the plant’s life cycle.

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The inside of the Hi.P.Po. (High Productive Powered Sputtering Cathode) system.

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Luxe Perfil: The Experts in the Impossible Rely on the New PrimeCoat® A109 Pre-Treatment Product’s High Performance Alessia Venturi ipcm®

In the field of metal architecture, each project requires a unique solution. However, a shared key prerequisite is the quality of the parts and structures that make it up. This is substantially assessed in terms of outdoor durability and corrosion and weathering resistance, both guaranteed by their finishes. Luxe Perfil, the European leader in aluminium coil coating, has chosen a very innovative, unique product on the market, PrimeCoat® A109 from DN Chemicals, to meet the quality specifications of its architectural products.

T

he industry of aluminium for architectural use is lively and dynamic, characterised by ever-new and more complex requirements in terms of design and performance. Responding

promptly to these needs by anticipating them is the speciality of Luxe Perfil, an Italian-Spanish aluminium specialist that produces profiles, doors, bioclimatic pergolas, roller shutters, and insect screens for commercial and private building projects in more than 40 countries worldwide.

It is well known that finishes are an integral part of the quality of an architectural structure because they are its first barrier, its first protection against everything that surrounds and affects it: atmospheric and environmental agents, mechanical and chemical stresses, cleaning

© Luxe Perfil

Luxe Perfil specialises in producing bioclimatic pergolas, roller shutters, and sunscreens.

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cycles, human impact. It is also well known that paint – any paint – alone is not enough to ensure excellence in performance: it always takes a team effort between pre-treatment and coating.

FOCUS ON TECHNOLOGY

What cannot be done by the latter due to chemical or application limitations is taken care of by the former, with the joint objective of complying with the project’s specifications.

That was also true for Luxe Perfil (Chiva, Valencia, Spain) and Alucofer (Robledo, Albacete, Spain), belonging to the same Group specialising in the production, finishing, and transformation of aluminium. Their collaboration with DN Chemicals (Milan, Italy) – already the supplier of the Group’s third subsidiary, the Italian firm Luxe Coat – for the experimentation and then the industrialisation of a highly innovative no-rinse, chrome-free conversion product enabled Luxe Perfil to achieve a corrosion resistance degree never before reached on its liquid and powder-coated coils. The company also managed to reduce its production times and costs, as DN Chemicals’s product even allows skipping the application

© Luxe Perfil

phase of a conventional primer.

The experts in the impossible With 30 years of experience, 320 employees, 130,000 m2 of facilities in Spain and Italy, and a production capacity of 50,000 tonnes per year of coated aluminium coils and 10,000 tonnes of extruded and coated profiles, Luxe Perfil describes itself as an ‘expert in the impossible’. “The Luxe Perfil Group consists of three companies specialising in aluminium processing, two of which are located in Spain, Luxe Perfil and Alucofer, and one in Italy (L’Aquila), Luxe Coat,” says Giuseppe Procopi, the Group’s General Manager. “Our production activities began almost 30 years ago with the manufacture of customised roller shutters. Then, based on our owner’s idea to respond to evolving market trends, other production processes related to the aluminium industry have been gradually integrated over the years. With 4 coil coating lines (3 of which apply liquid products and 1 liquid and powder products), 4

© Luxe Perfil

cutting lines, a foundry, 1 extrusion press, 15 roll forming lines for roller shutters and 2 for shutter boxes, 2 horizontal and 1 vertical powder coating plants for extrusions up to 8.5 m, 1 rolling mill, 2 continuous casting lines, and 1 tension levelling system, the Luxe Perfil Group has now vertically integrated the entire aluminium supply chain, reducing production times and increasing quality.

From top: The coil coating line treating coils up to a width of 1550 mm and a thickness of 3.05 mm with liquid and powder finishes.

One of the two chemcoaters applying the PrimeCoat® A109 no-rinse chrome-free product on Luxe Perfil’s coils.

The liquid coil coating head.

© Luxe Perfil

international PAINT&COATING magazine - SEPTEMBER/OCTOBER 2024 - N. 89

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SPECIAL ISSUE ON METAL ARCHITECTURE AND DESIGN

“The first coil coating line was installed here in Valencia to cope with

casting accessories, which are then powder-coated on one of the

our growing consumption of coated coils. Today, we have three coil

horizontal lines. A sublimation line completes the company’s equipment

coating lines at the Chiva plant. Later, with the significant increase

for finishing our extrusions.”

in demand for customised roller shutters, it was decided to invest

“The aim of these technological development efforts and the

in extrusions as well because no supplier could keep up with our

expansion of our production area was to offer an ever-increasing

demand. Alucofer was founded in Robledo 20 years ago. There, we

range of products, aiming to be sole suppliers to our customers and

installed our first extrusion press and a horizontal coating line. A few

facilitate procurement management, especially for foreign ones. In the

years ago, we added a vertical coating line, the only one in Europe

meantime, the shutter market evolved, specialising in the production of

to coat lengths of over 8.5 m, and a liquid coil coating line for small

shading and screening elements such as mosquito nets and bioclimatic

batches (60 cm in width), which were rapidly accounting for an

pergolas, with the latter now being among our core products. We

increasing percentage of the total volume of shutters we produced.

have a diverse customer base to which we offer quick, comprehensive

At Alucofer, we also started the production of PVC profiles with 6

service and excellent technical support thanks to our solid,

extrusion lines, as well as a foundry for extruding billets and die-

high-productivity structure.”

© Luxe Perfil

Luxe Perfil’s quality assurance laboratory in Chiva (Valencia).

Quality tests on paints applied by Luxe Perfil. © Luxe Perfil

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© Luxe Perfil

© Luxe Perfil

FOCUS ON TECHNOLOGY

Finishing: endless possibilities for just as many performance demands Luxe Perfil’s products have contributed to iconic architectural projects from Doha to Saransk, from Brussels to Rome and Montreal. “At Luxe Perfil, we are aware of the importance of employing the best finishes available on the market to guarantee unquestionable quality in terms of both aesthetics and outdoor performance. As we tackle projects in more than 40 countries worldwide, the environments in which our products are installed are the most diverse. With regard to the choice of finishes, in the Building sector, it is normally the architects who give precise indications. On many occasions, based on our many years of experience, we have developed colours and effects ourselves, consistently improving our products’ aesthetic impact. Our in-house R&D activities are always aimed at meeting and anticipating the needs we perceive in the market,” comments Procopi. “In the Coil sector, we are among the few in Europe able to coat coils up to

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a width of 1,550 mm and a thickness of 3.05 mm with liquid and powder finishes. We offer finishes in all RAL colours with different effects, textures, and gloss levels.”

“As I mentioned, it is of fundamental importance to continue to meet the ever-increasing performance requirements of the roller shutter and sunscreen sector: chemical resistance to cleaning products, mechanical resistance to opening and closing cycles, and corrosion, UV, and weathering resistance are the main quality measurement parameters. We should consider that roller shutters are the first exposed element outside a window and are subject to a greater risk of corrosion than the window itself, also because they can remain closed for a long time instead of being used more dynamically. Sometimes, customer demands for corrosion resistance are so high that paint suppliers are unable to meet them: in these cases, the role of the pre-treatment process we perform on our coils becomes strategic for compliance.

“We solved the problem of improving our performance degree through our collaboration with DN Chemicals, which started when we opened Luxe Coat in Italy and began doing application tests with excellent results1. After testing DN Chemicals’s products for several years and based on joint experimentation projects, we decided to also rely on them for Luxe Perfil. Their pre-treatment chemicals, which we use on all our coil lines at both Luxe Perfil and Alucofer, as well as Luxe Coat, guarantee high performance especially in terms of corrosion resistance, which other suppliers cannot provide.”

Giorgia Ricchiuti, “A Two-Step Transition From Chromate Treatment to a Chromium-Free Cycle on an Aluminium Coil Coating Line,” from ipcm® no. 75, Vol. XIII, May-June 2022, pages 94-99)

1

CM AUTOMAZIONE s.r.l.

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

SPECIAL ISSUE ON METAL ARCHITECTURE AND DESIGN

© Luxe Perfil

Solid pre-treatment “We provide Luxe Coat with a tried and tested chromefree pre-treatment cycle,” says André Bernasconi, the General Manager of DN Chemicals. “The innovative aspect lies in the fact that Luxe Coat has installed the world’s first atomisation system for pre-treating high-thickness (1.2 to 3 mm) coils for architectural use, particularly for curtain walls. At Luxe Perfil and Alucofer, on the other hand, the process is carried out with chemcoaters (special machines applying no-rinse products as if they were coatings), which applies an innovative product formulated with a special polymer that is fundamental for corrosion protection but also for giving the coated coils the flexibility required for the post-forming phase.

“The performance of PrimeCoat® A109 is similar to that of a chrome-free product, although it does not have any other metal in its formulation, i.e. 1,000 to 1,500 hours in acetic salt fog depending on the type of aluminium alloy treated. A further advantage is that the application of a conventional primer can be avoided, resulting in obvious cost savings and improved production speed.”

“Luxe Perfil uses DenClean 418 AS for alkaline degreasing

The coil cutting line.

and the DenAcid 774 deoxidiser for etching. Alucofer’s coil treatment line employs the same alkaline degreaser © Luxe Perfil

and the same conversion product, PrimeCoat® A109, but does not perform the acid neutralisation phase,” adds Gherardo Minotti, Business Development Specialist at DN Chemicals. “Both sites have also installed a water purification system developed in cooperation with us. When we approached Luxe Perfil after a long collaboration with Luxe Coat, we identified the need to modernise its whole pre-treatment phase, so we presented ourselves as a supplier of both tried and tested and innovative products.

“The electrochemical analysis of the performance of PrimeCoat® A109 is very interesting because it demonstrates its high level of protection from the electrochemical point of view, i.e. against corrosion, and its very low water permeability, ideal for preventing the corrosion of the substrate once it is exposed to the weather.”

A very positive change “Thanks to the integration of these products, in addition to our level of performance, we have also significantly The coil forming line.

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improved our production process, which has become

FOCUS ON TECHNOLOGY

more stable. We are very satisfied,” says Procopi. “We tend to change suppliers with great difficulty. Implementing DN Chemicals’ technologies at Luxe Coat was easy because it was starting from scratch; on the other hand, at Luxe Perfil, we tend to be very loyal over time unless failures on the part of the supplier itself force us to change. This was not the case with DN Chemicals: after a year of tests, they were very attentive and made it impossible for us to ignore them.”

“The conversion product was first tested on sample sheets in the laboratory, then with a half-day trial, and then with 2 one monthlong trials in 2022 and 2023. In spring 2024, we started supplying it,” summarises André Bernasconi. “It was a nice project, which took some time but was ultimately successful, which is also a source of pride for us at DN Chemicals.”

“A company may undertake a good project but end up not finding the right supplier to implement its vision. With DN Chemicals, it was © ipcm

about testing and implementing a product on which it was already working: we were both in the right place to develop a chemical that did not exist on the market,” concludes Giuseppe Procopi.

From left to right, Luxe Perfil’s Packaged Product Sales Manager Eduardo Llopis, André Bernasconi from DN Chemicals, Alucofer’s Coil Manager Fernando Montoya, and Gherardo Minotti from DN Chemicals.

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SPECIAL ISSUE ON METAL ARCHITECTURE AND DESIGN

Luxe Perfil’s Pre-Treatment Cycle 1 - Degreasing (6 m3, 50 °C) with Denclean 418 AS 2 - Cleaning (2 m3, room temperature) 3 - Acid etching (2 m3, room temperature) with Denacid 774 4 - Cleaning (2 m3, room temperature) with conductivity < 200 microS 5 - Cleaning (2 m3, room temperature) with conductivity < 50 microS 6 - Conversion in a chemcoater with chrome-free PrimeCoat® A109 Line speed: 40 -50 m/min PrimeCoat® A109 is a water-bed, chrome-free pre-treatment product specifically developed to improve the metal surface’s paint adhesion and bonding characteristics. If pre-treated with it, steel coated with an alloy of aluminium and zinc features excellent and durable adhesion for coil coating paints and good adhesive properties. The adhesive properties of PrimeCoat® A109 were tested in combination with various one-coat coatings and primers + topcoats after exposure to wet conditions, e.g. with humidity and boiling water immersion tests. When a suitable primer + topcoat system is used, the PrimeCoat® A109 pre-treatment process ensures good corrosion resistance, comparable to a conventional no-rinse chromate pre-treatment. Its label includes no hazard pictograms.

DN Chemicals regularly monitors the quality of the process with the following tests: • T-bend adhesion, adhesion after boiling, and impact tests • ASTM B117 acetic salt spray corrosion resistance tests • EIS – ACET electrochemical corrosion resistance tests.

ACET test results Max Z ( Ω*cm2)

Min Z ( Ω*cm2)

DELTA Z (%)

WATER UPTAKE (%)

1.24E+07

1.12E+07

0.62

0.028

The Max Z and Min Z values represent the maximum and minimum impedance values recorded from the start to the end of the test. The Delta Z value represents how much the sample degraded from the start to the end of the test. A low value indicates limited degradation. This is confirmed by the Bode diagram below, showing the impedance values recorded during the test: there are 7 overlapping straight lines, which corresponds to very low degradation.

The water uptake value provides an indication of the hydrophobic properties of the coating: in this case, the value is low and, therefore, the coating has very good hydrophobic properties (see image).

Water treatment The products supplied for the purification plant are as follows: • Denflok 7315, primary coagulant • Denflok 7504, polyelectrolyte • Dencide 7702, antibacterial sanitiser • Dencal 6304 OS, osmosis membrane treatment product.

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DON’T WORRY WE GOT THIS

ANTIBACTERIAL ANTIVIRAL SUPERHERO

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

FOCUS ON TECHNOLOGY

SPECIAL ISSUE ON METAL ARCHITECTURE AND DESIGN

Raising the Bar of Quality: Sirio Galv’s New Liquid Coating Plant for High-End Furniture and Lighting Accessories Ilaria Paolomelo ipcm®

Quality and aesthetics are determining factors in the world of luxury furniture and lighting. Sirio Galv, which has always been synonymous with excellence in galvanic treatment and painting, recently took a significant step towards raising its quality standards with a new liquid coating system designed and installed by Verona Impianti 2002. In addition to providing excellent finishes, the new line played a key role in supporting Sirio Galv’s environmental policy oriented towards reduced consumption and energy efficiency.

I

n the heart of Italy’s Veneto region lies an area internationally

lighting and furnishing sector thanks to high-quality products and state-

renowned for its manufacturing tradition in the lighting industry. This

of-the-art technologies. One of its most recent investments was the

industrial district, promoted by the municipality of Piombino Dese

installation of a new liquid coating plant, designed by Verona Impianti

(Padua), was formally established in 2008 as the Distretto Veneto dei

2002 (Colognola ai Colli, Verona), to meet the challenges of an ever-

Sistemi per l’Illuminazione – now Luci in Veneto – to gather a significant

changing market with greater efficiency while maintaining high quality

number of companies in the sector. Since the second half of the 2000s,

and environmental sustainability standards.

it has established itself as a centre of excellence capable of integrating assembly of lighting equipment to the marketing of end products.

