Issuu

The smart journal for surface treatments

ISSN 2280-6083

Special issue on ARCHITECTURE & DESIGN

ipcm digital on www.myipcm.com

Distributed at ALUMINIUM DÜSSELDORF

2026

17th Year - Bimonthly

INTERNATIONAL PAINT&COATING MAGAZINE

N°101 - SEPTEMBER/OCTOBER

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SEPTEMBER/OCTOBER 2026

CONTENTS

05 EDITOR’S LETTER

57 Special issue on ARHITECTURE & DESIGN

06 BRAND NEW

58 HIGHLIGHT OF THE MONTH

New finishes and decorative options for powder-coated aluminium coils

14 ADVANCEMENTS

From formulation data to development intelligence

FOCUS ON TECHNOLOGY Verniciatura Rosa’s new powder coating booth blends experience with automation

26 HIGHLIGHT OF THE MONTH

100 years of FreiLacke: a look back and key milestones

30 FOCUS ON TECHNOLOGY

Greenfield Engineering: raising the bar in powder coating – a strategic investment in quality, consistency and sustainability

36 SUCCESS STORIES

Datalec precision installations: rethinking the entire powder coating process through sustainability

40 BRAND NEW

62 HIGHLIGHT OF THE MONTH

Young GSB: a bridge between generations in aluminium and steel coatings

66 FOCUS ON TECHNOLOGY

From the laboratory to the production line: a new product for the pre-treatment of aluminium coils

72 BRAND NEW 74 ADVANCEMENTS

SurTec 650: one chemistry, four critical functions for aluminium surfaces

82 FOCUS ON TECHNOLOGY

Beyond extrusion: Estral builds a comprehensive service with support from its paint supplier

44 HIGHLIGHT OF THE MONTH

The power of 100 ipcm® issues. The excitement of a future yet to be written

48 ANALYSIS

Uncertainty as a driver for process optimisation through automation

90 ADVANCEMENTS

EcoDie: innovation and sustainability in aluminium extrusion die cleaning

94 FOCUS ON TECHNOLOGY

9 metres of flexibility: the new frontier for vertical coating lines with Coroxal

THE GLOBAL SOLUTION IN ALUMINIUM FOR SURFACE TREATMENT

Reduces waste and enviromental impact

Lower operating costs and increases efficiency

CAUSTIC SODA

RECOVERY

TECHNOLOGY

Recovered up to 80% of caustic soda Operates at room temperature

UP TO 80% CAUSTIC RECOVERY INNOVATION FOR ASODA SUSTAINABLE LESS WASTE | LOWER OPERATING COSTS ALUMINIUM INDUSTRY

SEPTEMBER/OCTOBER 2026

CONTENTS

104 ROAD TO 2050

138 SUCCESS STORIES

108 ANALYSIS

140 HIGHLIGHT OF THE MONTH

Modern process chemistry as a key to greater cost-efficiency: the relevance of energy efficiency in surface finishing

Durability and design freedom: how powder-coated aluminium is expanding façade possibilities

112 SUCCESS STORIES

Trasmetal expands in India with a new vertical coating line for aluminium profiles

Mirodur reorganises its factory to meet new market demand

142 HIGHLIGHT OF THE MONTH

The future of powder coatings: Rapid Coat’s private label offering

Gardo Haze: the future of aluminium pre-treatment is already here. DFV’s success case: sustainability, innovation, and digitalisation ®

116 HIGHLIGHT OF THE MONTH

From pre-treatment to coating: controlling aluminium surfaces

120 SUCCESS STORIES

Robustness, LEAN and process intelligence in surface finishing: ALUMIL and SurfChem on the new powder coating vertical line at Kilkis

128 ADVANCEMENTS

146 BRAND NEW 148 ADVANCEMENTS

The Kenosistec KSA line expands: decorative PVD reaches new levels of productivity

152 HIGHLIGHT OF THE MONTH

From the cataphoresis membrane to zero discharge: MEGA’s technologies for the coating industry

156 HIGHLIGHT OF THE MONTH

Ceramic membranes for more flexible water treatment

Your product, its surface... you must design it, and we are responsible for making it perfect and maintaining it

130 RESEARCH BREAKTHROUGH

A simple approach to rGO deposition on aluminium alloys for corrosion and wear protection

104

160 UCIF INFORMS

From a machine to a service: when finishing takes time

162 MEETING THE INDUSTRY

130

156

EDITOR’S LETTER

n late 2025, in one of my editorials, I wrote that the word ‘resilience’ is so overused it has lost its meaning. Yet this year I find myself using it for the second time in these opening lines, which I write at the start of each new ipcm® issue to offer readers food for thought, rather than as a key to interpreting the entire

magazine.

In March, I used the adjective ‘resilient’ to describe the Western manufacturing industry, which was facing an unprecedented energy crisis. Today, I must use it to describe what is increasingly guiding material choices in industries that require operational continuity and the ability to respond to critical situations: resilience, precisely. I was inspired by a report1 produced by the ALUMINIUM 2026 trade fair (Düsseldorf, Germany, 6–8 October) in

collaboration with Panorama Marketing, which featured interviews with stakeholders in the aluminium sector. In applications characterised by particularly demanding and strategic operating conditions, ranging from transport and logistics to emergency management, critical infrastructure, and defence, reliability, durability, and operational readiness are increasingly important. In these fields, material selection is rarely based on cost comparisons alone: performance, weight, durability, workability, certifications, and regulatory compliance are all factors that help identify the most appropriate solution for a given application. As governments and supranational organisations increase their investment in emergency preparedness, logistics, and critical infrastructure, there is a growing demand for materials that ensure efficiency, durability,