Sirio Galv: artisanal excellence and technological innovation

A few kilometres from Piombino Dese, more precisely in

Sirio Galv is the brainchild of Claudio Vaccarin, an entrepreneur

Camposampiero (Padua), is the headquarters of Sirio Galv, a company

who began his career in the field of galvanic treatments and quickly

specialising in the galvanic treatment and industrial coating of high-

developed a profound knowledge of this industry. Fascinated by the

end furniture and design accessories. Founded by Claudio Vaccarin in

precision and discipline required to produce high-quality chrome,

1996, it has established itself as a strategic partner for companies in the

nickel, and gold finishes, Vaccarin set up his own company twenty-

the entire lighting technology supply chain, from the production and

© Sirio Galv

FOCUS ON TECHNOLOGY

© ipcm

© ipcm

© ipcm

From left to right: The coating plant’s loading area; Manual drying with compressed-air blow-off; The entrance to the drying/baking oven.

first to the lighting industry and then to the furniture one. “When the

An accurate production method from substrate preparation to coating

lighting sector shrank due to production relocation, Sirio Galv was able

Sirio Galv’s production method is characterised by thorough attention to

to reorganise and focus on furnishing while expanding its range with

detail and extreme care for quality, which are reflected in every process

advanced technical solutions, without ever renouncing the degree of

step, from initial cleaning to final coating. “Every part that reaches

craftsmanship that sets us apart,” says Claudio Vaccarin, the company’s

our plant goes through a production cycle designed to guarantee the

owner. Today, Sirio Galv stands out for its production flexibility, thanks

highest standards of precision and aesthetic perfection,” states Claudio

to three highly specialised galvanic plants. Two of these are semi-

Vaccarin.

automatic and designed to guarantee impeccable quality on small and

The first stage – when required – is robotic cleaning to remove any

medium components; the third is a manual plant machining oversized

imperfections and machining residues and ensure that the surfaces are

parts or applying special finishes, thus meeting even the most complex

ready for subsequent operations. The components are then subjected

customisation requirements. With a team of more than twenty-five

to a preparation stage prior to the galvanic treatment, which includes

professionals, the company offers galvanic treatments and the high-

degreasing and ultrasonic cleaning to remove any oils, pastes, and

precision application of chrome, nickel, gold, and other custom finishes,

other residues left by previous processing phases. “At this point, the

combining advanced technology and expertise for outstanding aesthetic

components are treated with a layer of nickel, an essential base for

and functional results.

ensuring the adhesion of the subsequently applied finishes. Depending

“Our growth and success are the result of a constant commitment

on customer requirements, Sirio Galv uses different colours, including

to innovation: from optimising our coating processes to adopting

gold, copper, and black, guaranteeing high uniformity and durability

increasingly efficient and sustainable solutions, we have been able to

thanks to a precisely controlled galvanic immersion cycle,” continua

seize every change in the market as an opportunity for development,”

Vaccarin.

eight years ago and started offering galvanic treatments and coatings

adds Vaccarin.

international PAINT&COATING magazine - SEPTEMBER/OCTOBER 2024 - N. 89

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SPECIAL ISSUE ON METAL ARCHITECTURE AND DESIGN

After the galvanic process, the parts move on to the coating stage.

approves a series of test results on prototypes, thus ensuring that each

“The components handled by Sirio Galv are intended for interiors and,

finish, whether glossy, semi-matte, or pigmented, meets its expectations

therefore, require finishes that focus primarily on aesthetics rather than

perfectly. “Glossy chrome is currently making a remarkable comeback

corrosion protection. The latter is guaranteed by the galvanic layer,

– a marked change from the previous decade, dominated by matte and

whereas the paint product plays an essentially aesthetic role in adding

coloured finishes,” notes Vaccarin.

beauty and uniformity to the object. In this industry, aesthetics and must be flawless,” emphasises Marta Vaccarin, the daughter of founder

The coating cycle and the new plant’s technical characteristics

Claudio and the representative of the second generation at the

In order to succeed in this competitive, high-end market, Sirio Galv

company’s helm.

chose to rely on partners of excellence, such as Verona Impianti 2002

functionality must coexist in perfect harmony, and every component

Trends in an evolving market

for the construction of its new coating plant and Lechler (Como, Italy) for the supply of coating products. “The loading and unloading of

“Speaking of aesthetics, it is essential that the components are not

components are done manually; for logistical reasons, the two areas are

only impeccable in terms of finishing quality but also adapted to the

not located in the same place, as is usually the case in coating plants.

most varied customer requirements,” explains Marta Vaccarin. *“The

We designed the loading area to be adjacent to the electroplating tanks,

trends and demands of our target sectors are constantly changing,

whereas the unloading one is located close to the quality control station

and we need to respond to a variety of needs by offering a wide range

before packaging and shipping,” explains engineer Albino Tamellin, the

of finishes and colours, with a catalogue of around a hundred coating

owner and founder of Verona Impianti 2002. After being loaded, the

products.”

components are dried manually in a compressed-air blow-off phase,

Every project starts with a sampling phase during which the customer

then taken by the monorail conveyor to the drying oven, where they

© ipcm

© ipcm

From left to right: Before entering the application booth, the components are transported to a storage buffer for cooling; The application phase; Coated components exiting the booth.

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© ipcm

FOCUS ON TECHNOLOGY

dwell for about 20 minutes, and finally, moved to a storage buffer and

new plant concerned sustainability and reduced consumption. We thus

subjected to forced cooling. “The conveyor is also equipped with a

paid special attention to limited consumption and energy efficiency. For

splash guard tray, which is essential to prevent the chain lubrication oils

example, we designed an oven with a degree of thermal insulation that

from contaminating and soiling the hung components,” adds Tamellin.

exceeds the drying temperature requirements of the paint products

“Subsequently, the parts enter the temperature-controlled coating

used by Sirio Galv. In addition, to ensure impeccable finishing quality,

booth (26 °C). “Done manually by an operator with a gun supplied by

we designed a filtration system that covers the entire air recirculation

Wagner (Valmadrera, Lecco, Italy), this operation is a distinctive element

area inside the oven and took measures to retain any particles or

that gives Sirio Galv’s products a unique craftsmanship value. Since we

residues coming from other stations, such as the heat generator. During

work on small batches, individual parts, and components with complex

heating cycles, the parts of the generator that cannot be painted tend

geometry, manual application enables us to reach surface areas that

to develop small traces of oxide that could diffuse into the oven: in this

are difficult to paint and achieve perfect finishes on each workpiece,”

plant, metal filters suitable for high temperatures ensure complete flux

notes Claudio Vaccarin. “The number of coats applied varies according

filtration, allowing recirculating completely clean air just like in the car

to customer requirements. Usually, for our products, we perform a

body industry,” says Pietro Tamellin from Verona Impianti 2002.

wet-on-wet finishing process or, alternatively, the application of a first of the same topcoat followed by oven drying.” Finally, each component

Determining factors in the plant’s selection: the collaboration with Verona Impianti 2002

is individually checked before packaging to ensure it meets the quality

When Sirio Galv decided to upgrade its coating system, the choice was

standards required by a high-end market that demands attention to

driven by specific requirements and the need to respond to new market

detail and zero imperfections.

challenges. Its old plant, installed in 1996 and designed to process

“One of the first requests we received during the design phase of the

chandelier components and small parts, was no longer adequate for the

layer of topcoat followed by baking at 140 °C for 25 minutes and then

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© ipcm

© Sirio Galv

new demands of the high-end furniture and

pressurisation balance,” indicates Tamellin.

interior design market. After more than twenty

Recently, the company also installed a

years in operation, it was outdated and unable

photovoltaic system that powers heat pumps,

to meet today’s requirements for efficiency

thus further saving on gas usage.

and quality. To address this transition, Sirio

“Environmental sustainability is not only

Galv consulted some of its partners and

about reducing consumption but also VOC

suppliers in the industrial coating sector,

emissions. Despite using solvent-based liquid

asking them to recommend manufacturers

paints, we have always paid great attention to

of state-of-the-art coating equipment. After

what we put into the atmosphere. However,

careful evaluation and several consultations,

we wanted to reduce our ecological footprint

the company found its ideal partner in Verona

even further. We worked in synergy with the

Impianti 2002. This company immediately

Verona Impianti 2002 team to achieve more

connected with Sirio Galv and understood

sustainable results. Today, our emissions have

its specific needs, thus becoming a natural

fallen compared to the much higher values

choice.

of the past,” adds Vaccarin, highlighting the

“We had two main requirements: replacing

success of this project.

our previous plant with a new generation

Finally, reflecting on the installation of the

system that was in line with our standards of

new system, the owner of Sirio Galv points

consumption, emissions, and sustainability

out: “The space we had in our factory for the

and solving a pollen pollution issue. Being

installation of this plant was very narrow. The

located close to the countryside, we were

galvanic process tanks limited us in terms

often faced with a challenge: pollen is very

of width and the building’s walls in terms of

light, and it tended to settle on freshly coated

length. However, despite these difficulties, we

components. That forced us to repaint

managed to fit all the necessary technology

numerous parts to eliminate the defects

into the available area, and the plant was

caused by these contaminants. With the new

delivered to us very quickly during the summer

system, we have finally solved this issue: the

period, which allowed us not to delay the

plant is fully pressurised, and each access

delivery of orders. We are extremely satisfied

point is equipped with air blades that prevent

with the collaboration with the Verona Impianti

dust particles from entering,” says Vaccarin.

2002 team and with the system they provided.

In addition, in line with its strong commitment

It is reliable and meets all our needs. We have

to sustainability and reduced consumption,

never had a breakdown, and this has enabled

Sirio Galv has been operating according to a

us to continue with our production without

“zero liquid discharge” philosophy since 1996.

any interruption.”

The water used in its production processes is treated internally and reused, whereas the necessary electricity is produced via a co-generator. “The coating line’s motors

Samples of some of the available finishes.

are controlled by inverters to optimise

Sirio Galv specialises in the galvanic treatment and industrial coating of high-end furniture and design accessories.

power consumption and maintain perfect

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ADVANCEMENTS

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EcodePure: the Road to Water Recycling and Zero Discharge Jesús Galindo ALSAN - Álvarez Schaer - Paterna (Valencia), Spain

marketing@alsan.es

The purification of discharge water constitutes a key element in powder coating and anodising production lines, and its proper functioning is essential to ensure that the final waste satisfactorily comply with the legislation.

Compliance with increasingly restrictive discharge parameters, together with the growing scarcity of water, has led Alsan to conduct studies on the reutilization of this valuable resource.

I

n a conventional depuration process, such as ALSAN’s AludePure

concentration. These waters not only fulfil discharge limits but are also

system, the precipitation of sulphates, fluorides, aluminium, and

suitable for reuse, thereby reducing overall consumption.

other metals is achieved through the use of lime and HCl, which also

EcodePure is the new purifying process developed by ALSAN, and can

act as pH regulators. However, some discharge parameters, such as

be easily implemented on an already existing AludePure systems (Figs.

conductivity and sulphate concentration, turn out to be, in some cases,

1-3). The main difference lies in the employment of specially developed

difficult to meet through this classical treatment. The company aimed

additives, specifically designed to precipitate sulphates, aluminium

to enhance the precipitation or removal of contaminants, ensuring that

and fluorides to values much lower than those usually achieved by

the resulting waters exhibit very low conductivity and low contaminant

conventional processes.

© AdobeStock

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ADVANCEMENTS

As we will explain further, the diagram for the treatment and reuse of

© ALSAN

the wastewater varies depending on the type of production line, with separate purification of acidic and alkaline effluents being crucial.

Alkaline effluents will follow the standard treatment process which is based on the neutralization and the precipitation of the dissolved aluminium as alumina. On the other hand, the acidic effluent will be subjected to the new purification process effectively reducing the contaminant concentrations below the most demanding discharge limits. It is important to highlight that the entire fluoride and sulphate content is found in the acid effluent. These three parameters: sulphates, fluorides together with conductivity, turn out to be the most difficult to meet currently with standard water treatment processes based on the precipitation of pollutants with lime (Table 1).

© ALSAN

Parameter of discharge

Limit for discharge

Values obtained with lime

Values obtained with EcodePure

Sulphates (ppm)

1500

1500-3000

< 250

Fluorides (ppm)

10

20-30

< 10

Conductivity (μS/cm)

3000

4000-15000

< 2000

Depending on the treatment process, this is, an acid coating pretreatment, a dual pretreatment or an anodising line, the purifying diagram and the percentage of recycled water will be different.

ALSAN presents the key solution for powder coating lines through the EcodePure PC system, and for the treatment of anodising wastewaters

© ALSAN

through the EcodePure AN system. A brief description of the development and operation of each of these solutions follows.

From top: Figure 1 - The new EcodePure purifying process developed by ALSAN can be easily implemented on an already existing AludePure systems.

Figures 2 and 3 - Some equipment from the AludePure system.

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© ALSAN

EcodePure PC: acid pretreatment powder coating line This line constitutes the easiest scenario since all the generated wastewater is entirely acid, so that there is no need for effluent separation before treatment. This acidic effluent is subjected to the new water treatment process, EcodePure PC, where in a first step it is neutralized with lime and the additives for the precipitation of sulphates and fluorides. Once the precipitate has been separated, the effluent is neutralized with CO2 and filtered, rendering it ready to

cover the needs of water in the line rinses. In this case, 100 % of the water employed in the line is reused.

Figure 4 - EcodePure PC process for acid powder coating pre-treatment lines.

The use of CO2 as reagent in the neutralization stage is essential

since it allows to diminish the pH and reduce the calcium content.

The use of HCl, which is the most common reagent for pH regulation

© ALSAN

in water treatment plants, is strongly discouraged if there is a wish to reuse the water, since it would introduce chlorides into the process water, leading to pits of corrosion in the material. A scheme of the water treatment process is indicated in Fig. 4.

ALSAN tested the EcodePure PC system with a sample of one of its clients that uses its acid attack product, ALCID 2005RH, and its chrome-free product, Ecoal® 20AH1, in their production line. The wastewater effluent produced in the line is therefore exclusively acid. After undergoing the EcodePure process and subsequent neutralization, the resulting water exhibits a conductivity, sulphate and fluoride concentration low enough to be reused in the process.

The parameters of this water before and after treatment are shown in Table 2.

Figure 5 – EcodePure PC process for dual powder coating pre-treatment lines.

© ALSAN

Parameters of discharge

Sulphates (ppm)

Fluorides (ppm)

Conductivity (μS/cm)

pH

Inlet to Waste Treatment Plant

864

941

3200

2.45

After EcodePure treatment

46

5.8

1000

6.8

EcodePure PC: dual pretreatment powder coating line In this type of line, effluents will be separated into acidic and alkaline streams and will be treated independently. On one hand, acidic effluents will be treated as explained in the previous case, resulting in a stream with low conductivity and minimal pollutant content. This water, which after the EcodePure PC process possesses an alkaline pH, can be reused in alkaline rinses of the line without needing pH Figure 6 – EcodePure AN process for anodising lines.

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regulation, or it can be neutralized and sent to either acid or alkaline

ADVANCEMENTS

rinses. The employment of CO2 will be studied for each case.

On the other hand, alkaline effluents will be treated in the

conventional way to precipitate aluminium and adjust the pH within the range of the discharge standards. In the case of the powder coating line, alkaline effluents originate from rinses that are only slightly concentrated and have low amounts of sulphates and fluorides, therefore, the fulfilling of the discharge parameters does not pose a problem. A schematic representation of the EcodePure PC system for dual pretreatment lines is presented in Fig. 5.

The utilization of EcodePure PC in your pretreatment lines allows the reuse of from 50% to 100% of the current water consumption, providing a necessary solution aligned with the protection of our environment.

EcodePure AN: anodising lines Like at dual pretreatment coating lines, the separation of acidic and alkaline effluents if crucial at the anodising lines. However, in this case, alkaline effluents generally represent a lower percentage of the total volume of wastewaters, around 20-30% depending on the line.

Consequently, by subjecting the acidic wastewaters to the EcodePure AN process, and after neutralization, the volume of recycled water will reach the 65-75% of the water of the process (Fig. 6).