Alessia Venturi Editor-in-chief Direttore Responsabile

and long-term performance under demanding conditions. Aluminium continues to offer significant advantages where weight reduction, corrosion resistance, and operational efficiency are key selection criteria. And, when properly treated and protected with suitable finishes, it can meet increasingly complex technical requirements. This is where coatings, and more generally, all surface treatments that increase, improve, and enhance the intrinsic performance of this material, come into play. Anodising and coating have kept pace with – and in many cases anticipated – the growing demand for higher efficiency, developing solutions that ensure ever-greater durability and corrosion resistance, even in the most aggressive environments. This evolution was by no means a given, as it was driven by regulatory constraints, such as the ban on hexavalent chromium and TGICs, which forced researchers to find new ways to maintain comparable or superior performance. Today, surface properties are integral to design using this material and to its ability to withstand the test of time. You will find these topics explored in depth throughout much of this ipcm® issue, which also includes a focus on architecture and design, two industries traditionally closely linked to aluminium and serving as a testing ground for this metal as it enters ever-new and increasingly challenging sectors. The aluminium industry is heading into the final months of 2026 amid a complex landscape. The reliability of energy and raw material supplies remains a crucial issue. At the same time, demand driven by electrification, the energy transition, and digital infrastructure is reinforcing the strategic importance of aluminium2 and its surface treatments. At ALUMINIUM 2026, which this year will host over 800 exhibitors and is expected to attract more than 20,000 visitors over the course of the event’s three days, ipcm® will once again take centre stage with a stand (6M73), ready to be at the heart of all conversations that matter.

Richiedi la versione in italiano a info@ipcm.it

https://www.aluminium-exhibition.com/germany/en-gb/blog/industry-news/resilience-opportunities-aluminium.html

https://www.aluminium-exhibition.com/germany/en-gb/blog/energy/interview-roxana-calimente-gie-en.html

ipcm® - SEPTEMBER/OCTOBER 2026 - N. 101

BRAND-NEW

BYK-Gardner introduces the new byko-spectra LED 6 light booth BYK-Gardner introduces the byko-spectra LED 6, a compact light booth for precise and reproducible visual colour assessment. Its advanced LED technology simulates a wide range of standardized and real-world lighting conditions, ensuring reliable, standards-compliant colour evaluation.

YK-Gardner is introducing the new byko-

D65 at the highest quality level (MIvis Class

the byko-spectra LED 6 features a compact

spectra LED 6. This light booth represents

A) and various warm-white LED illuminants,

yet modern design. The light booth fits easily

the next generation of standardized LED

such as LED-A, LED-B1, and LED-B2, which

on standard laboratory benches while still

illumination for visual colour assessment

represent typical retail lighting conditions. In

providing ample space to evaluate samples up

and sets new benchmarks in precision and

addition, LED-B3 enables the realistic simulation

to 64 × 48 cm (25 × 19 in). The exterior walls

reproducibility.

of lighting environments commonly found in

are robust, and the interior surfaces are finished

As traditional incandescent and fluorescent

modern retail stores, characterized by a cool,

in matte light-grey Munsell N7, providing a

light sources are increasingly being phased

fresh light appearance.

neutral and controlled viewing environment. A

out due to their high energy consumption

Optional UV illumination can be activated

long-life diffuser ensures uniform illumination

and hazardous material content, the byko-

for the evaluation of optical brighteners and

across the entire viewing area, fully meeting the

spectra LED 6 is based entirely on modern,

fluorescent effects.

requirements of international standards such as

sustainable LED technology. Its smart LED

This allows all relevant everyday lighting

ASTM D1729 and ISO 3668.

module simulates all CIE standard illuminants

situations to be reliably simulated – from

The light booth can also be assembled quickly

with outstanding accuracy and delivers stable,

natural daylight and residential lighting to

and without special tools, enabling fast and

reproducible spectral power distributions that

modern retail environments. The precise

straightforward installation.

significantly outperform those of conventional

reproduction of these conditions ensures

For maximum ease of use, the byko-spectra

fluorescent lighting systems.

that colours and materials can be evaluated

LED 6 is equipped with a large touchscreen

The byko-spectra LED 6 offers a wide range

consistently under various lighting scenarios.

display. Users can switch between illuminants

of standardized illuminants, including daylight

In addition to its advanced lighting technology,

directly, adjust light intensity, and monitor key parameters such as correlated colour temperature. Fast switching between illuminants and the display of the remaining LED lifetime support efficient workflows. An automatic sequencing function allows predefined lighting conditions to run consecutively, enabling reproducible colour evaluations without manual intervention. With the introduction of the byko-spectra LED 6, BYK-Gardner further strengthens its position as a technology leader in colorimetric and visual quality control. The combination of advanced LED technology, a compact and durable design, and intuitive operation establishes a new standard for reliable, precise, and standardscompliant visual colour assessment in industrial and laboratory environments. For further information:

www.byk-instruments.com

N. 101 - SEPTEMBER/OCTOBER 2026 - ipcm®

BRAND-NEW

BYK introduces a new sustainable additive for coatings DISPERBYK-2180 is suitable for a wide range of applications, including architectural coatings, industrial coatings, and automotive OEM coatings. Besides these, the additive is also deployed in marine coating and corrosion protection. The underlying polycarboxylate-ether structure thus extends the available spectrum of potential solutions for the dispersion of inorganic pigments and fillers.

ith DISPERBYK-2180, BYK has introduced a new

concentration of ionic adhesive groups allows

wetting and dispersing additive for inorganic

DISPERBYK-2180 to be particularly effective in

pigments and fillers in water-based systems. The

deflocculating and stabilising of all kinds of inorganic

polycarboxylate-ether-based additive is designed for

particles such as titanium dioxide, transparent iron

applications requiring a high degree of stability across

oxides and fillers.

a wide pH range.

The additive also ensures a distinct reduction in

The polycarboxylate-ether-based structure of

mill base viscosity, thereby permitting high pigment

DISPERBYK-2180 opens up further formulation

dosages and, at the same time, good processability.

opportunities and meets the growing importance

Fine particle sizes and a uniform distribution of

of ecological demands. Due to its tolerance of

particles are achieved resulting in an extremely

extreme pH values, the additive is ideal for use in

positive effect on colour and transparency.

P25 column standard or customizable system to hang from the smallest parts to heavy 6-metre long bars

VOC-free architectural coatings - such as (dispersion) silicate paints. Its molecular structure with a high

For further information: www.byk.com/en

Area of application for DISPERBYK-2180.

HANGING SYSTEMS

Excellent viscosity reduction with DISPERBYK-2180.

COMPLETE SOLUTIONS FOR © BYK

HANGING AND MASKING

www.rostirolla.it

BRAND-NEW

Topping-out ceremony for the new Product Technology Centre (PTC) at FreiLacke A significant milestone for a forward-looking construction project at the headquarter in Döggingen, Germany.

ith the topping-out ceremony, FreiLacke

application processes. In future, the concept of

has reached another significant milestone

system coatings can also be taught here in a

in the construction of the new Product

practical manner, as powder and liquid coatings

Technology Centre (PTC). Numerous guests

can be applied at a single location for the first

from the trades, the architectural sector and the

time. This means that technical customer

project team gathered to mark the successful

training courses can be made even more

completion of the structural work.

practical and illustrative.

The event was opened by Managing Director

 First floor: development laboratories for

Dr. Rainer Frei, who emphasised the importance

water-based and solvent-based liquid coatings,

of the new building for the company’s future. The

as well as for PG composite systems.

PTC will form the technical heart of FreiLacke

 Second floor: spacious training and meeting

and bring together state-of-the-art development,

area for customer events, seminars and

application and training facilities under one roof.

professional exchange.

“With this topping-out ceremony, we can look

With its new Product Technology Centre (PTC),

back on a project that has run smoothly so far.

FreiLacke is creating the ideal conditions

The excellent work of the tradespeople, the high

for integrating development, application

quality of the workmanship and strict adherence

technology, product presentation and customer

to the schedule form the basis for our ability to

service even more closely. State-of-the-art

commission our Product Technology Centre as

laboratory and application technology form

planned in spring 2027,” says Dr Rainer Frei. The

the basis for meeting the growing demands

traditional topping-out speech was delivered by

placed on research, development and practical

Mr Lonscha from the structural engineering firm

customer training.

Stumpp in Rottweil, which successfully carried

With this forward-looking investment, FreiLacke

out the structural work.

is strengthening its headquarter in Döggingen

The construction project is now moving on to

and creating a centre of excellence where

the next phase as planned. Work on the interior

customers can experience and test innovative

fit-out, as well as on the façade, windows and

coating solutions under real-world conditions,

doors, began back in July 2026. Completion

and further develop them in collaboration with

of the new Product Technology Centre is

the paint manufacturer’s experts. The PTC was

scheduled for April 2027. The construction

announced as a strategic investment in the

project is therefore on schedule.

future of the company and its customers as

Functional layout for development, application and knowledge transfer

Mr. Lonscha from the structural engineering firm Stumpp in Rottweil bestows his blessing on the building with the traditional topping-out speech.

early as the ground-breaking ceremony. For further information: www.freilacke.de

The three-storey building brings together

development, application technology, product presentation and customer training in a modern working environment:  Ground floor: application technology for powder and liquid coatings using state-of-the-art

N. 101 - SEPTEMBER/OCTOBER 2026 - ipcm®

Micha Bächle, Mayor of Bräunlingen, and Georg Baum, Head of the Local Council, offer their congratulations to the management team at FreiLacke.

BRAND-NEW

EcoPump GW iD – reliable coating application quality for industrial applications Dürr is launching an optimized gear metering pump designed specifically for use with common 1K and 2K coating materials in industrial coating processes. The new pump is designed with a focus on durability, ease of use, and cost efficiency.

he new EcoPump GW iD series is suitable for

opens automatically in the event of overpressure,

a wide range of industrial coating applications

thereby reliably protecting the downstream application

that require precise volumetric delivery of consistent

equipment from potential operating errors and process

amounts of coating. With flow rates ranging from 90

disruptions. Furthermore, the flushable models feature

to 900 ml/min, the pump can be adapted to different

a patented shaft bearing. This significantly extends the

applications as required. In addition, the pump is

pump’s service life, resulting in lower maintenance and

compatible with Dürr’s ready2integrate concept. This

repair costs while enhancing operational reliability.

concept ensures that the control system, metering technology, and applicator are optimally coordinated and delivered as a preconfigured solution. Customers benefit from quick installation, high process reliability, and a solution tailored to their specific requirements.

Reliable paint finish quality and high process reliability

Flexible integration into compact dosing systems

The EcoPump GW iD is part of the Fluid Board2, which combines all the components required for high-precision paint metering within a compact space. This allows the system to be easily and efficiently integrated into painting processes. For existing

To meet the high demands of industrial coating

applications, the pump can also be retrofitted onto

processes, all models come standard with an

the Fluid Board1, offering additional flexibility during

Amorphous Diamond-Like Carbon (ADLC) coating.

upgrades. Furthermore, the new EcoPump GW iD

This coating ensures high durability and helps

is compatible with existing systems and can be

maintain surface quality over the long term.

retrofitted as a standalone component at any time.

For added operational reliability, the EcoPump GW iD is optionally available with a bypass valve. In addition to its pressure-relief function, the valve

For further information: www.durr.com

The EcoPump GW iD is available in various models, such as one with a pressure regulator.