The alkaline effluent, typically highly concentrated, may exhibit a high conductivity effluent even after conventional treatment, so in these cases reverse osmosis equipment will be necessary for the already treated alkaline effluent. It is noteworthy that this treated alkaline effluent mainly contains sodium chloride, so that it is suitable for the reverse osmosis system. The resulting osmotised water can be reintroduced into the production line, thereby increasing the proportion of recycled water to 90% and leaving a rejection from the osmosis, corresponding to 10% of the total water used, which can be managed or evaporated, reaching zero discharge in both cases.

In conclusion, the new EcodePure system allows, thanks to the use of specially designed additives, the exhaustive precipitation of metals, sulphates and fluorides to values lower than those established in the discharge limits and the reuse of between 50 and 90% of the water.

A recommended solution for all those companies that decide to take a step forward in their commitment to environmental management and care for the natural resources of our planet.

SUCCESS STORIES

SPECIAL ISSUE ON METAL ARCHITECTURE AND DESIGN

ItalMesh Clads the New Burger King in Rovereto with Perforated and Painted Aluminium Panels The ItalMesh team engineered and executed the external cladding of the new Burger King restaurant in Rovereto (Italy), opened in 2023.

I

talMesh is an Italian company exceptionally proficient in the realisation of architectural projects using expanded metal mesh and perforated panels, which is well-established both nationally

and internationally. ItalMesh products can be used to clad external architectural elements such as façades, sunshades, balustrades, and fences, as well as for interior applications such as false ceilings and other design elements. Its projects are versatile and consistently innovative through a seamless integration of cutting-edge technology, premium materials, and exceptional craftsmanship combined with limitless possibilities in shapes and colours, achieving an ideal balance between aesthetics and functionality.

An example of this is the cladding designed and installed for a new Burger King restaurant, part of the renowned American fast-food chain. Located in Rovereto, in the autonomous province of Trento, it is one of the 250 restaurants distributed across Italy. This project, developed in collaboration with StudioA22 Architettura e Design, also based in Rovereto, utilised approximately 1,250 m² of perforated aluminium sheet, painted with an exceptionally long-lasting white powder coating. Depending on the reflection of sunlight and the observer’s position, the panels create a sense of depth and movement in the structure. ItalMesh also designed all red inserts and profiles, which provide a striking contrast to the glossy white walls. The outcome is a subtle structure that integrates seamlessly into the Trentino landscape while featuring an unmistakable profile that immediately connects it to American fast food, lending tone and character to the exterior.

ItalMesh: the power of cladding The company, based in Montirone in the province of Brescia, offers the market over 300 models of customisable expanded metal mesh and perforated panels, produced in various materials and thicknesses. "We carry out the surface treatments of our products using non-toxic thermosetting powders with high resistance to UV rays and corrosion, or via anodic oxidation," explains Luca Baronchelli, Export Manager of ItalMesh. "These finishes offer several advantages, including the self-cleaning properties of the material © ItalMesh

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and the ability to retain their functional and aesthetic characteristics

SUCCESS STORIES

SPECIAL ISSUE ON METAL ARCHITECTURE AND DESIGN

over time. They are designed not only to deliver special aesthetic effects that enhance each project, but also to provide protective coatings that ensure high durability, even under the most extreme weather conditions. ItalMesh has three state-of-the-art coating plants equipped with anthropomorphic robots, automatic colour change systems, and continuous process control.”

Characterised by a strong focus on sustainability and automation, and supported by an experienced and well-established technical team, ItalMesh guides and assists customers through every phase of a project - from concept and design to engineering, realisation, and installation. This approach has led to significant international success, with its innovative products reaching markets globally, from Canada to Australia, the United States to New Zealand, as well as some of the most demanding regions in the Middle East.

A new approach to sustainability The Brescia-based company has consistently embraced environmentally sustainable technologies with minimal impact.

"Our production has always been mindful of the current challenges posed by Climate Change and the need of Nature restoration," says Baronchelli. "We recycle waste, recover raw materials, and strive to reduce energy consumption, thanks to a photovoltaic system that covers 90% of the plant's needs. We are also committed to developing products with a focus on their environmental impact." One example of this commitment is the company’s Zero Gravity Eden project (which will be explored in more depth in a future issue of this magazine, Editor's note), stemming from the belief that vertical plant technologies offer a sustainable solution for enhancing both urban and industrial environments. This innovative project involves creating expanded and painted metal mesh designed to support plant life, resulting in green walls that grow into true vertical gardens capable of covering the façades of any structure.

ItalMesh’s growth strategy is rooted in over 30 years of experience in the industry, along with the foresight to anticipate market demands with innovative, bespoke architectural solutions that combine functionality, durability, aesthetic appeal, and eco-sustainability.

For further information: www.italmesh.com

© ItalMesh

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RIPOL in Bayreuth: Innovation and Avant-Garde Design The art of powder coating meets innovation at the prestigious Institute for African Studies of the Bayreuth University (Germany).

A

lways at the forefront of the powder coating industry, RIPOL is

metal pillars that optimise energy efficiency and give the building a

committed to providing solutions that combine aesthetics and

distinctive appearance.

functionality with a focus on the environment. Our contribution

Institute for African Studies (IAS) is a clear example of this, where our

Colour palette: a homage to the African research studies conducted in Bayreuth

technology merges with innovation to create architecture that leaves

The choice of colours for this façade, from vivid yellow tones to warm

the mark.

browns and reds (codes NCS S 1070-Y10R, NCS S 2060-Y30R, NCS S

to the Africa-related research centre of the University of Bayreuth’s

Architectural innovation

4050-Y40R, and NCS S 4550-Y80R), was influenced by the variety of tints that are often found in African art, as well as in the logo of the

An innovative architectural project is taking shape on the university

Institute of African Studies. The wavy effect created with these colours

campus in Bayreuth that is destined to become a landmark for

on the façade adds elegance and modernity to the structure and blends

innovation and African studies. The laying of the foundation stone on

perfectly with the aesthetics of the surrounding buildings.

24 March 2023 marked the start of a journey towards the realisation of a state-of-the-art research centre, scheduled for completion by the

Technical excellence in coating: the RIPOL 52L series

end of 2024.

RIPOL’s 52L Poliestere series of smooth and matte architectural

Sustainability, aesthetics, and technology in perfect harmony

polyester coatings was selected to paint the sunscreens. This includes powder coating solutions designed to meet the performance requirements of the GSB and QUALICOAT architectural specifications.

The choice of materials was central to this project. Sustainability,

These products are formulated to withstand severe chemical and

aesthetics, and technology were its main pillars right from the

mechanical conditions, and they have successfully passed laboratory

construction phase, balancing functionality and style without

tests that have confirmed their technical properties. They are

compromising on the use of sophisticated materials. In particular, the

characterised by exceptional weather resistance, good salt spray and

centre’s façade is a harmonious combination of functional vertical

humidity resistance, and excellent colour and gloss retention.

Commitment to quality and sustainability

© RIPOL

The powder coatings used are manufactured and tested in line with ISO 9001 quality systems to ensure superior performance and batch consistency. Suitable for application on aluminium, steel, and galvanised steel, the 52L series, like all RIPOL products, is environmentally friendly.

RIPOL’s powder coatings contain no solvents and do not release Volatile Organic Compounds (VOCs). Any oversprayed powder can be recovered as virgin powder using suitable equipment, with minimal waste. Disposal is easy and safe. Finally, all RIPOL products are free of heavy metals.

With this project, RIPOL is proud to reaffirm its commitment to environmentally friendly innovation, offering an ideal solution for any infrastructure that strives to achieve excellence in sustainable architecture and actively contribute to building a greener future.

For further information: www.ripol.com

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The new electrostatic Rotary Bell Atomizer

Nanobell 803

Solvent paint

High voltage

0.5 to 500MΩ.cm

80kV

Waterborne paint

Current (3 versions)

< 0.5 MΩ.cm

100, 200 & 500µA

Dual shaping air

Paint flow

Rotation speed

30 to 800 cc/min

up to 65.000rpm

Magnetic bellcup

WHY A NANOBELL 803 AMONG OTHER SPRAYING TECHNOLOGIES ?

Premium Finishing Quality High Transfer Efficiency Easiness of Integration and Use Improved Maintenance Enhanced Safety

Discover our solutions

www.sames.com

ROAD TO 2050

SPECIAL ISSUE ON ALUMINIUM

Ice Cream Spoons and Golf Tees: Completely Absorbed by Nature Dr. Timo Porsch Managing Director of periplast GmbH & Co. KG - WuppertaL, Germany

t.porsch@periplast.de

Frank Siegel Sales Manager for the small parts coating division of Walther Trowal GmbH & Co. KG - Haan, Germany

f.siegel@walther-trowal.de

Rotamat drum coating clears the way for eco-friendly throwaway goods.

I

n Europe alone each year billions of plastic ice cream spoons

Currently the annual worldwide production of plastic materials amounts

are produced, most of which are carelessly discarded into the

to more than 400 million metric tons. Around 50 % of this staggering

environment. periplast produces spoons consisting of a bio-

quantity is used for packaging purposes and throwaway goods, which

degradable granular material – developed in-house – that completely

are only used for a limited time. Only 15 % of these items are recycled,

dissolves when it is exposed to moisture. To prevent this dissolution

and more than 30 % are carelessly discarded into the environment.

process from happening too early, the spoons receive a thin protective

For example, ice cream spoons are only used for about half an hour.

film in a Rotamat coater.

Subsequently they become garbage … or, worse, are dumped into the

© Walther Trowal

Ice cream spoons in the drum of the Rotamat system, model R 80.

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SPECIAL ISSUE ON ALUMINIUM

© periplast

© periplast

The coating in the Rotamat system ensures that the spoons dissolve only after they have been used. periplast supplies items for one–time use in different colors.

environment. Each spoon weighs just a few grams, but in Germany

ensure that they are completely dissolved within a time period of about

alone 360 million ice cream spoons are used each year, whereas in

20 weeks. However, to make sure that the spoons are not dissolving

Europe this number reaches several billion. For this reason, periplast

during use, for example, the consumption of ice cream, they must be

searched for a solution that allows the cost-efficient production of such

coated with a waterproof material. At this point Walther Trowal became

spoons which simply dissolve after they have been used.

involved: For many years periplast has been using Trowal mass finishing

A material that recycles itself!

equipment for surface finishing of metal components. Through this connection the two partners came to talk about the coating issue for

The solution is the granular material “periamyl“, developed by periplast,

the ice cream spoons … for Walther Trowal a brand-new application for

and for which a patent application is pending. This is a 100 % natural

its Rotamat coating equipment.

polymer consisting of corn starch – a naturally growing raw material.

Based on processing trials in the TTC Test & Training Center at Walther

When it reaches the environment, it degrades under practically any

Trowal in Haan a coating material was developed consisting of a multi-

condition. It can be reproduced naturally at very reasonable costs.

component ceramic solution. This forms a silicon dioxide structure

periplast produces the granules at its Wuppertal location.

on the surface of the spoons, which is not only stable for a long time

Another significant benefit of periamyl is that it can be easily shaped

but is also tasteless. The standard version of the Rotamat R 80 coater

under heat. This allows the cost-efficient production of items for one–

immediately met all the periplast requirements so that no technical

time use with standard injection moulding equipment – thus creating

modifications were needed.

ideal conditions for the economic production of throwaway goods on

The thickness of the ceramic coating is such that it remains absolutely

an industrial level. For example, it allows the production of throwaway

stable during use. However, after a few hours the coating is infiltrated

cutlery pieces or golf tees with a plastic look, but which consist of a

by water, for example, through the edges of the spoon. This causes the

100% naturally growing material that is available in abundance. Above

base material to expand so that the coating, basically consisting of sand,

all, the material degrades very quickly, even in salt water.

is split off: The dissolution process begins!

Initial project “ice cream spoons”

The result

The first industrial-level application for this material are ice cream

It was highly beneficial for the project that the coating aims were

spoons. Once they are thrown away, the bacteria in the environment

achieved with a standard machine from Walther Trowal that required

international PAINT&COATING magazine - SEPTEMBER/OCTOBER 2024 - N. 89

117

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© periplast

no technical modifications. At the moment periplast is using the R 80 Rotamat coater for processing batches consisting of around 4,000 spoons. The weight of this batch size allows the manual loading/unloading of the drum without undue stress for the operator.

The actual coating operation runs fully automatically. The people who operate the injection moulding machines are also loading/ unloading the Rotamat coater and monitor the entire process. This means that no additional personnel was required for the coating operation. The machine was commissioned in 2023 and has been working with no problems whatsoever. Maintenance work is limited to the occasional cleaning of the drum and the periodic exchange of the air filters.

The future Besides ice cream spoons complete throwaway cutlery sets made

Besides ice cream spoons periplast also produces small forks for French fries and golf tees.

from periamyl are now also available. During the introduction phase these are supplied in lot sizes of 10,000 pieces. Like ice cream © Walther Trowal

spoons, they also receive a protective ceramic film in the Rotamat coater. Besides their ecological compatibility and sustainability, they offer the additional benefit that the ceramic coating and resulting sharp edges easily allow cutting a steak.

Another item with a huge market potential are golf tees. In Europe alone every year around 1.4 billion pieces are used and thrown away. If only 10 % of the plastic tees are discharged into the environment, over just a few decades huge amounts of plastic will contaminate the soil of golf courses. On the other hand, tees made from periamyl will have dissolved quickly.

The Rotamat coater The Rotamat system represents an economical solution for coating mass-produced small parts, such as O-rings, handles, springs and screws. It allows the treatment of a broad spectrum of parts made from metal, wood, rubber and all kinds of plastic materials.

This includes parts for the automobile and cosmetic industry, components for writing utensils, toys, parts for the textile industry as well as seals and attenuators (dampening elements). The coating materials can be water- as well as solvent-based.

Rotamat systems are used for decorative coatings with numerous water- and solvent-based ornamental and functional lacquers.

But they are also employed for coating with anti-friction lacquers, bonding agents, corrosion protection materials or insulation lacquers.

In Rotamat systems batches of small parts are coated in a rotating, closed spraying chamber (drum). Automatic spray guns are Coated ice cream spoons are discharged from the Rotamat system.

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evenly applying the coating material onto the work pieces, which

© periplast

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 If exposed to water, after six weeks the spoons are nearly completely dissolved.

are continuously tumbling over each other. This results in precisely coated surfaces with an even coating thickness and an excellent life expectancy of the applied coating material.

Even geometrically complex or very delicate parts are discharged from the machine with a highly homogeneous coating, completely dry and without sticking to each other. After leaving the Rotamat the work pieces can be immediately processed in downstream manufacturing or assembly operations.

The coating process runs fully automatically. The operator must only load new batches of raw parts and unload the batches with finished parts. The costly and time-consuming placement of the parts on special racks – required with conventional coating systems – is completely eliminated.

About periplast Since 1978 the periplast GmbH & Co. KG company in Wuppertal (Germany) has specialized in the production of highly precise injection moulded plastic components. Ever since it was founded, the familyowned mid-size company produces reels for yarns and wire. A few years ago a second manufacturing location was established in Romania to better serve the customers in this country.

Since 2010 – at its Wuppertal headquarters – periplast has been developing products from bio plastics that can be produced without the need for any fossil materials and which are quickly bio-degradable.

The managing director, Dr. Timo Porsch, graduated in Chemistry and has been working for the company since 2015.

Via Vincenzo Monti 173 20099 Sesto San Giovanni (MI) - ITALY Tel.(+39).02.24.89.583/02.26.224.313 Fax(+39).02.26.21.065 e-mail: info@defil.it www.defil.it

ROAD TO 2050

SPECIAL ISSUE ON ALUMINIUM

© periplast

© periplast

Test: After being exposed to soil for 21 weeks (right-hand side of the picture), the ice cream spoons are completely dissolved.