BRAND-NEW

ECKART launches VERSALAN, a next-generation aluminium pigment preparation for efficient and safe processing ECKART presents VERSALAN, a next-generation aluminium pigment preparation designed for efficient and safe processing. Directly dispersible in water without pre-wetting or solvents, the dust-free, low-VOC formulation improves handling and workplace safety. Its classification as non-dangerous goods also simplifies logistics and can help reduce costs.

Efficiency along the value chain

inorganic SiO₂ coating. Building on HYDROLAN® technology, it addresses

wetting and high aluminium content support efficient pigment utilization.

increasing performance, regulatory, and sustainability requirements in

Available in multiple particle sizes, VERSALAN enables metallic effects

modern coating systems.

from intense sparkle to structureless effects. It is suitable for automotive

Delivered as a free-flowing, dust-free powder, VERSALAN enables clean

OEM and refinish coatings, industrial coatings, plastics, UV-curable

handling, precise dosing, and reliable processing, supporting efficient

systems, and processes such as RIM, FIM, and wrapping.

CKART introduces VERSALAN, a next-generation aluminium pigment preparation based on high-purity, flake-shaped pigments with an

production across industries.

Direct dispersibility simplifies processing

Solvent-free transport reduces logistics complexity and costs. Improved

Future-ready technology

Positioned as the successor to HYDROLAN® BG and PG grades,

VERSALAN can be dispersed directly in water without pre-wetting or

VERSALAN is suitable for water- or solvent-borne, UV-curable, and 100%

solvent pre-mixing and can be added at any stage of production. This

systems, combining performance, safety, and sustainability.

reduces process steps, shortens production times, and allows precise adjustments of colour and metallic effects while lowering solvent use.

For further information: www.eckart.net

Clean handling and process reliability

Optimized flow properties and a tailored additive package ensure excellent wetting and improved flowability compared to conventional aluminium pastes. This results in cleaner processes, reduced contamination risk, and consistent product quality. With VOC content below 5% and no classification as dangerous goods, VERSALAN supports safer handling, simplified transport, and regulatory compliance. Low flammability further improves safety and eliminates the need for hazardous-material logistics.

From left to right: Low flammability and dispersible in water or solvents at any stage of production; Structureless effects for coatings; Flake-shaped, dust-free SiO₂ coated powder.

N. 101 - SEPTEMBER/OCTOBER 2026 - ipcm®

BRAND-NEW

Eisenmann GmbH establishes new subsidiary in Poland The company is expanding its international presence in Eastern Europe to strengthen its project and service activities, providing customers with closer support and tailored solutions for local market requirements.

ffective June 1, 2026, Eisenmann GmbH

and neighbouring markets, providing direct and

established a new subsidiary in Rzeszów,

efficient support for project-related activities.

Poland. This new location will further expand

The Rzeszów team also supports Eisenmann

the company’s international presence and

GmbH’s Böblingen headquarters in engineering,

strengthen its activities in the Eastern

project management, and reliably handling spare

European market. Grzegorz Kuter will lead

parts and service requests for the installed base

Eisenmann Poland Sp. z o.o., supporting local

of paint shops in Eastern Europe.

customers and partners and coordinating the

By expanding its corporate presence in the

subsidiary’s activities.

growing Polish market, the Eisenmann Group is

The on-site Eisenmann Poland Sp. z o.o.

pursuing sustainable growth and strengthening its

team of ten has many years of experience in

position as a reliable partner in the international

plant engineering, particularly in conveying

coating industry.

systems. They serve as a local point of contact for customers and partners in Poland

For further information: www.eisenmann.com

www.heliosquartz.com

Grzegorz Kuter will lead Eisenmann Poland Sp. z o.o.

BRAND-NEW

TAP Air Portugal advances fleet efficiency with lighter aircraft coating technology from AkzoNobel Aerospace Coatings Fleet-wide rollout of lighter basecoat technology from AkzoNobel is expected to help TAP Air Portugal save approximately 428 tonnes of fuel and reduce CO2 emissions by around 1,353 tonnes annually. application enhancements designed to improve film build control, sag resistance and process repeatability in real-world paint shop operations. Using a validated cross-coat application technique, the Aerobase UPD enables the required hiding power and finish quality to be achieved through a single basecoat application cycle, eliminating the need for a second full basecoat layer and associated flash-off stages. In addition, the simplified application process also delivers operational productivity benefits for applicators by removing one whole paint cycle. The enhanced formulation also delivers approximately 40% greater sag resistance compared with the traditional two-layer system, helping improve consistency and repeatability across varying operational paint shop conditions and applicator experience levels. “At TAP Air Portugal, we continuously evaluate opportunities to improve © AkzoNobel Aerospace Coatings

operational efficiency and reduce environmental impact across our operations. The results achieved through this collaboration with

AkzoNobel Aerospace Coatings demonstrate how relatively small kzoNobel Aerospace Coatings and TAP Air Portugal have

weight reductions, when applied consistently across aircraft fleets,

successfully completed operational trials of a lighter aircraft

could contribute to meaningful long-term fuel and emissions savings,

basecoat technology that can reduce coating weight by up to 26 kg per

while also supporting operational efficiency,” has stated João Carvalho,

aircraft, supporting the airline’s ongoing focus on operational efficiency,

Structures Engineer at TAP Air Portugal.

fuel savings and lower emissions.

“This program with TAP Air Portugal demonstrates how incremental

The trials, carried out using AkzoNobel Aerospace Coatings’ Aerobase

innovations in coating technology can deliver measurable operational

UPD formulation, demonstrated that the system can reduce total

benefits and emissions savings for airlines. By reducing total film build

basecoat film thickness by 36% compared with a traditional two-coat

and simplifying the application process, Aerobase UPD helps operators

application process, while maintaining the durability, appearance and

lower aircraft weight, improve paint shop productivity and maintain the

finish quality standards required for commercial aviation operations.

high-quality finish standards required across commercial aviation fleets.

Field testing on a TAP Air Portugal A320 aircraft achieved a 24kg weight

The aviation industry is focused on identifying practical opportunities

reduction. Following these results, a second A320 has also been recoated,

to improve efficiency and reduce emissions, and coatings technology

with rollout plans being put in place to extend the lightweight basecoat

can play an important role in supporting those wider sustainability

across the fleet.

ambitions,” has added Aurore Bournazel, Segment Manager OEM, MRO &

Based on projected fleet-wide implementation, the lighter coating

Airlines at AkzoNobel Aerospace Coatings.

technology is expected to contribute to annual fuel savings of

Aerobase UPD is certified to AMS3095 standards for global mixed-

approximately 428.5 tonnes, resulting in annual cost savings of more than

fleet MRO operations and integrates with the upgraded Aerobase

half a million euros and an estimated reduction of approximately 1,353

activator and existing Aerobase hardeners, enabling straightforward

tonnes of CO2 emissions.

implementation within existing paint shop processes.

Aerospace Coatings’ proven Aerobase platform through formulation and

For further information: https://aerospace.akzonobel.com/en

The Aerobase UPD formulation used in the trials builds on AkzoNobel

N. 101 - SEPTEMBER/OCTOBER 2026 - ipcm®

ADVANCEMENTS

From formulation data to development intelligence Marc Egelhofer LabV Intelligent Solutions GmbH, Selb - Germany marc.egelhofer@labv.io

Why coatings R&D needs connected data, structured workflows, and AI-supported formulation development.

deally new formulation projects start from what a company has

historical data or making decisions without a clear view of past results is

already learned through years of R&D work. Yet while everyone

no longer viable.

is talking about AI, many R&D teams face a more basic problem:

The question is not whether enough data exists, but whether this data

Formulations, reports, measurement exports, project decisions, and

can be used. This is where Material Intelligence comes in: it connects

process notes are stored across Excel files, PDFs, local folders, instrument

data, workflows, and AI so that existing R&D knowledge can be searched,

exports, ERP systems, notebooks, and archives. Some data is highly

compared, and applied in development decisions. Only when data is linked to

relevant, some is outdated, and some can no longer be understood

the workflows in which decisions are made can AI create real value (Fig. 1).

without the person who created it. As a result, teams may repeat trials, overlook useful formulation building blocks, or spend too much time searching. Even Artificial Intelligence (AI) can add no value if the underlying

When existing knowledge becomes hard to reach

A recent anonymised implementation at a medium-sized coatings

data is not structured, reliable, and accessible.

manufacturer shows how scattered formulation data can be turned into

This is a competitive disadvantage for R&D teams in the coatings industry.

a structured, usable knowledge base. The manufacturer had built up a

Customers expect faster development cycles, higher performance,

large base of more than 8,000 recipes. However, data were distributed

more sustainable solutions, and reliable documentation. Raw material

across Excel spreadsheets, PDF reports, local drives, instrument files,

availability can change quickly and regulatory pressure continues to

and individual project documentation. In total, the available information

increase. At the same time, experienced formulation specialists are

represented more than 30,000 data points. Yet the development

retiring, taking with them knowledge that is not always captured in a

team could not see which formulations were current, which had been

structured way. In this environment, spending hours locating relevant

successful, which variants had failed, or which raw materials had already been tested under similar conditions. © LabV

The issue was not a lack of knowledge, but the lack of a structure that made this knowledge usable in daily development work. As the company’s head of formulation development put it: “We already had the knowledge, but it was spread across thousands of files. Only when we created a central structure did it become truly usable.” The consequences were familiar to many R&D organisations: developers spent up to 1 hr every day just looking for previous experiments and similar formulations. Variants were sometimes tested more than once because earlier results were not found. Relationships between formulation parameters and performance properties, such as gloss, density, viscosity, or behaviour on critical substrates, were difficult to identify. The challenge was that information was fragmented across the organisation and hard to utilise when developers had to make decisions. For the company, the goal was to make existing know-how easier to find, to compare and to reuse in future development projects.

N. 101 - SEPTEMBER/OCTOBER 2026 - ipcm®

ADVANCEMENTS

Fig. 1 (left) - Material Intelligence connects material, process, and measurement data with R&D workflows and AI functions such as data search, data analysis, and predictive AI.

Fig. 2 (right) - Full device integration connects rheological, physical, stability, compatibility, analytical, and chemical testing with enterprise systems and databases, enabling automated data import and reuse in formulation development.

Building a foundation for Material Intelligence

had been selected or rejected. The reasoning behind decisions will remain

To address this challenge, the company introduced in its R&D department

accessible even years later, for example when projects change hands or

a Material Intelligence platform. The implementation was designed around

experienced specialists retire.

three connected foundations: data, workflows, and AI. Rather than treating these as separate digitalisation projects, the company brought them

Step 3: AI-supported development

together in one environment.

With structured, trustworthy, and context-rich data in place, artificial intelligence can begin to support formulation development. Instead of

Step 1: creation of a central and harmonised data basis

searching through spreadsheets, reports, and historical folders, developers

Existing sources such as Excel formulations, PDF evaluations, analysis

could query their R&D data directly.

results, measurement files, and ERP information were structured.

The AI assistant helped the formulation specialists to trace previous

The software connected to the company’s existing data landscape, from

formulation issues, compare similar projects, and identify raw materials or

legacy spreadsheets and PDF archives to laboratory instruments, analysis

process conditions that had already delivered the required performance.

data, and ERP-related information such as the price of raw materials.