If exposed to soil, discarded golf tees are completely dissolved after just a few weeks.

Walther Trowal - Surface finishing technologies from the inventor of the “Trowalizing” process

customers, develop the optimal process technology for the finishing

Since 1931 Walther Trowal has been developing and producing

required specifications…with short processing times and a high degree

systems for the refinement of surfaces. Initially focusing exclusively on

of consistent, repeatable results. Walther Trowal is one of the few

mass finishing – the term “Trowalizing” originated from the company’s

manufacturers who develops and produces all machines and mass

cable address “Trommel Walther” – Walther Trowal has continuously

finishing consumables in-house, including ceramic and plastic grinding

expanded its product portfolio. Over time the company has developed

and polishing media as well as compounds.

a broad range of machinery and systems for mass finishing, shot

The company’s equipment range also includes all kinds of peripheral

blasting and coating of mass-produced small components.

equipment for handling the work pieces like lift and tip loaders, conveyor

With the invention of new systems like, for example, drag finishing

belts and roller conveyors, in addition, special driers for mass finishing

and the development of special finishing methods for 3D printed

applications and, last-but-not-least, systems for cleaning and recycling of

components, the company has proven its innovative capabilities again

the process water.

and again. Walther Trowal develops and implements complete surface

With its exchange program for wear items like work bowls, which are

treatment solutions that can be seamlessly integrated into linked

part of a continuous recycling program, Walther Trowal conserves

production systems existing at the customers. This includes the entire

valuable resources and, thus, makes a significant contribution towards

process technology, perfectly adapted to the specific surface finishing

sustainability in the field of industrial production. Quick technical

requirements of the work pieces: Equipment and the respective

support and the global repair and maintenance service ensure high

consumables always complement each other in a perfect manner.

uptimes for our equipment.

Each individual work piece and each manufacturing process must

Walther Trowal serves customers in a wide range of different industries

meet special technical requirements. That is why the experienced

all over the world, for example, automotive, aerospace, medical

process engineers in our test lab, in close cooperation with the

engineering and wind power.

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task at hand. The result: Work piece surfaces that meet exactly the

SUCCESS STORIES

© Dürr

PAN-DUR manufactures insulating glazing for commercial refrigeration equipment.

The company recently started using Dürr’s EcoPaintJet to do this. The EcoPaintJet’s high edge definition paint application without overspray allows PAN-DUR to increase flexibility and speed in production while reducing paint costs.

PAN-DUR Paints Refrigeration Equipment with Dürr’s EcoPaintJet – Without the Need for Masking The EcoPaintJet, initially introduced for overspray-free paint application in industrial vehicle painting, is now benefiting other industries. Refrigeration manufacturer PAN-DUR insulates glazing for commercial refrigeration equipment and has been using Dürr’s innovative applicator to paint glass surfaces for several months. This technology saves time and materials by eliminating the need for individual screens in the screen printing process.

W

e are all familiar with large refrigeration units from

Opaque decorative stripes are applied to obscure the unsightly bonded

supermarkets: wall shelving, cabinets, or counters, behind

and sealed seams at the edges of the glass and the refrigeration

whose glass or plastic panels a wide range of foodstuffs

technology behind them. Until now, PAN-DUR used a screen printing

are stored. PAN-DUR uses enhanced safety glass (ESG) for its glass

process for this, which required a new screen or template for every

elements.

color, size, or design variation.

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SUCCESS STORIES

More flexibility, lower costs

© Dürr

The EcoPaintJet’s high edge definition paint application without overspray allows PAN-DUR to avoid the complex screen printing process, increasing flexibility and speed in production while reducing paint costs. Each contour is simply programmed and applied in the desired color to the corresponding predefined area without having to mask the glass surfaces first, eliminating the complex and costly manufacture of individual templates as well as the need to devote valuable space to storing them.

One-stop shop for the full range of process technology Dürr not only supplied PAN-DUR with the paint applicator but also provided all process technology, from the system for extracting paint from the containers to the system for supplying it to the applicator. The installed components include the Fluid Board color dosing and color changing system, the applicator cleaner, and the EcoAUC control unit. PAN-DUR developed a multi-axis portal to mount

EVAPORATION TECHNOLOGY FOR INDUSTRIAL WASTEWATER TREATMENT WATER RECOVERY MINIMIZATION OF WASTE TO BE DISPOSED OF REUSE OF DISTILLATE DISPOSAL COST REDUCTION ZLD: ZERO LIQUID DISCHARGE

SUCCESS STORIES © Dürr

Other industrial applications are also possible for the EcoPaintJet, for example, in the timber industry, in window or kitchen building, and in the field of painting railway vehicles.

the EcoPaintJet’s swiveling and height-adjustable application head

Other industrial uses possible

seamlessly integrating the process technology. “We linked the Dürr

Other industrial applications are also possible for the EcoPaintJet, for

process technology with our system’s interfaces. The implementation

example, in the timber industry, in window or kitchen building, and in

couldn’t have gone any more smoothly,” explains Jens Verhoef, Head of

the field of painting railway vehicles. “There is potential everywhere that

Development of Electrical and Automation Technology at PAN-DUR. The

straight stripes are applied to flat surfaces and that type of painting still

biggest challenge was finding the right paint for use on glass surfaces.

requires masking right now. We’re getting many inquiries from different

Specialist paint company Votteler, a long-standing partner of PAN-DUR,

industries,” says Fabian Schilt, Head of the European Industrial Sales

was also involved in the development. Project manager Uwe Schmidt

Team at Dürr. An additional advantage that makes the whole system

explains: “Painting glass surfaces is extremely challenging. You need

attractive for other uses is that all components are ready to integrate

specially developed paints whose rheological properties, coverage,

into existing production systems.

and particle distribution are perfectly tailored to the system. This paint system can also be used on other substrates. So, we needed a few practice rounds until we found the right paint.”

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For further information: www.durr.com

ROAD TO 2050

© NOF Metal Coatings Group

SPECIAL ISSUE ON ALUMINIUM

M10 screws coated with new generation of PFAS free PLUS® Silver topcoats.

Ahead of Regulation for More Environmentally Friendly Coatings Edited by NOF METAL COATINGS EUROPE SA Creil, France

inforfr@nofmetalcoatings.eu

NOF Metal Coatings unveils PFAS-free topcoat range.

P

FAS, or poly- (or per-) fluoroalkyl substances, widely used

of low concern” by the Organization for Economic Co-operation and

in different industrial sectors are now coming under

Development (OECD), NOF Metal Coatings Group does not use any

increasing scrutiny due to their long-lasting presence in

other PFAS in its products.

the environment. A possible European ban on PFASs based on

Regardless of potential restrictions imposed by environmental

REACh, might come into force as early as 2027 for specific industrial

authorities on PTFE, the company has taken this new regulation as an

segments.

opportunity to develop a new PFAS-free topcoat range generation with

Apart from PTFE, a fluoropolymer currently classified as a “polymer

worldwide availability.

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ROAD TO 2050

The ambitious objectives of these developments were to be able to offer a new range of more environmentally friendly products, while guaranteeing the same

© NOF Metal Coatings Group

PFAS free PLUS® Series

SPECIAL ISSUE ON ALUMINIUM

tribological performance as current NOF Metal Coatings Group’s PLUS® range, the most popular topcoat range:  PLUS® XL 2 Silver: COF 0.06 – 0.09 (ISO 16047)  PLUS® VLh 2 Silver: COF 0.09 – 0.14 (ISO 16047)  PLUS® ML 2 Silver: COF 0.10 – 0.16 (ISO 16047).

Applied on top of NOF Metal Coatings Group's GEOMET® waterborne zinc flake basecoats, these PFAS-free alternatives to PLUS® XL, global OEM requirements and specifications while providing outstanding tribological properties including:  Multi-tightening and high-speed tightening

© NOF Metal Coatings Group

PLUS® VLh, and PLUS® ML meet or exceed the

 Compatibility with various mating substrates (e-coat, aluminium, zinc, and steel)  Stick slip avoidance  Behaviour in loosening tests (including at high temperature – PLUS® VLh 2 Silver and PLUS® ML 2 Silver).

From top: PLUS® XL 2 Silver coefficient of friction according to different standards.

PLUS® VLh 2 Silver against E-coat (MBN 10544).

Total Finishing Systems is a leading designer and integrator of high-quality and complex industrial finishing systems. Whether you need an in-depth process analysis or require finishing equipment and components, our equipment exceeds expecta ons and our innova on and automa on is industry leading.

ROAD TO 2050

SPECIAL ISSUE ON ALUMINIUM

© NOF Metal Coatings Group

Improved aesthetics of coated parts To offer its customers the best products on the market, NOF Metal Coatings Group has taken this opportunity to enhance the aesthetics of the products in this new range by adding aluminium pigments, thus obtaining a uniform silver colour. This enhancement will improve the visual appearance of assemblies where fasteners are visible by customers.

In addition to the improved aesthetics with aluminium pigments in the coating, all three new PFAS-free topcoats will include fluorescent pigments for ease of positive identification – a feature unique to NOF Metal Coatings Group topcoats.

On the road to greener future © NOF Metal Coatings Group

Meanwhile, in the company’s R&D laboratories, the NOF Metal Coatings Group’s teams are continuing to work on PFAS-free coatings and GEOBLACK® systems, with the addition of black topcoats to PFAS-free PLUS® range to be ready before the end of the year.

From top: PLUS® VLh 2 Silver against aluminium (MBN 10544).

PLUS® ML 2 Silver chatter (stick-slip) testing at 300RPM to yield against E-coat (M10 Flange Bolt).

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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

HIGHLIGHT OF THE MONTH

The Evolution of Vernici Caldart: an Italian Success Story Through Fifty Years of Innovation From an interview with Gianluca Zanardo and Cristian Sala Vernici Caldart – Bellusco (Monza e Brianza), Italy

gianluca.zanardo@vernicicaldart.it; cristian.sala@vernicicaldart.it

From being a small company specialising in postcard varnishes, Vernici Caldart has gone through a journey characterised by research and innovation that has enabled it to expand worldwide and become a benchmark supplier for multiple industries.

T

he Italian chemical industry is one of the pillars of the country’s

Founded over fifty years ago, it has been able to grow and innovate,

economy as well as a highly competitive and technologically

thus gaining a leading position at the national and international levels.

advanced sector. Vernici Caldart operates in this context as

Indeed, it has evolved through the continuous search for advanced

a company specialising in the production of industrial liquid paints.

and tailor-made solutions for its customers, distinguishing itself in the

© Vernici Caldart

Samples of the many products offered by Vernici Caldart.

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HIGHLIGHT OF THE MONTH

production of high-quality paints for various sectors, including eyewear, automotive, general industry, cosmetics, packaging, and metallisation. Thanks to its established knowhow and research laboratories, Vernici Caldart can also develop high-performance paints for all kinds of materials, including metal, plastic, and glass.

We interviewed its directors Gianluca Zanardo and Cristian Sala, the company’s International Sales Director and Italy Sales Director, respectively, to better understand the winning features of Vernici Caldart and its evolution.

Can you briefly describe the history of Vernici Caldart?

Gianluca Zanardo: “The company was founded in 1976 by Carlo Caldart, an entrepreneur originally from Belluno. Initially dedicated to the production of postcard paints, it was described in the as a ‘producer

© Vernici Caldart

Paint drums’ packaging.

of special paints’. Our characteristics attracted the attention of a well-known eyewear manufacturer in the early 1980s, which

Cristian Sala: “In addition to our

for plastic and metal spectacles, as well as

was looking for a supplier of coatings for

headquarters in Bellusco (Monza e Brianza,

coatings for personal protective equipment

its products. When asked, ‘Do you produce

Italy), which is responsible for research and

for professional and sports use, such as ski

eyewear paints?’ our founder replied, ‘No,

development, production, and shipping

and motocross goggles and helmets made in

but we can try’, which still represents our

on behalf of the divisions dedicated to the

PVC and polyurethane. Our paint products are

company’s spirit today. The history of Vernici

eyewear and cosmetics industries, we also

also used in the cosmetics, beverage, fashion

Caldart has been, and will continue to be,

have a site in Pojana Maggiore (Vicenza, Italy)

accessories, automotive components, lighting,

characterised by constant research and

devoted to the industry/car refinish division.

and furnishing sectors. Finally, our technology

development, always oriented towards

We also operate a warehouse in Apulia and

is employed in the field of costume jewellery

meeting our customers’ needs.”

one in Sicily and can count on a network

and for small accessories such as hair clips,

of agents and resellers covering the whole

brooches, and buckles, but also to create

How is Vernici Caldart structured today?

Italian territory, accounting for around 75%

perfect finishes for containers, caps, flacons,

GZ: “Specific areas of excellence have now

of our annual turnover. Abroad, we are active

and various types of bottles.”

developed within our company, such as

in France, Spain, Poland, Turkey, USA, Brazil,

CS: “We are also a leading manufacturer of

our research and development and quality

Argentina, Thailand, and China.”

coatings used in metallising, sputtering, and

control laboratories. Thanks to the expertise

PVD processes. The latter, in particular, is an

of our technical service team, high-quality raw

What are your target sectors?

environmentally friendly technology that is

materials, and state-of-the-art production

CS: “We specialise in producing polyvalent

expanding very rapidly. Thanks to its special

processes, we manufacture high-performance

paints and tinting systems – consisting

characteristics, it can replace conventional

paint products that are used in many

of solvent- and water-based binders and

galvanic coating cycles and performs very well

different markets and always combine unique

colouring pastes – for the general industry,

on different substrates, from plastics such

aesthetics enhancing the treated surfaces with

but we are also renowned for our products

as ABS and PP to metal and glass. Another

the technical characteristics required for each

of excellence for the eyewear sector. We are

widely demanded solution is our EFT series

end use.

the world’s leading manufacturer of paints

of chrome-effect paints, which includes one-

international PAINT&COATING magazine - SEPTEMBER/OCTOBER 2024 - N. 89

131

and two-component products for direct adhesion on plastic and metal,

with the addition of new warehouses and a state-of-the-art production

available in a variety of colours such as grey, silver, blue, red, green, gold,

department to optimise the manufacturing of paint batches and

and pink. This range is a valid alternative in the creation of high-quality

improve our ability to adapt to customised volumes and requirements.

and low-impact surfaces and visual effects, as they faithfully imitate the

That enables us to guarantee a fast service and offer tailor-made

appearance of chrome, silver, copper, bronze, nickel, and titanium.”

coating solutions. We also created a technical centre with a strategic training area to pass on skills to customers through specialised training

What are the distinctive elements of your offer?

sessions.”

GZ: “We combine creative drive with the ability to interpret the latest trends on a daily basis, investing in technology that enables us to

Is your product and service portfolio’s constant expansion your

produce high-quality industrial coatings at competitive costs and

key growth driver?

with efficient customer service. We also pay the utmost attention to

CS: “Simultaneously, we have developed a solid corporate structure

respecting and protecting the health of users and the environment.”

that has allowed us to expand our sales and distribution network while

CS: “Our production’s foundations lie in the R&D of coatings in full

also investing significantly in internal training. Our products’ reputation,

compliance with environmental and health protection regulations. In

fostered by word of mouth about their quality and performance, has

order to meet the expectations of our customers and stakeholders,

further contributed to our growth. In 2005, our company’s turnover

we have implemented a quality management system complying

exceeded 5 million Euros, and since then, it has grown steadily, reaching

with the requirements of ISO 9001:2015. At the same time, from the

16 million in 2017 and 30 million in 2023, the year in which we initiated

very beginning, Vernici Caldart has been characterised by extreme

the closing with the fund Itago SGR S.p.A.”

production flexibility: we constantly develop new paints because we strive to tailor our solutions to each customer’s specific needs. In fact,

Can you go into more detail about that acquisition and what it

we have recently expanded the space devoted to our research and

means for your company?

development laboratories and hired new personnel to further evolve

CS: “Before the entry of the Itago SGR fund, Vernici Caldart had just

our structure at both the production and managerial levels.”

reached a record turnover of 30 million Euros. However, fears emerged

GZ: “Our site in Pojana Maggiore, in the Veneto region, is a key asset

within the Caldart family that the lack of a generational transition could

for our operational flexibility. It specialises in the production of grinding

lead to stagnation. Therefore, the offer from this fund represented

products, pastes, and tinting systems and uses modern technologies

not only a capital gain opportunity for the family but also a strategy to

in line with Industry 4.0 principles. Recently, this plant was expanded

ensure the company’s continuity and future growth potential.