It also turned relevant findings into visualisations, making relationships

Measurement and process data could be imported automatically,

visible that would otherwise have remained buried in individual reports.

standardised, and made available to the formulation team without

This did not mean handing formulation decisions over to an algorithm. The

additional manual transfer into spreadsheets. Figure 2 shows how this

system acted as an assistant, not as a replacement for expert judgement.

integration can include laboratory testing devices, enterprise systems, and

It helped reach relevant information faster, explore possible formulation

databases within one connected R&D data environment.

routes, and understand why certain suggestions might be worth testing.

This changed the daily formulation work. R&D data were no longer isolated

The final decision remained with the formulation experts.

in different formats or locations. Instead, they became available where they were needed: in the laboratory, during evaluation, and in project steering. Existing formulations could be compared more reliably, and new

From trial-and-error to smarter experimental planning Design of Experiments (DoE) is already used in many development

projects could start from a clearer view of what had already been tried.

environments to structure experimental R&D work. It helps define test

Historical data became a source of orientation for development questions.

plans, compare variables in the formulations, and reduce the number of

A recipe from a previous project could be assessed not only as an isolated

random trials. However, traditional DoE also has its limitations: It requires

record, but in relation to the measurements, raw materials, test conditions,

teams to define the relevant variables, levels, and ranges before the

and decisions connected with it.

experiments begin. If those assumptions are incomplete, the plan may explore a part of the formulation space that is not promising. In addition,

Step 2: workflows

classical DoE is usually not adaptive: even when early results point in a

The formulation process was digitally structured from the project request

different direction, the team may still need to continue with a predefined

or order definition through to final evaluation. Tasks, requirements,

test matrix. In complex coating formulations, where many components

measurement results, test standards, notes, and decisions were

interact, this can consume unnecessary time and resources.

documented in one place. This gave project participants a clear view of

This is where AI-supported methods such as predictive modelling and

their R&D projects and made it easier to trace why a formulation route

Bayesian optimisation can accelerate formulation development. Early

ipcm® - SEPTEMBER/OCTOBER 2026 - N. 101

ADVANCEMENTS

validation work at LabV indicates that AI-

access all 30,000 data points through a central,

from distributed files to a central structure,

based prediction can support formulation

filterable database. Information that previously

and transparency around decisions increased

decisions when the underlying data is

required hours of searching could be found in

significantly.

sufficiently structured and contextualised.

seconds using filters or AI-supported search.

The structured data basis also improved

While detailed performance data cannot yet

In practice, this translated into 66% less data

knowledge transfer. Findings, relationships,

be disclosed, the direction is clear: Instead of

search effort, as teams gained direct access to

and decisions were no longer tied as strongly

treating an experimental plan as fixed, AI-

all relevant information.

to individual employees or informal handovers.

supported optimisation could use incoming

The company also reported 30% fewer

They now remained accessible even when

results to refine the next steps and prioritise

iterations, as developers could draw on

projects changed hands or experienced

the experiments most likely to generate

historical results instead of restarting from

specialists left the company. For an R&D

useful information. For coatings R&D, this is

scratch. Relevant historical approaches were

team facing generational change, this is more

particularly relevant because changing one

easier to identify and connections between

than an efficiency gain. It is a way to preserve

parameter can affect multiple properties such

parameters and target properties became

formulation knowledge as a strategic asset.

as viscosity, application behaviour, drying,

transparent. Repeated trials were reduced

cost or raw material compatibility. The long-

because previous experiments became

term goal is not to replace expert judgement,

easier to find and understand. Alternatives

but to combine historical knowledge, DoE,

could be identified more quickly when raw

actually used by the people making formulation

and AI-supported optimisation in an adaptive

material substitutions or changing customer

decisions. For this reason, usability is an

development process, shortening the path from

requirements created the need for new variants.

important factor. A clear interface, intuitive

question to first trial, and eventually from first

Documentation effort was also reportedly

navigation, and limited training effort made it

trial to target formulation.

reduced by 50% through automated data

easier for the R&D team to adopt the software

The implementation described here represents

transfer and report generation. Team

in daily work. Because relevant information,

an important step toward that goal. Its

discussions also became more factual

project context, and AI-supported functions

immediate value was not yet fully automated

because information could be consolidated

were accessible in one environment, developers

optimisation, but the creation of a structured

and visualised rather than reconstructed from

could see the value without adding unnecessary

data foundation that made existing formulation

separate files (Fig. 3).

complexity to their routines. For the team, the

knowledge searchable, comparable, and usable

Operational indicators reflected the shift. The

software was useful because it made their

in daily R&D work.

average time to the first approved formulation

own expertise easier to apply. It helped them

fell from 10 to 14 days to 4 to 6 days. Reused

find relevant information, compare options,

formulation building blocks increased from less

and prepare decisions, but the final judgement

than 10 percent to more than 50 percent. The

remained with the formulation specialists.

After more than 8,000 formulations had been

time required for experimental planning dropped

As one project manager summarised: “The

structured and harmonised, the R&D team could

significantly. Project documentation moved

platform does not work against us, but with

From structured data to measurable R&D gains

The human role remains central

Digital tools only create value in R&D if they are

us. It thinks along with us, but it leaves the decisions to us.” This matters in coatings R&D. Formulation development remains a specialist discipline shaped by chemistry, application experience, material behaviour, customer requirements, and practical judgement. Digital tools are most valuable when they make this expertise more effective. In this implementation, the software brought formulation data, project workflows, resources, and analysis functions into one © LabV

environment, while existing specialist systems and human decision-making remained central.