© Vernici Caldart

© Vernici Caldart

The Bellusco (left) and the Pojana Maggiore plants.

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HIGHLIGHT OF THE MONTH

GZ: “Itago SGR expressed interest in acquiring us in early 2023, recognising our steady growth and significant potential. After an in-depth analysis of our business plans, it agreed with our mapped-out strategies and decided to co-invest in the company, supporting us in business development and structuring. With the closing finalised in May 2024, Cristian Sala and I [Gianluca Zanardo, Ed.] were appointed as directors and involved in the shareholding structure, and we initiated a growth plan entailing the expansion of our technical, administrative, and commercial staff to support this new phase of development.

CS: “In summary, the changes will only affect internal organisational aspects, as the fund recognised our managerial expertise and granted us total autonomy in operational management.”

In conclusion, what do you foresee for Vernici Caldart’s future?

CS: “We absolutely want to maintain our position as a flexible and reliable partner for the industry, able to offer innovative and high-quality solutions thanks to our wide range of products and focus on research, enabling our customers to benefit from a highly specialised service and customised coatings for every production requirement.”

GZ: “We are also committed to continuous product innovation and technological evolution, paying attention to constantly changing regulations while respecting the health of users and the environment. Other important factors for us are development, process optimisation, and know-how. In addition, customers from sectors where we are not currently fully present are also starting to turn to us because of our expertise. For example, we are seeing an increase in turnover from the automotive industry, which we would like to grow further. We are investing significantly to expand our production of water-based and UV-baking liquid coatings, responding to the growing demand for environmentally sustainable solutions. This commitment reflects our strong sensitivity to environmental issues and our proactive role in driving change towards more sustainable manufacturing processes, without ever compromising on quality and innovation.”

© HangOn

ANALYSIS

The Choice: The Ecological Transition and the HangOn Green Effect Adriano Antonelli Tecno Supply - Ibix Srl, Lugo (Ravenna) – Italy

adriano.antonelli@tecnosupply.com

Today, the issue of energy savings achievable through maximum efficiency of production processes in general and of the coating department in particular is more topical than ever. In this detailed analysis, Adriano Antonelli, the sales manager of Ibix Srl – Tecno Supply, explains how carefully designing a workpiece hanging system can help reduce the energy resources consumed for the coating phase, cutting costs and increasing the lines’ efficiency.

A

n era of checks and balances is ending that has allowed the

infrastructure. The Chinese market enabled us to buy many products

international economy to operate in a stable socio-economic

as if we were in a deflationary condition. Low-value-added products

environment until recently, providing the conditions for steady

such as textiles and components, for example, were relocated to exploit

and progressive growth over the long term. Above all, Europe was able

cheap labour and loose regulations compared to those in the EU. The

to receive raw materials such as natural gas and oil at competitive prices

US’ supremacy and international policy maintained a balance in the

from Russia and North African countries. The absence of turbulence

most unstable areas by avoiding possible military interventions. The

allowed for adequate supply without the need for new providers and

climate issue, even if it already existed, was not as pressing in public

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ANALYSIS

© HangOn

© HangOn

Figure 1 - Part hanging density can be decisive in achieving significant savings in the coating process.

Figure 2 - The HQW D frame is designed to be used when a sudden need arises and to avoid hanging hook after hook.

opinion and did not affect the lives of citizens and businesses at a

losing jobs and skills in many fields and market segments. Some warning

regulatory level.

signs are unnerving the financial markets: the risk of recession looks

All this seems to have crumbled in just a few years. The Chinese market’s

just around the corner. Until recently, for example, one would have

growth is considered weak: China’s aggressive international policy

predicted a soft landing for the US economy, keeping the cost of money

implemented through state aid has flooded the European markets with

almost stable and with a strong labour market at its peak. However, this

its products. Unfortunately, these are no longer only low-end products

has been disregarded by the latest surveys, which, together with the

but mainly value-added goods such as solar panels and, soon, electric

percentage reduction in American buyers’ purchasing power in the last

cars – two significant examples of how below-cost selling supported

quarter, were further signs that destabilised the stock markets.

by state subsidy is destroying long-standing and strategic national industrial fabrics in Europe. American policy seems to have changed,

At the same time, climate change calls for further corrective actions in

focusing more on national borders than on international ones. The

our companies. Reducing emissions, making production more efficient,

previous President’s slogan, “America First”, drew a clear dividing line

and starting the transition are now compelling objectives. They are

with the past: no more investments to act as “the international sheriff”

demanded by regulations, markets, and customers, as well as the

but projects to support the country’s own economy and domestic

possibility of increasing profits. Future partners will be selected based

affairs. The withdrawal of troops from countries needing to be stabilised

on environmental efficiency passports.

and, above all, from international cooperation projects are the

Energy efficiency is actually a topic that goes beyond purely

consequences of the new administrations’ choices. Failure to desist from

environmental issues, especially because it has become a significant

military interventions has resulted in the start of micro-wars in strategic

part of European and national regulations. For example, not to be

areas such as Russia-Ukraine and the Middle East. Sanctions imposed

underestimated and to be studied in detail is the Transition 5.0 Plan

on some countries and government instability have reduced the supply

recently launched by the Italian government. The programme aims to

of vital raw materials for our economy.

support investments in the green transition through tax credits. The

The climate issue and its related political choices are leading to some

companies that successfully reduce their production units’ energy

questionable regulations. Imposing the use of electric cars by a specific

consumption will be rewarded. In addition, investments in the self-

date without the possibility of developing alternative technologies

production of energy from renewable sources and staff training to

to achieve the same objective, i.e. reducing emissions, could mean

consolidate green knowledge and technologies will be supported. The

completely passing the ball to the Chinese market for the next few

Decree is intended to help companies in the challenges of digitalisation

decades, which is far ahead of the Western market. This would result in

and sustainability, two areas in which international economic balances

international PAINT&COATING magazine - SEPTEMBER/OCTOBER 2024 - N. 89

135

are likely to be redrawn. Finally, tax credits

sustainable. The aim should be to increase

phases of pre-treatment, coating, baking,

will be granted for investments in production

density and thus fill the production line. Before

etc. The energy source can be electricity, a

facilities within the Italian borders that are

describing some solutions to improve the

combination of electricity and gas, diesel, or

innovative in terms of consumption of energy

efficiency of a coating operation, let us analyse

LPG. The environmental footprint changes

resources.

the consumption and CO2 values of surface

dramatically depending on this and on how

treatment processes, although we can only

such energy is produced. Coal-fired electricity,

do this in a general and approximate way in

for example, produces over 30 times more

Maximum efficiency in coating Let us look at the latter aspect, starting with

the space of this article. A coating line emits

how a coating department can be efficient and

CO2 due to energy consumption in the various

CO2 emissions than hydroelectric power.

Powder coatings can play a decisive role in calculating the CO2 produced by the treatment

cycle, depending on the hanging density

(fig. 1). Finally, hanging with hooks and other equipment can result in entirely different emission rates. The use of suitable tools, therefore, can change the line’s efficiency and, thus, its results.

The HangOn Green Effect So, what is the HangOn Green Effect? It is the idea that a smart hanging solution ensures maximum density, enabling to achieve the goal of filling the line and increasing the amount of parts that can be coated in one cycle. It should be considered that 80-90% of energy consumption in a coating cycle is © HangOn

constant, regardless of the amount of coated workpieces. That means that increasing the

Figure 3 - The new HQW S system has an upper hook oriented at 0 and 90°.

hanging density reduces CO2 consumption

per painted product, thus reducing costs and, consequently, increasing profits.

© HangOn

Frames What types of hanging systems can be implemented to bring about a green transition in a coating department? One example is our HQW D system, a 2 mm-diameter tree-shaped frame with fixed hanging points (fig. 2). The range is vast, so every customer can choose its ideal pitch. To have a compact frame (also in terms of packaging, like a box of hooks, for example), the top hanging must be done using a separate hook. This frame is designed to be used when a sudden need arises and to avoid hanging hook after hook. This is key because “chain” hanging results in longer hanging times and significantly fewer pieces than the Figure 4 - The Flexi-Frame system’s diagram.

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HQW D solution. At www.hangon.it, you

ANALYSIS

Efficient and reliable

can find some spreadsheets to test the savings you can achieve by entering your data, but also videos that give you an idea of how this application works. The cost per hanging point is similar to that of a single hook (the total is less than 1 Euro), so the issue of regeneration does not arise.

On the other hand, the new HQW S system (fig. 3) is complete with an upper hook oriented at 0 and 90°, and the hooks have a variable

solutions for surface coating since 1988.

distance. This economical frame avoids improvised hanging with hooks, which can lead to a loss of density and efficiency. The 2 mmdiameter hook and the reinforcement along the frame’s entire length guarantee hanging stability.

A further solution that ensures maximum flexibility is the Flexi Frame system (fig. 4). Its core concept is a frame that can be completely disassembled and stored on a shelf. The frame consists of a T-shaped bar housing two horizontal bar holders. HQL, HCL BHL, H11B, and HQS bars can be accommodated. This system is designed to be stocked and then used in case of urgent need.

It guarantees several advantages, including as follows:  saving storage space and reducing storage problems;  lower transport costs, including one-off ones;

electrostatic systems for liquid painting

 easy handling;  flexible and compact design;  self-locking;  customisable as required;

electrostatic systems and spraying booths for powder coating

 reduced cost.

The newest addition: the HQS frame The HQS frame (fig. 5) features metal slats for hanging elements from

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

individual parts to profiles. The central 4 or 5-mm hook guarantees an overall frame resistance of up to 100 kg. This frame model has been recently launched on the market with various types of hooks, with which each customer can find the best configuration for its specific

IR and UV drying systems

use. The tree can be up to 2,400 mm long, whereas the slats are 1.0 mm thick and 18 mm high. It is possible to create different slat configurations, e.g. sheared (i.e. on one side only), zigzag-shaped, or bent from 0 to 180°. This type of frame was designed to avoid using

robot and reciprocators

individual hooks. It is manufactured automatically, guaranteeing a low cost equal to single hooks. The new configurations made available allow the users to find the appropriate hook shape for every workpiece to be hung. Another innovation is the adapter that enables HQS frames to be extended using standard or currently available hooks. The HQS frames can be used for hanging small parts, but also workpieces with varying weights, including profiles.

Bars and eliminating the need for regeneration. Hooks with a diameter

www.cmspray.it

eosmarketing.it

The HQL bar (fig. 6) is produced fully automatically, reducing costs

CM SPRAY s.r.l.

of 1 mm can be inserted into it on both sides to hang the workpieces

© HangOn

symmetrically. For example, the 800x33 HQL bars accommodate 46 hooks over a length of 800 mm. The bars can be inserted into the HCF universal system. This makes the system modular and enables bars to be inserted according to the length of workpieces. Moreover, the HQL G6 caps guarantee perfect electrostatics. 1.5 mm-hook bars in spring steel are also available for small, heavy parts. Different configurations are available in the range, including the triple-bend one, which provides more secure anchoring for light workpieces that could be lifted into the air during pre-treatment.

HQL bars for single-sided hanging are also available, in case it is necessary to hang parts only on one side and thus avoid any shading effects and other issues.

The advantages of using this bar are numerous:  time savings: it is possible to achieve a speed that is 30 times higher than with single hooks;  the hooks leave only a slight mark on the coated parts;  spring steel material;  possibility to configure the bars with special hooks;  smart packaging to reduce transport costs.

A more robust version of the HQL bar is the HQC one. It accommodates hooks with a diameter of 1.5 mm, but only on one side. Its coupling allows hooks to be inserted into a central 10 mm-diameter one. The R 58 bar holder enables the bar to be stable and easily removed, also thanks to the BH G 20 cap. The resulting frame is economical and flexible, as it is also possible to avoid filling all the levels. The hooks have a pitch of 50, 75, or Figure 5 - The HQS frame features metal slats for hanging anything from single workpieces to profiles.

100 mm. This bar type was also designed to avoid using individual hooks, dramatically reducing the operators’ hanging time. Indeed, the availability of a ready-to-use frame eliminates the need to handle single hooks. In addition, it allows for easy offline pre-hanging. Another advantage is that it can be

© HangOn

used for multiple hanging configurations. This bar’s production technology makes its cost similar to an individual hook’s. Therefore, there is no extra cost for purchasing frames rather than standard hooks. Finally, to make this frame even more versatile, a new metal adapter was launched that also allows H11B bars to be inserted. This way, using the same central hook, a bar can be accommodated that allows hooks up to 4 mm in diameter to be inserted, thus achieving horizontal flexibility.

The H11B bar is a punched bar inside which hooks are lodged. That ensures clean and protected contact points as well as the flexibility to change the hanging hooks whenever necessary. Standard or twin hooks can be used with the same bar, fitting between the two punches and remaining fixed.

As far as twin hooks are concerned, any configuration can be chosen for even greater flexibility. This bar is highly durable (HangOn has assessed and wrote a report on the weight it can support depending on the length). Even more robust H2B, H25B, and H3B versions are also available. These bars can Figure 6 - The HQL bar is produced fully automatically: here, hooks with a diameter of 1 mm can be inserted on both sides to hang the workpieces symmetrically.

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N. 89 - SEPTEMBER/OCTOBER 2024 - international PAINT&COATING magazine

accommodate hooks up to 10 mm in diameter. Hooks can be welded at their ends to obtain a T-shaped frame. That guarantees part stability, whereas the system’s modularity allows hooks to be inserted where needed without

ANALYSIS

losing conductivity.

be hung. This leads to a significant reduction

The HCL bar has housings for inserting springs

in the number of frames required for the

or hooks made from round rods or sheet

different workpieces processed, in the space

metal. Its ends are protected with silicone

needed for storage, and in the possible

caps that allow easy removal and ensure

handling problems. The universal frame can

conductivity. It can have single or double

also be used for cataphoresis operations:

housings to increase hanging density. It is,

the structure remains the same, but the bars

therefore, extremely flexible, eliminating the

and accessories are changed to guarantee

need to build a different frame for every part

maximum conductivity. Already welded

to be coated. Special accessories can be

bars with universal hooks are available in

created depending on the workpieces. Two

the range, allowing for minimal contact. For

springs can be accommodated inside the hook

greater flexibility, we also offer hook holders

holder with a 4-end outlet. This bar can also be

where universal accessories and, at the top,

used for cataphoresis processes thanks to a

protective caps can be inserted.

© HangOn

cap system that protects its ends and prevents the coating product from climbing up.

Magnets

The flexibility of the HCF universal frame

Another interesting application is the use of

allows using interchangeable bars and, in

magnets (fig. 7). In cases where no metallic

some cases, bars with accessories that can

paint is applied and where it is acceptable to

be inserted depending on the workpiece to

have an unpainted area on one of the two

Figure 7 - In cases where no metallic paint is used and where it is acceptable to have an unpainted area on one of the two faces of the metal workpiece, magnets can be employed for hanging.

SIMPLE, SUSTAINABLE, EFFICIENT

MODULAR & DRY SEPARATION SYSTEM creates highest quality ensures energy-efficiency

Eisenmann has always represented customized engineering solutions for economically and ecologically sustainable paint shops for the automotive, metal and wheel industries.

Our technologies provide consistent quality standards throughout the whole process from pre-treatment to final assembly.

Discover E-Cube & more. www.eisenmann.com

© HangOn

Figure 8 - Besides the automatically produced and standardised HangOn range, frames, hooks, and systems can be tailor-made according to customer requirements.

© HangOn

Figure 9 - HangOn’s trolleys are designed to be modular and flexible and to be combined depending on the type of frame used.

faces of the metal workpiece, magnets can be employed for hanging.

designed to be modular and flexible and to be combined depending

That makes this delicate preparatory phase quicker and trouble-free,

on the type of frame used. If switching among frames with different

especially when there are no holes. Our range includes different

coupling devices or sizes, trolleys adapt to the various requirements

magnets depending on the weight to be supported. Silicone masking

to perform two functions: that of allowing pre-hanging and bringing

systems always cover the magnets to prevent them from getting dirty.

all the frames on the coating line and that of storing unused frames in

In addition to the automatically produced and standardised HangOn

an orderly manner. Special trolleys can be designed according to the

range, frames, hooks, and systems can be tailor-made according

various requirements posed by the components’ characteristics.

to customer requirements (fig. 8). One-step hanging and masking solutions reduce time and avoid excessive product handling so that the

A new calculation tool

required quality targets are achieved without neglecting hanging density

A tool that can be useful for moving from ideas to figures and comparing

and speed.

different hanging systems is the new CCC calculation system on the website www.hangon.it. Business data such as the cost of powder, the

Trolleys

number of people employed on the line, machine costs, and process

Implementing trolleys offers the possibility of managing treatment

times can be entered here.

processes even better (fig. 9), having become essential to reduce process times and increase density. In-line hanging may not be efficient

The Italian distribution and technical structure of Tecno Supply - Ibix

in terms of density when it is not possible to adequately fill the m3

division is characterised by capillary presence throughout the country,

available within the line handling time. Trolleys allow pre-hanging and

guaranteeing reliable assistance and immediate support for all technical

handling the parts to be coated within the factory. HangOn’s trolleys are

and commercial issues that may arise with coaters.

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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

Defil Srl: Innovation in Industrial Filtration From an interview with Alfredo Pellegrino Defil Srl - Sesto San Giovanni (Milan), Italy

Defil Srl, a company specialising in filtration, dust collection, and air treatment solutions for civil and industrial structures since 1985, has been investing in new filter production machinery over the past two years, including a new 4.0 electronic pleating machine matched with a new longitudinal cutter. The aim was to improve its quality standards and cut processing times while reducing raw material waste.

T

he industry of filtration systems for the industrial coating sector

international markets, with a strong presence in Spain, France, Portugal,

is booming, fuelled by the increasing demand for sustainable

and Russia, where we work with local distributors to expand our sales

solutions that optimise production efficiency and reduce

network,” explains Alfredo Pellegrino, Sales Manager at Defil.

environmental impact. Defil Srl (Sesto San Giovanni, Milan, Italy) stands Pellegrino in 1985, the company initially focused on distributing and

Industry 4.0-oriented investment: the new electronic pleating machine

marketing various filter systems, from simple mats for spray booths to

The integration of 4.0 technologies transforms industrial productions,

complete filter units.

making processes more efficient and customisable. Defil, with its

Over the years, it has evolved thanks to the professionalism of its staff

constant focus on innovation, has recently taken a major step in this

and partners and a focus on innovation and quality, moving from being

direction by equipping itself with a new electronic pleating machine

a sales company to a manufacturer of filters under both its own and its

linked to a cutter.

out as a key market player in this landscape. Founded by Nicola

customers’ brands. “Today, we offer customised filtration solutions for a

“We purchased this plant to manufacture pleated filter cartridges

wide range of industries, including coating, automotive, pharmaceutical/

while improving our production flexibility and significantly reducing our

chemical, food, cosmetics, energy, and air conditioning, among the

processing times. This versatile system allows obtaining components

many ones served by Defil’s products. We operate in national and

with different heights and thicknesses; moreover, thanks to 4.0

© ipcm

Defil Srl specialises in filtration, dust collection, and air treatment solutions for civil and industrial structures.

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HIGHLIGHT OF THE MONTH

technology, we can quickly change production programmes and control

Tailor-made filters for the coating market

raw material consumption in real-time, which enables us to reduce

One of Defil’s main target sectors is industrial coating, which accounts

the pleating/cutting times of our filter mats and ultimately improve our

for about one third of its turnover. “We have developed a range of

process quality, in some cases with a zero scrap rate,” illustrates Alfredo

advanced products for both powder and liquid coating processes.

Pellegrino.

For powder coating, we offer a selection of cartridge or sleeve filters

“In the past, for some specific processing phases, we relied on external

designed and manufactured with different filter mats and characteristics

partners that followed our drawings and worked exclusively with our raw

to ensure high performance and meet any customer requirement,”

materials. Now, we are trying to limit outsourcing as much as possible

indicates Alfredo Pellegrino.

to cut costs and increase our competitiveness,” says Paola Pellegrino,

“For the liquid coating sector, our flagship product is the Max Paint filter,

Quality and Raw Material Purchasing Manager at Defil.

a special, high-performance, honeycomb-shaped filter mat of which Defil is the exclusive dealer for the Italian market. Other widely used products

Product quality

are paint accumulators, dry filters designed for manual or robotised

“Our company takes great care to achieve a good level of production

coating booths and based on the principle of separation by inertia,

quality and thus meet our customers’ needs and demands as best as

effectively capturing overspray and ensuring excellent application

possible. All this is possible by purchasing raw materials from European

results. Our catalogue also includes original paint stop filters from

parent companies, optimising products in stock, and technically training

Andreae Filters, of which Defil is an official dealer for Italy, and fibreglass

our staff,” indicates Paola Pellegrino.

filters, ideal for capturing fine particles and ensuring air purity. Thanks to the variable arrangement of fibres and their density, these products

On the side: the pleating machine’s feeding rolls (left photo) and filter mats inside the pleating machine.

The touch screen of the new 4.0 pleating machine and the metal structures containing the filter mats.

© ipcm

© ipcm

© ipcm

© ipcm

international PAINT&COATING magazine - SEPTEMBER/OCTOBER 2024 - N. 89

143

© ipcm

© ipcm

© ipcm

Cartridges in different sizes and, from left to right, Simona, Alfredo, and Paola Pellegrino.

offer high dust holding capacity and a lower risk of release, thus further

our offer by insourcing our metal components’ moulding phase, which

optimising production processes,” adds Alfredo Pellegrino.

would allow us to further increase our independence and diversify our

Over the years, Defil has expanded its range of coating filters, including

product portfolio,” says Alfredo Pellegrino.

filter bags for cataphoresis, cartridges for liquid application, porous

Simona Pellegrino, the General Manager of Defil, concludes by

mats, and cleaning systems such as Venturi tubes and rotating nozzles.

expressing great satisfaction with the purchase of the new electronic

“Thanks to the experience gained in almost forty years in business, Defil

pleating machine: “We are more than satisfied with our recent

can offer valuable know-how in filtration, workplace health and safety,

investment, which enables us to better position ourselves on the

and air pollution abatement,” summarises Paola Pellegrino.

national and international markets. Defil is now a benchmark supplier

Future projects and conclusions

in the industry, thanks to our ability to constantly innovate and adapt to the needs of an ever-changing market. Investments in 4.0 technologies

With an eye always on technological innovation and sustainability, Defil

and continuous efforts to improve our production processes have

confirms itself as a partner of excellence for customers seeking cutting-

enabled us to increase the quality of our filters and strengthen our

edge industrial filtration solutions.

international presence. With an eye on an increasingly automated

“We plan to automate our panel cutting process for the construction

and sustainable future, we are ready to consolidate our position by

of filter cells, which is currently manual, to achieve a fully digitised and

continuing to offer advanced solutions.”

integrated production flow. In addition, we are considering expanding

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SUCCESS STORIES © Delco Trailers

Delco Trailers Revolutionises Its Trailer Finishing Process with a New Automatic Coating Line Delco Trailers, a company specialising in the production of trailers, has undertaken an ambitious project to automate its manufacturing process by implementing a new, fully automated coating line. The company chose Total Finishing Systems as its strategic partner. The goal? To achieve flawless finishes and increase production capacity to 500 coated trailers per week.

“W

hen seeing a trailer, the first thing anyone will notice is the

Delco Trailers’ objective was ambitious and clear: to achieve the highest

finish.”

finishing standards and guarantee aesthetically impeccable products

This statement by William Dyck, the COO of Delco Trailers,

through meticulous control at every stage of the process. At the

perfectly encapsulates the challenge this company has been facing

same time, implementing the new coating line not only improved the

in recent years. Headquartered in Brookston (Texas, USA), Delco

quality of finishes but also addressed the need to significantly increase

has embarked on an ambitious journey to automate its production

productivity. “Delco aimed to coat around 500 trailers per week – an

department by investing in a new, fully automated coating line. To tackle

ambitious target that required an increase in production capacity,”

this project, it relied on Total Finishing Systems (Montclair, California,

states Total Finishing Systems’ President, Ty Crowder. “With the new

USA), a leading provider of turnkey coating solutions.

system, we were able to achieve this goal.”

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SUCCESS STORIES

Delco’s commitment to innovative solutions and attention to detail

components from the welding to the coating department, significantly

ensures that every trailer produced is not only aesthetically perfect

reducing the labour input, speeding up turnaround times, and

but also designed to withstand the toughest challenges. Dyck also

significantly increasing productivity.

emphasises that “each trailer is made entirely of steel, which ensures

“The parts are then subjected to mechanical pre-treatment by shot

strength and durability even in the harshest conditions”. This project

blasting. This process occurs in two dedicated areas, for manual and

represents a major step forward for Delco Trailers, further strengthening

automatic shot blasting, respectively,” explains Fabian Cardenas, the

its reputation as a manufacturer of high-quality trailers in the American

General Manager of TFS. “After these, the power&free conveyor, which

market.

extends over 2900 m (9500 ft) in length, bifurcates: the components following the primary line pass through a three-stage pre-treatment

The coating plant

tunnel and then into a drying oven; those that follow the secondary

The coating line supplied by Total Finishing Systems is a highly

line, on the other hand, undergo blow-off, manual cleaning, and drying

sophisticated plant featuring state-of-the-art technology and a complex

operations.”

conveyor system that branches out in several directions to ensure

In the subsequent phase, the components are transported to the coating

maximum operational flexibility.

application booths. Again, the conveyor branches off to take each part to

There are 27 loading and 27 unloading automated zones to ensure

the correct booth. The two conveyor lines feature two adjacent booths

a continuous and organised workflow. “Previously, the operators had

for primer application and two for powder coating application. Each

to move the trailers manually or with forklifts from the welding area

booth is 48 m (160 ft) long and has a powder recovery system with a

to the storage one and then to the coating line. Now, thanks to the

cyclone. After coating, the components reach the two curing ovens,

new automated system, an overhead crane automatically takes the

which are also adjacent to each other.

© Total Finishing Systems

The layout of the coating plant with the 27 loading/unloading automated zones clearly visible.

international PAINT&COATING magazine - SEPTEMBER/OCTOBER 2024 - N. 89

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SUCCESS STORIES

Finally, the two lines merge again in one chain to transport the

control was also essential. We worked to provide Delco with the best

components to the unloading area.

possible technology without going over budget, producing a system that

Meeting the company’s needs

fully met its expectations.”

In addition to this significant technological investment, Delco is fine-

“When Delco Trailers decided to adopt a new finishing system, it was

tuning its internal production processes to optimise its corporate

already clear about the type of solution it needed, and we are thrilled

organisation. It primarily aims to improve forecast management and

that they found Total Finishing Systems to be the perfect partner for this

reduce material inventory while enhancing warehouse procedures to

project,” states TFS’s General Manager. “When we met at the Fabtech

track components more efficiently.

trade fair in Chicago in 2021, Delco was looking for a supplier capable of offering a complex, turnkey coating system to handle heavy components

Strategic collaboration with a pool of companies

up to 15 metres (52 ft) in length and achieve a production capacity of

When Delco Trailers decided to implement a new finishing system, the

around 500 trailers per week.”

requirements were clear: a highly customised and complex system. “We

“A decisive factor in its choice was our ability to design an innovative,

are proud that they chose Total Finishing Systems as the ideal partner

tailor-made layout. We fully customised it to meet the precise

for this ambitious project,” says the General Manager of Total Finishing

requirements of the customer, which had a detailed vision of how to

Systems. Careful analysis and in-depth study were essential to design a

organise production.” Another crucial aspect was the limited space.

layout of such complexity. “Collaboration with our partners was crucial:

“Despite the system’s imposing size, there was little space available. We

Erzinger (Joinville, Brazil) supplied the booths and the powder recovery

had to use every square metre very carefully,” notes Crowder. “Cost

system, Railtechniek (Tiel, Netherlands) built the power & free conveyor,

© Delco Trailers

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and Total Finishing Systems was responsible for designing the pre-treatment tunnels and the drying and curing ovens, as well as integrating all technologies along the line,” illustrates Crowder.

“Each project stage required great attention to detail and meticulous preparation to ensure that all the customer’s requirements were fully met,” summarises Fabian. “We are thrilled with the results so far. We have already delivered 95% of the system, and we are going to continue to work on perfecting it until it is fully operational.”

Components entering the curing oven (left) and a coated trailer.

© Delco Trailers

ROAD TO 2050

SPECIAL ISSUE ON ALUMINIUM

Olea FP: a Natural, Sustainable Option for the Paints & Coatings Industry From Waste Stream to High-performance Functional Powders Kathrin Schilling Founder & Director of BioPowder - Birkirkara, Malta

All around the world and across industries, businesses are called to be more sustainable, green, and clean.

Hence, companies are increasingly required to balance economic, social, and environmental considerations to ensure a better quality of life for current and future generations.

A

midst this push for sustainability, the paints and coatings

BioPowder2 further processes them into top-grade micronized powders

industry may face some challenges due to the environmental

with different surface functionalization options. Marketed under

and health impacts of some of the chemicals commonly used

the brand name Olea FP (Functional Powders), they are fully circular

in its products. However, the market now provides natural, sustainable options that can even enhance physical and mechanical properties of coating formulations. These alternatives include bio-based binders, biodegradable texturizers, recycled content, and natural pigments.

additives with desirable properties for modern coating formulations.

Technical benefits of micronized performance powders from recycled olive stones For paints, floorings and other coating systems, Olea FP present an

The incredibly useful olive

exceptional range of opportunities thanks to the following mechanical

A circular raw material that has lately gained wider attention is the olive

properties:

pit, a by-product from the olive oil mill. Olive oil manufacturing involves

 High hardness of >3.5 on the Mohs scale

compressing of the whole olive, which produces a solid residue of pulp,

Olea FP have a high level of hardness, making them suitable for use

peel, and fragmented pits. In the past, raw olive pits have mainly been

in coatings that require elevated strength, stability, and abrasion

used for combustion. In some countries, they are still considered as

resistance. This results in a long lifespan of functional coatings for

waste products and not yet part of any upcycling value chain.

outdoor and high-traffic areas.