Fig. 3 - Structuring and harmonising formulation data led to measurable R&D gains, including 30% fewer iterations, 50% less documentation effort, and 66% less time spent searching for data.

N. 101 - SEPTEMBER/OCTOBER 2026 - ipcm®

Following the successful implementation, the platform is being expanded to additional sites.

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Conclusion: from scattered data to reusable knowledge

The example shows that the main challenge in many coatings laboratories is not a lack of data, but the lack of a usable structure around it. Formulations, test results, raw material information, process parameters, and project decisions only become valuable when they can be connected, searched, compared, and understood in context. Material Intelligence provides this structure by bringing together data, workflows, and AI-supported analysis in one environment. In the described implementation, this changed daily R&D work in concrete ways: historical results became easier to reuse, documentation effort was reduced, data search became faster, and formulation decisions could be discussed on the basis of consolidated information rather than scattered files. For coatings manufacturers, this is becoming increasingly important. Development cycles are getting shorter, formulations are becoming

more complex, and experienced specialists are leaving organisations

with knowledge that is not always fully documented. A structured

Material Intelligence approach helps preserve this expertise while

making it usable for current and future teams.

The long-term relevance goes beyond efficiency. Once formulation knowledge is structured and contextualised, AI can support more than search. It can help identify patterns, support decision-making, and eventually guide experimental planning through prediction and optimisation. In this sense, the path toward AI-ready coatings development starts not with an algorithm, but with making existing

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FOCUS ON TECHNOLOGY

Verniciatura Rosa’s new powder coating booth blends experience with automation Monica Fumagalli ipcm® © ipcm

The new Gema booth installed at Verniciatura Rosa, a company specialising in contract powder coating, reduces colour change times to around 90 seconds and, thanks to its dual-tank system, it enables the simultaneous use of virgin and recovered powder, reducing downtime. This investment has increased the line’s flexibility and supported the development of the skills required to manage increasingly automated coating systems.

n a coating line, not everything that determines process outcomes is set in a programme or displayed on the

touch screen. Part of that expertise still lies in the experience of those who, after decades in a coating shop, can recognise an anomaly from the behaviour of the powder, adjust a hook to suit the workpiece, or determine which component caused a production stoppage. But what happens when this generation of operators gradually gives way to technicians and coaters who have grown up in less specialised contexts, particularly in increasingly automated and digital production environments? The answer does not seem to be to replace experience with technology, but rather to transfer the knowledge gained in production while, at the same time, building new skills to manage increasingly complex systems. This is the path chosen by Verniciatura Rosa Srl, a family-run business specialising in contract powder coating, based in Ronco Briantino (Monza e Brianza, Italy).

FOCUS ON TECHNOLOGY

Top view of the 6-stage pre-treatment tunnel installed at Verniciatura Rosa.

The interior of the shot blasting machine.

After almost forty years of upgrading and developing its facilities, it now

with the evolution of the manufacturing market by adapting its expertise,

faces a workflow characterised by a wide variety of components and

production organisation, and plant engineering solutions. In its early days,

frequent colour changes, a common denominator among contractors,

it operated primarily in the lighting sector, which has since shrunk, in part

where flexibility is a daily requirement that calls for minimising downtime

due to growing competition from imported products. Over the years, its

without compromising finishing quality. This is where automation

production has gradually shifted towards metalworking and parts for

becomes critical to maintaining its line’s ability to adapt to different

various industrial applications. This journey has led it to venture into

batches, introducing technologically advanced management methods that

different markets, including the construction sector more recently, and to

operators must learn to understand and interpret.

offer an increasingly diverse range of processes, creating a need for plant

Verniciatura Rosa’s recent investment in a new Gema coating booth,

solutions capable of keeping pace with this evolution.

equipped with an innovative powder centre, fits precisely within the

“Right from the start, we have focused on implementing the most

balance among production flexibility, automation, and skills. Its goal was

advanced technologies, combining traditional methods with modern

to make the management of colour changes and powder recovery more

innovations,” says Monica Rigamonti, one of the three owning partners.

streamlined and flexible, and to reduce the downtime associated with

“We specialise in coating a wide range of steel and aluminium

set-up operations; however, this technological solution did not diminish the

components, placing great emphasis on both the aesthetic appearance

value of experience: it transformed it, requiring operators to acquire new

and the durability of every coating we apply. Every stage of the process is

skills in order to fully leverage its potential.

monitored with the utmost precision, from surface preparation to powder

Verniciatura Rosa: where experience meets innovation

application. We use only certified and sustainable products, mindful of our responsibility towards the environment.” Over time, business growth

Founded in 1985 in the same industrial area where it operates today,

has also necessitated an expansion of Verniciatura Rosa’s premises: the

Verniciatura Rosa, currently managed by three partners, has kept pace

production areas have been supplemented by additional buildings for

ipcm® - SEPTEMBER/OCTOBER 2026 - N. 101

FOCUS ON TECHNOLOGY

warehousing, reflecting the company’s expansion and the increase in

make full use of all the hooks.” Admittedly, this change has also resulted in

volumes handled over the years.

a different balance of consumption. “With the bell oven, gas savings were

Plant engineering evolution

greater, but with the direct-fired one, we have gained space and improved the continuity of our handling process.”

The growth in production requirements has led the company to gradually

Verniciatura Rosa has also recently insourced its hook paint stripping and

expand its range of services, complementing powder coating with

cleaning operations by installing a thermal paint stripping system, also

additional processes such as shot blasting. “In 2008, during the economic

supplied by Silvi.

crisis, many customers chose to renovate rather than replace items such as gates and railings. We therefore installed a shot blasting machine so we could carry out the mechanical preparation of metal structures in-house,” indicates Monica Rigamonti.