According to the International Olive Council , the global olive oil

 Low oil- and water-binding capacity

production volume for the 2021/22 crop year is estimated at 3.10

Due to their low oil- and water-binding capacity, Olea FP provide particle

million metric tonnes, up 2.9% from the year before. Hence, there is

stability with no risk of swelling or expansion. This feature facilitates

a massive amount of olive pomace (pulp) left behind, which comes

incorporation in both water- and solvent-based formulations, improves

with certain disposal challenges because of its fat and polyphenolic

the durability of coatings and reduces the likelihood of cracking or

compound content. Fortunately, new technologies have emerged to

peeling.

recover this waste stream and to break it down into its components.

 Low density

Specialized machines are used to process the pomace in a moist state,

Olea FP are low in density and therefore ideal for use in lightweight

and olive pit fragments are separated from pulp and shell through a

materials. This feature can also offer cost-saving potential by reducing

centrifugation process. The fragments are then mechanically cleaned,

the per-kg amount needed for volumetric batches.

dried, and screened based on their particle sizes. Through this complex

 Compact particle shape

treatment process, BioPowder recovers light beige granules that are

The compact particle shape of Olea FP allows for high predictability

free of any dust/pulp and nearly odorless.

and ease of incorporation in coatings. The effect is generally a good

1

dispersability leading to a smooth texture.

1

International Olive Council, The World of Olive Oil, 13 Jan 2022

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2

www.bio-powder.com

ROAD TO 2050

SPECIAL ISSUE ON ALUMINIUM

 Reactive particle surface

at a concentration of 10%. The comparative study showed a reduced

Surface reactivity of Olea FP can either be taken advantage of or

gloss at all incident angles, with the 0-100 μm being most effective

suppressed through functionalization. This feature allows for the

particle size range. On the whole, the conducted studies demonstrate

production of coatings with tailored properties such as improved

the effectiveness of Olea FP as a matting agent in various types of

adhesion or water resistance.

paint formulations, including epoxy and acrylic paints. By reducing the gloss of such coatings, Olea FP can help create a matte finish, which is

 Thermal resistance and insulating properties

desirable in many applications such as automotive or furniture coatings.

Olea FP have thermal resistance and insulating properties. This is

Additionally, their use as replacements of traditional matting agents like

particularly relevant for industrial coatings, e.g. for use in pipelines or

PE powder can greatly reduce the environmental impact of coatings

storage tanks, where thermal resistance and insulation are critical.

manufacturing.

Demonstrated effects of Olea FP in formulations

Reinforcement and enhanced abrasion resistance

Reduction of Gloss

The high hardness of Olea FP makes them ideal for use as reinforcing

One way in which Olea FP can enhance paint and coating formulations is

agents in coatings. By adding variable doses of Olea FPs, manufacturers

by reducing their gloss. The micronized powders have proven effective

can improve the coatings’ resistance to wear and tear, i.e. caused by

as matting agents, among others in the following ways:

impact and abrasion. This feature is particularly useful in applications

 As natural pigments in a PU-acrylate matrix: Olea FP was added to

where coatings are subjected to high levels of stress, such as in marine

a PU-acrylate matrix to modify the color and gloss of the coating. The

or industrial settings. As part of a comprehensive study, the following

addition of the powder resulted in a color change towards the red/

tests were conducted:

yellow spectrum and a gradual opacification of the paint. The overall

 Indentation tests: In a PU-acrylate coating reinforced with Olea FP

gloss of the paint was reduced to nearly 50%, creating an increasingly

particles, it was found that doses of olive stone powder as low as 5%

matte finish.

could increase the hardness of a paint by up to 20%.

 In replacement of polyethylene (PE) matting powders in acrylic paint

 Taber tests: The abovementioned PU-acrylate formulation with varying

formulations: a functionalized (hydrophobic) grade of Olea FP was added

load percentages of Olea FP was subjected to rotating Taber wheels.

© BioPowder

BioPowder obtains a consistent supply of top-grade olive pits from carefully selected mills and c onverts them into pure, clean granules, powder, or flour of specific micron-range accuracy.

international PAINT&COATING magazine - SEPTEMBER/OCTOBER 2024 - N. 89

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SPECIAL ISSUE ON ALUMINIUM

The latter applied pressure on the surface, which gradually removed the

 Decorative particles and pigment carriers: Besides being well suited

coating layer. It was found that the use of olive stone powder reduced

for decorative effects, Olea FP texture particles are powerful pigment

mass loss by up to 50% in less than 600 cycles.

carriers. Tests have demonstrated high levels of effectiveness with

These results demonstrate that olive stone powder improves the

pigments from both natural and synthetic sources. In response to the

abrasion resistance and hardness of formulations. Consequently, Olea

high demand for all-natural texture particles, e.g. as alternatives for

FP can help extend the lifespan of coatings, which ultimately boosts

quartz or polymer particles, BioPowder has recently launched its own

efficiency and supports less frequent use. Additionally, the powder’s

color particle range marketed under the brand Olea Colors.

feather-light properties make it an attractive option for lightweight coatings in applications where every gram counts.

In sum, the use of Olea FP in coatings comes with multiple advantages.

As a compostable material, it constitutes an eco-friendly alternative to

Natural particles for texture and surface effects

conventional matting particles. Its resistance and lightweight properties

In addition to its use in matting and reinforcement, Olea FP are also

make it an attractive reinforcing option, while its customizable micron

an excellent option for creating unique surface textures in coatings.

ranges provide versatile surface texturing opportunities. Manufacturers

Manufacturers looking for bio-based alternatives can consider using

would ideally take advantage of these effects in combination to create

Olea FP for the following uses:

attractive design coatings from renewable sources.

 Functional filler and viscosity agent: Incorporating olive stone powder adjustments while improving the overall strength of the formulation.

Bio-based functional powders: green innovation with an optimized carbon footprint

 Surface texture particles: Olive stone particles can be scattered on the

The need of companies to adopt sustainability throughout their value

surface of coatings to create a decorative and/or anti-slip effect. Olea

chain has doubtlessly become imperative. But what does it take to be

FP texture particles are available in grain size ranges from <50μm up to

truly eco-friendly and set new standards for responsible manufacturing

4mm, allowing for a large spectrum of texturing options.

practices? Specifically, what makes a coating stand out as more

in epoxy, acrylic, or other formulations allows for viscosity and rheology

© BioPowder

BioPowder’s reinforced linoleum ‘naturazzO’ is a resilient flooring solution that contains up to 40% of Olea FP composite fillers. It has been proven effective for high-load industrial surfaces.

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© BioPowder

Manufacturers can create unique surface textures with BioPowder’s natural particles.

Recommended systems for particle incorporation include epoxy, PU, and poly-aspartic resins.

ROAD TO 2050

sustainable? The answer lies in the carbon footprint, and hence a full life-cycle assessment, of all materials used in a formulation.

Measuring the CO2 output in all stages of the manufacturing value chain has

SPECIAL ISSUE ON ALUMINIUM

About BioPowder

become a recognized benchmark. In this regard, BioPowder has committed

BioPowder is a responsible producer and supplier

to lean practices that are deeply ingrained in the circular ecosystem of olive

of high-grade fruit stone powders and bio-based

by-products. As a consequence, olive stone particles come with an optimized carbon footprint: they are manufactured 100% mechanically, i.e. with electricity being the main required utility. The use of water is minimal, and production

abrasives that are free of chemical additives. Derived from food processing side streams, the company’s

does not generate any waste. Most remarkably, olive trees are among the

products support a circular economy and enable

plants that bind the largest amounts of CO2. Evidence shows that roughly 1.5kg

manufacturers to reduce their environmental impact.

of CO2 is produced per liter of extra virgin olive oil. However, an olive orchard

can absorb up to 10kg of CO2 while growing the equivalent quantity of olives3.

In conclusion, it can be said that olive stone powders are doubtlessly creating opportunities for carbon-efficient innovation in paints and coatings. The

Founded in 2017 and headquartered in Malta, the company sources from the Mediterranean region and manages production in Southern Spain. BioPowder

BioPowder team supports coatings manufacturers throughout all stages of

is part of a sustainable supply chain that strongly

R&D and production and looks forward to new project partners.

believes in processing agricultural by-products (not crops), sourcing locally or regionally, and ensuring that its activities do not disrupt the food chain.

International Olive Council, Application for the Calculation of CO2 Balance in Olive Farming, 27 Jul 2016

3

Exhibition Center Düsseldorf October 8-10, 2024 Hall 1, booth A51

eosmarketing.it

ALU MIN IUM

ve r t i c a l p l a n t s

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

FINISHING SYSTEMS

www.trasmetal.com www.varnishtech.it

UCIF Informs

Corporate Cybersecurity: a Shared Commitment to Digital Security Manuela Casali UCIF – Italian Surface Treatment Equipment Manufacturers’ Association, Milan, Italy

info@ucif.net

Cybersecurity, which used to be the exclusive competence of IT departments, now involves increasingly broader areas of the corporate structure, personally affecting all employees regardless of their role.

I

n an increasingly digital world, corporate cybersecurity is no longer

active participants in protecting corporate assets, understanding the

an exclusive responsibility of the IT department.

impact a single mistake can have on the entire company.

Today, every employee plays a crucial role in protecting information

In addition to training, prevention is crucial. Companies should take

and assets. The increasing complexity of cyber threats makes it

proactive measures such as constantly updating systems, implementing

essential that everyone, regardless of their position in the company,

advanced security software, and regularly checking for vulnerabilities. It

pays attention to potential cyber attacks, including those from

is also essential to establish clear procedures for incident management

unexpected sources.

so that the company can respond quickly and limit the damage in the

Most cyber attacks do not start with sophisticated systems hacking

event of an attack.

operations but rather with something much simpler: a phishing email,

In other words, corporate cybersecurity is a challenge that requires the

a suspicious link, or a USB stick left unattended. These attack vectors

active participation of all members of the organisation. Only through

exploit the trust and carelessness of employees, turning them into

a combination of training, awareness, and preventive measures can

gateways for cybercriminals. This means that even the best security

companies protect themselves effectively against cyber threats. At

system can be vulnerable if people are not adequately trained and

a time when information is one of the most valuable assets, digital

aware of the risks.

security must be a priority shared by all.

One aspect that is often overlooked is the origin of threats. Not only

Cybersecurity regulations vary by jurisdiction and industry, but some

professional hackers or organised groups can pose a risk, but also

international and local laws do exist that are crucial for companies and

former employees, external suppliers, and even accidental mistakes

organisations. The main international regulations currently in force

by the internal staff can compromise corporate security. Therefore,

include, for example, the GDPR, which applies to all organisations that

everyone should be aware of these potential sources of risk and able to

process personal data of EU citizens, regardless of location; ISO/IEC

recognise suspicious or unusual behaviour.

27001, an international standard that specifies the requirements for

Training is the first line of defence against cyber threats. Regular

information security management systems; and even the Cybersecurity

cybersecurity refresher courses help employees recognise and

Act, which came into force in the EU in 2019 and establishes a

correctly respond to threats. Training should not be limited to

framework for cybersecurity certification within the European Union.

theoretical sessions but also include practical simulations, such as

Through its collaboration with ANIMA Confindustria, UCIF offers

phishing tests, to prepare the company’s staff to react in real-life

refresher and training workshops on this subject to help its members

situations. At the same time, such a safety culture should be promoted

keep abreast of new issues and be informed on how best to manage

at all levels of the organisation. Employees should feel empowered as

their activities.

© Adobe Stock

INFRARED THERMAL SOLUTIONS

www.infragas.com

COLOUR STUDY

The Irresistible Charm of Pink Ilaria Paolomelo ipcm®

Often associated with sweetness, love, and femininity, pink has a rich and varied history spanning art, literature, nature, cinema, and mass culture. In this article, we explore the origins of this colour, its meaning, and the ways in which it has been used over the centuries.

A

s a colour rich in history and symbolism, pink has gone through

good luck and happiness. Today, this colour is also associated with

centuries of cultural and artistic transformation, eventually

tranquillity and serenity. Psychological studies have shown that it can

finding a significant role in film, fashion, and psychology. Rare and

have a calming effect and reduce levels of aggressiveness – which is why

precious in ancient times, pink underwent a profound evolution from

it is used in environments such as hospitals, prisons, and schools to

the Renaissance to the 18th century, becoming a symbol of elegance

provide a serene atmosphere.

and power thanks to figures such as Madame de Pompadour. In the 20th century, it took on connotations of femininity and delicacy, although it was also considered a masculine colour in the past. In psychology, pink is associated with tranquillity, compassion, optimism, and creativity and is thought to have a calming power and positive impact on our state of mind. From iconic films like “Breakfast at Tiffany’s” and “Mean Girls” to pop culture and awareness campaigns like the “Pink Ribbon” one, this hue continues to influence and inspire, remaining central in today’s cultural and social trends.

Pink in history Obtained by mixing red with white, pink has gone through centuries of cultural and artistic transformation. In ancient times, it was difficult to obtain and, therefore, rare and precious. The first use of this colour in art can be traced back to ancient Rome, where it was utilised for frescoes and ceramic decorations. As the centuries progressed, during the Renaissance, pink became more accessible thanks to advances in pigment production and was used in religious paintings to depict human skin and sacred garments.

The word “pink” first appeared in the 17th century, but the colour only spread widely in the 18th century. It was in this period that Madame de Pompadour, King Louis XV’s mistress, was known for elevating pink to a symbol of fashion and prestige, so much so that La Manufacture Nationale de Sèvres, one of the most famous porcelain manufacturers in Europe founded in 1740 in Sèvres (France), christened a shade of pink porcelain “Pompadour Pink” by order of the sovereign himself.

At that time, pink was worn by women and men alike and considered an elegant and powerful tint. However, its meaning has changed over time.

In the West, it is now traditionally associated with femininity, sweetness, and innocence, a connotation that was consolidated in the 20th century.

Before the 19th century, pink was actually often considered a masculine colour, especially for children. In many Asian cultures, pink symbolises

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ART WITHIN SURFACES

The origin of the word “pink”

In Italian (and similarly in other European languages), the name and

In English, before the end of the 16th century, this hue was called

adjective rosa is linked to another flower, the rose. This plant had

“incarnation”, with the meaning of “flesh colour”. It then began to be

considerable symbolic and cultural importance in ancient civilisations,

called “pink” from the common name of a garden plant with flowers in

which led the term to spread widely. In many of these cultures, the

this colour, called dianthus – although earlier, this word indicated a

rose has been associated with love, beauty, and passion, and these

greenish yellow. To further complicate the matter, the origin of this word

connotations have also been reflected in language. For example, in

is unknown. Some etymologists suggest it was taken from an earlier verb

Greek mythology, it was associated with Aphrodite, the goddess of love,

that means “to wink,” as some pinks look like the irises of eyes. Other

and in Roman times, with Venus.

1

sources indicate that it was derived from a different verb “pink” that means “to perforate in an ornamental pattern,” referring to the jagged

Pink in literature and art

edges of most pinks. Or, perhaps, it was from Dutch pink meaning

The colour pink has played a significant role in both literature and

“small” or “narrow,” itself obscure.

art, taking on different meanings and connotations depending on the historical and cultural context. In literature, it is traditionally

1

associated with delicacy and sensitivity. For example, in many of Jane

https://en.wikipedia.org/wiki/Dianthus

Austen’s works, female characters are often described in pink dresses, symbolising purity and romance. However, the meaning of pink has © AdobeStock

never been static: in the novel “Bad Girls” by Joyce Carol Oates, for instance, this colour is used to represent rebellion and inner strength, being associated with strong and independent female characters.

Pink has undergone significant transformations in art as well. During the Rococo period, it represented elegance and refinement, as shown in the works of François Boucher and Jean-Honoré Fragonard.

© Marc Wathieu

Jeff Koons’ balloon dog.

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157

© AdobeStock

In the 20th century, artists like Pablo Picasso and Mark Rothko employed

for its pink sand, formed by pink and red foraminifera and shells that

pink innovatively to explore emotion and introspection. Picasso, in

pulverise on contact with seawater. The pink beach of Budelli, located in

particular, went through a “Pink Period” in which his works expressed

the La Maddalena archipelago in Sardinia (Italy), is also well known for

serenity and warmth. In Postmodernism, artists such as Jeff Koons have

its pink sand, composed of calcareous shells of a unicellular organism,

used pink to explore mass culture and kitsch, often to comment on the

Miniacina miniacea, and fragments of coral.

commercialisation of beauty and the superficiality of popular culture.

Pink in nature

Pink-mania Pink has had a crucial impact on cinema and mass culture, evoking

Pink can be found in nature in many forms, from flowers to landscapes.

specific atmospheres and setting characters apart as symbols of

One of the most famous examples is Japan’s cherry blossoms, or sakura.

elegance, rebellion, and power. This shade has found ample space in

These flowers colour landscapes with delicate pink tints and take on

numerous iconic films and has left a significant imprint on fashion and

deep cultural meanings. Celebrated during Hanami, their blossoming

social trends.

symbolises the ephemeral beauty of life and the importance of

In the film “Breakfast at Tiffany’s”, pink emphasises the elegance, vivacity,

appreciating fleeting moments.

sophistication, and glamour of Holly Golightly, the famous character

On the other hand, flamingos are famous for their bright pink plumage

played by Audrey Hepburn. Similarly, in “Grease”, the “Pink Ladies” group

due to their diet. Contrary to what one might think, these birds are not

adopts pink as a symbol of friendship and teenage rebellion, creating

born pink but with grey or white feathers. During their lives, they acquire

an enduring icon of 1970s fashion and pop culture. Pink continued to

this colour by eating crustaceans and algae rich in carotenoids: these

be a distinctive colour in popular culture with films like “Mean Girls”,

organic pigments, once digested, are metabolised and deposited in their

where the famous line “On Wednesdays we wear pink” became a

feathers, beak, and skin. The pink colour thus becomes a visual indicator

symbol of conformity and belonging to a social group. Such use of

of a flamingo’s health and diet: the richer the diet in carotenoids, the

pink to represent power and social dynamics among teenagers has

brighter the plumage.

consolidated its role in youth culture.

Finally, nature offers us some beautiful landscapes in various nuances

At the same time, besides cinema, pink is deeply rooted in

of this colour. Described as the “Caribbean of the Mediterranean” and

contemporary mass culture. It is the distinctive colour of many brands

located on the southwestern coast of Crete, Elafonissi Beach is one of

and products, including the iconic Italian Big Babol chewing gum, the

Greece’s most popular summer destinations; it is also world-famous

Victoria’s Secret logo, and Barbie’s packaging. Launched in 1959 by

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COLOUR STUDY

© AdobeStock

© AdobeStock

Mattel, Barbie initially did not have pink as her predominant colour.

However, pink is also linked to more serious and important issues that

However, in the 1960s and 1970s, this emerged as a key element in

usually revolve around women. The “Pink Ribbon”, the international

the branding of the world’s most famous doll, reinforced in the 1980s

symbol of the fight against breast cancer, is much more than just a

and 1990s through targeted marketing strategies. Today, Barbie Pink

pink ribbon. It represents solidarity and hope for millions of people

has become an iconic and ubiquitous symbol in pop culture, giving the

worldwide, helping raise awareness and funds for research and

brand and those who wear this tint a strong sense of femininity and

treatment of this oncologic condition. Finally, pink has also been

glamour.

finding significant application in social and political movements. The

Such success was further amplified by the movie Barbie, directed by

“Pink Protest”, for example, is an initiative that uses colour to support

Greta Gerwig and starring Margot Robbie and Ryan Gosling, which was

women’s and minority rights, proving that pink can also be a powerful

a resounding success at the box office, grossing over 1.4 billion dollars

tool for advocacy and activism.

globally and becoming one of the biggest cinematic successes of 2023 as well as the highest-grossing film ever produced by Warner Bros. This movie not only made Barbie fashionable again but also demonstrated cinema’s ability to affect cultural and commercial trends. The dominant bright pink of the setting and costumes awakened and amplified the appeal of this colour, leading to a renewed interest in using this shade in fashion and decoration. An example of this is the powder-pink Arizona sandals produced by German company Birkenstock: according to the online shopping platform Lyst, only one week after the film’s release, online searches for pink Birkenstocks increased by 110%2. The representation of Barbie’s world has fuelled a wave of nostalgia and stimulated a debate on femininity and gender identity-related topics,

From left to right:

suggesting that pink will continue to be a central element in pop culture.

- Cherry blossom season in Japan.

- The famous pink beach of Budelli, Sardinia.

2

https://www.yahoo.com/lifestyle/birkenstock-riding-high-searches-soar-143114021.html?

- The Barbie brand has made pink its dominant colour.

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MEETING THE INDUSTRY

COVERED BY ipcm®

Idrotecnica Celebrates 40 Years of Success in the Innovation of Water Purification and Demineralisation Systems On Saturday, 7 September, the ipcm® team had the pleasure of attending the 40th anniversary of Idrotecnica. It was an important occasion to reminisce about the history of this manufacturer of water treatment systems and celebrate the many successes achieved in four decades of activity.

I

drotecnica, a company designing,

production department, where the first water

been an intense 40 years, full of challenges

producing, and installing water purification

treatment plants supplied by Idrotecnica in

and successes, and we look to the future

and demineralisation systems for various

the 1990s were on display alongside the most

with the same enthusiasm, determination,

industrial sectors, including cosmetics,

modern and advanced systems in use today.

openness, professionalism, and above all

pharmaceuticals, research laboratories, and

This exhibition offered an insight into the

humility that have distinguished us from

coating, celebrated its 40 anniversary on

firm’s technological evolution, highlighting its

the beginning,” said Marcenaro. He also

Saturday, 7 September in its headquarters in

constant commitment to innovation.

expressed his deep gratitude to all those

Genoa (Italy). This event was an opportunity to

One of the most meaningful moments was

who have contributed to the company’s

celebrate but also look back over these four

the speech by CEO Federico Marcenaro, who

success: employees, partners, suppliers, and

decades of successes and innovations that

recalled with great emotion the foundation

customers, whose support has been crucial

have made Idrotecnica a solid and globally

of the company by his father Alessio,

in achieving ambitious goals. Special thanks

recognised company.

emphasising that passion, commitment, and

were reserved for his family, who have always

The participants had the opportunity to take

the continuous search for excellence have

supported the company on its journey.

part in a guided tour inside the company’s

guided Idrotecnica in its path of growth. “It has

Marcenaro illustrated the importance of

th

innovation and quality, two values that © Idrotecnica

continue to guide Idrotecnica in facing the challenges of the global market. Finally, the event offered a glimpse into the future, with Marcenaro anticipating some of the opportunities and challenges that await the company in the coming years, stating that Idrotecnica will continue to invest in research and development to remain at the forefront of the industry by meeting the needs of everchanging and increasingly demanding markets.

The day ended in a festive and convivial atmosphere with a toast and a lunch offered to all those present. “This 40th anniversary is not only an important milestone but also a new starting point for successfully tackling future challenges and continuing to write Idrotecnica’s history in the decades to come,” the CEO concluded.

Idrotecnica’s CEO, Federico Marcenaro.

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MEETING THE INDUSTRY

COVERED BY ipcm®

Helios Quartz Celebrated 85 Years of Success Helios Quartz has celebrated 85 years of activity by inaugurating a new warehouse and welcoming over 150 guests to honour the employees and their families.

O

© ipcm

n Thursday 12th September 2024, Helios Quartz celebrated an important milestone: 85 years of history. The historic Italian company based in Cambiago (Milan) and renowned for its quartz

glass processing and the production of IR and UV lamps organised an exclusive event in its new facility, welcoming over 150 guests for a moment of celebration and reflection. The evening, reserved exclusively for employees and their families, created a warm and engaging atmosphere, where pride for the path taken merged with hope and enthusiasm for future challenges.

“Helios Quartz continues to consolidate its role as a reference in the sector.

I would like to honour our journey by celebrating not only the results that we have achieved, but above all the people who have been part of Helios Quartz and who have contributed to its growth”, has stated the CEO Armando Giro, who has inherited his father’s legacy with the same vision and determination. “The future of Helios Quartz is bright and I am truly excited to share it with all of you.”

Particularly touching was the recognition reserved for Enrico Giro, father of the current CEO Armando, a key figure in the development of the company.

However, Giro has also expressed warmth and gratitude towards the employees of the company, considered to be the beating heart of Helios Quartz, underlining how dedication and teamwork have contributed to building the success of Helios Quartz.

About Helios Quartz Founded in 1940, Helios Quartz was born as a family-owned company and it is now an international group with two production plants - in Italy and Switzerland - and its own sales offices in the USA, China and Asia. The company is now a major international supplier for quartz glass processing and the manufacturing of IR & UV lamps, and it also produces specialised equipment for industrial, scientific, and medical applications. Over 70 years of experience in several different industries has enabled Helios Quartz to acquire advanced technology know-how, deep knowledge of production processes and solid skills in many areas of various applications: Helios Quartz companies are able to approach every request, studying solutions for the most specific and complex applications, also thanks to a cutting-edge testing centre located in the production plant of Cambiago.

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MEETING THE INDUSTRY

Paint & Coatings Italy: Enhancing Business with Colours The next edition of Paint & Coatings Italy will take place from October 22 to 23 in Milan (Italy).

P

aint & Coatings Italy returns for its third year, taking place 22 –

Supported by AssICC, the conference will address various regulatory

23 October at the NH Milano Congress Centre in Assago (Milan,

topics, presenting updates on labelling and PCN notification according

Italy). Supported by AssICC and ASSOVERNICI, Paint & Coatings

to the recent CLP regulations. Further content will cover the importance

Italy has been developed with the sector operators in mind. The event

of REACH and CLP controls to ensure compliance with European

is packed with a content that covers a diverse range of topics, combined

regulations.

with an exhibition featuring the leading suppliers active in this industry.

A highlight will be the session dedicated to the certification of coaters

So, regardless of experience level, the event has expertise, creative

and the state of the art in Italy, followed by a presentation on using

insights, knowledge, services, tools and targeted professional contacts.

the Environmental Product Declaration (EPD) to communicate the

P&C Italy is the opportunity to add colour to the sector’s business. Over

environmental impacts throughout the product lifecycle.

the two days, attendees will have the chance to make connections, find

ERMA, the European Resin Manufacturer Association, will play a crucial

solutions, and discover the latest trends, innovations, and technological

role in guiding sustainability discussions, providing both a regulatory

advancements that will help drive business forward.

framework and practical strategies to help companies become more

The exhibition will be the largest yet, with an increased number of

environmentally responsible. The full program is available at: www.paint-

exhibitors at your disposal, thousands of products to find and more

coatings.it/la-conferenza.

industry experts on hand to share their knowledge.

Given the success of the Polymer Academy at the previous edition, P&C

Running alongside the exhibition is a comprehensive programme

Italy will once again focus on polymer binders, involving the leading resin

of content that provides a unique opportunity to discover new

producers. This Congress highlights how innovation and sustainability

solutions, form strategic collaborations, and stay updated on industry

are central to progress in the coatings and polymers sector, with a

developments.

strong focus on the quality and efficiency of production processes.

The P&C Italy Conference features experts and companies from the

New for 2024 is the Additives Academy, led by the top additive

chemical and materials sectors discussing current and relevant topics.

manufacturers in the industry. The dedicated conference focuses

The main objective is to explore innovative and sustainable solutions

on innovative and sustainable solutions for paints and coatings. The

that meet increasing environmental demands and current regulations.

main topics include the use of antimicrobial additives, sustainable marine coatings, PFAS-free wetting agents, and wax-based additives.

The discussion also covers performance enhancements in coatings

© Stefano Pedrelli

with smart additives, PFAS substitutes, biodegradable waxes, and advanced thickeners. Finally, the conference explores the challenges and opportunities in formulating eco-sustainable paints, with a focus on natural additives, two-dimensional crystals, and pigment recycling.

Paint & Coatings Italy returns to the NH Milano Congress Centre in Assago, ready to solidify its reputation as a flagship event in the national paint and coatings landscape. Lunch and coffee are offered to all visitors arriving onsite before 10 AM. For further information: www.paint-coatings.it

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MEETING THE INDUSTRY

ALUMINIUM 2024: Showroom, Business Barometer and Impulse Provider for the Global Aluminium Industry For many industrial sectors, the “magic metal” aluminium is and will continue to be the material of choice for sustainable and technically unrivalled products. Just under 800 exhibitors from 50 nations will be demonstrating the potential it holds and how the aluminium industry is rising to current challenges and gearing for the future at the world-leading trade fair ALUMINIUM 2024 in Düsseldorf from 8 – 10 October.

E

very two years, the biggest showcase of the aluminium industry

The extensive programme in the ALUMINIUM Conference and the

brings together producers, processors and technology providers

Speakers Corner also offers in-depth insights: the conference, organised

along the complete value chain: from raw material production and

by Aluminium Deutschland and considered a central hub for knowledge

the segments of primary production, machine and plant engineering

transfer and experience exchange at the trade fair, provides valuable

to processing technologies and semi-finished and finished products,

impulses for current issues, and The Innovation Plaza “Sustainability &

as well as directional recycling technologies. Here, they will showcase

Recycling” will again be all about the sustainable, green transformation

the innovative solutions made possible using aluminium in automotive

of the aluminium industry this year.

production, mechanical engineering, construction and engineering,

The trade fair will debut the “Women with Metal – ALUMINIUM Awards”

aviation and air space, electronics, packaging and transport.

on 9th October to promote gender equality and diversity in the

For the international industry giants, ALUMINIUM is the most important

aluminium industry, recognising women’s achievements and addressing

meeting point and showroom every other year. Additionally, many SMEs

skilled labour shortages by encouraging more women to pursue careers

and start-ups also leverage this leading international trade fair to make

in the field.

an appearance on the market, exchange ideas with their customers and

The ALUMINIUM trade fair will open on 8th October, featuring an industry

network with other industry representatives. To them all, ALUMINIUM

dialogue between Aluminium Deutschland, IG Metall, and IG BCE on

serves as both a business barometer and impulse provider.

socio-economic transformation. This dialogue aims to foster crucial

780 exhibiting companies along the entire aluminium value chain will

discussions with policymakers, with speakers including Mona Neubauer,

be presenting themselves in five exhibition halls this year. Halls 1 and 4

Minister of Economic Affairs for North Rhine-Westphalia.

are dedicated to semi-finished products while Hall 5 focuses on furnace construction, metal working, joining technologies and automation. In

For further information: www.aluminium-exhibition.com

Hall 3 surface treatment and rolling technologies will be centre stage, including the Surface Pavilion and the Surface & Design Lounge. In Hall 6 everything will revolve around casting and heat treatments, furnace construction, primary production and recycling. Here visitors will find not only the Primary and Foundry Pavilion but also the Foundry Community Café, the ideal location for networking and exchange.

Another highlight is the relaunch of the Media & Education Lounge in Hall 6. This provides not only a retreat with plenty of reading material but also valuable insights and interesting facts about the material that is aluminium. In addition, information on further training options and skilled labour shortages will be offered here and an accompanying special programme for students and trainees is planned.

ALUMINIUM will not only present current solutions and a glimpse of the future to visitors in the exhibition area.

Scan the QR Code to purchase your ticket

international PAINT&COATING magazine - SEPTEMBER/OCTOBER 2024 - N. 89

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EDITORIAL BOARD Prof. Massimiliano Bestetti:

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Material Engineering and Industrial Technologies, University of Trento - Product Design

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EDITOR IN CHIEF / DIRETTORE RESPONSABILE

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