Flexibility in colour changes: a new production requirement

While in the past the company’s production could be organised around

The evolution of the workflow has also affected the line’s configuration.

a relatively stable colour schedule, the evolution of the markets it serves

One of the most significant changes concerned the oven, which is used

has gradually made management far more complex. “I started out as a

both to dry parts after the 6-stage chemical pre-treatment process and to

coater specialising in chrome plating,” says Oliviero Biella, the founder

cure paint at 200 °C. “In collaboration with Silvi Srl, a company based in

of Verniciatura Rosa. “When I set up this business forty years ago, our

Lesmo (Monza e Brianza) specialising in the design and construction of

main target market was the lighting industry, where 80% of requests

complete lines for the pre-treatment and coating of metals and plastics,

were for white, black, or white with shades of blue. Our production

we replaced our bell-type oven, which took up considerable space and

schedule therefore allocated the first three days of the week to white,

limited our layout options, with a direct-fired oven.”

and Thursdays and Fridays to the other colours, which we handled in two

The new layout has also enabled Verniciatura Rosa to increase the

separate booths.”

maximum length of the parts it can coat. “The bell-type oven’s entrance

Today, the market has changed profoundly, particularly in the architecture

configuration forced us to change our standard pitch between hooks for

and design sectors, where surface finishes are increasingly seen as

vertical handling: out of 250 hooks, we could lose as many as 20. With the

integral to projects intended to be unique, and requests for specific colours

new oven, however, the parts are handled in a continuous flow, and we can

can vary even within the same order. For a coating contractor, this means

Top view of the new Gema coating booth.

N. 101 - SEPTEMBER/OCTOBER 2026 - ipcm®

Close-up of the monorail conveyor.

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FOCUS ON TECHNOLOGY

dealing on a daily basis with a much wider colour range and the need to switch quickly from one job to another, minimising downtime associated

Features of the new Gema booth

The coating booth installed at Verniciatura Rosa is equipped with 6 spray

with colour changes.

guns on each side and features one pre-finishing and one post-finishing

In response to this development, Verniciatura Rosa has progressively

manual station. It can process components up to 2 m in height, 0.9 m in

invested in Gema technology. “We installed our first Gema booth a few

width, and 3 m in length. At the heart of the new system, however, is the

years ago and were very pleased with it: we were able to complete a colour

powder coating centre. “The OptiCenter All-in-One OC11 is the first powder

change in 8 minutes. With the new booth, we have taken a further step

management system to combine electrostatic and feeding technology in

forward, completing a change in around 90 seconds.” The new booth,

a single, highly compact unit,” explains Gianluigi Baroni, sales director at

which uses dense-phase application technology, has also increased the

Gema Powder Coating. “It is equipped with two OptiSpeeder containers

line’s operational capacity, enabling the processing of longer workpieces.

(DualSpeeder), combined with the latest OptiSpray All-in-One pumping

The investment was made possible in part by incentives under the

technology, which integrates advanced loading technology with the

Italian government’s Transition Plan 5.0, which supported the company’s

second generation of SIT dense-phase powder feeding technology. The

adoption of the new technology.

two containers allow two distinct colours to be applied in succession, enabling extremely rapid colour changes. The OptiCenter system also

The coating booth was installed in 2025.

The interior of the booth, with 6 spray guns on each side.

ipcm® - SEPTEMBER/OCTOBER 2026 - N. 101

FOCUS ON TECHNOLOGY

utilises MultiColor Switch technology, which enables rapid switching between OptiSpeeder containers and ensures a particularly clean colour

An experienced user’s opinion

“Coating quality has improved significantly, and we have considerably

change between alternating colours.”

reduced cycle times,” says Biella. “One advantage we have found is the

One of the key features of the OptiCenter All-in-One OC11 is its ability

ability to manage recovered and virgin powder separately. The first spray

to use both powder containers simultaneously. “The system allows

guns can use recovered powder, and the next ones use fresh powder. In

simultaneous, independent application, using only virgin powder from

this way, any minor imperfections that may arise from the first application

one container and a mixture of virgin and recovered powder from the

phase are covered by the subsequent spray guns, resulting in improved

other. Virgin powder is used on surfaces requiring a ‘class A’ finish, while

aesthetics.” The ability to manage the two powders separately was one

recycled powder can be used on areas that are less critical from an

of the factors Verniciatura Rosa considered when choosing its new

aesthetic point of view. Verniciatura Rosa found this feature particularly

powder coating centre. “With our previous system, we had already devised

appealing, as it allows powder usage to be managed according to varying

a solution to use recovered powder with the first spray guns and new

quality specifications, reducing waste while meeting the required finish

powder with the subsequent ones: with Gema’s plant system, we can

standards.”

manage this process directly via the two tanks.” Another aspect appreciated by the company’s technical team is the

The booth is equipped with pre- and post-finishing stations.

N. 101 - SEPTEMBER/OCTOBER 2026 - ipcm®

The two OptiSpeeder containers.

ability to adjust the line’s operating conditions to meet maintenance requirements. “We reported to Gema an issue with the proximity between the oven and the booth, which tended to cause powder to cure on the booth floor. We suggested a solution to make cleaning easier, and its technicians stepped in to adapt the system. This is important because the more build-up there is, the greater the risk of dirt being carried along, and Gema understood this immediately.” In addition, the system offers a feature that, although Verniciatura Rosa currently uses it only to a limited extent, can be utilised more fully in the future: the option to use the two containers with the

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same powder. Having a larger quantity of product already available reduces the need for refilling during prolonged production runs and, consequently, minimises downtime. “The system signals when the powder is running low, allowing operators to top it up. For us, this

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The cyclone.

More Information:

FOCUS ON TECHNOLOGY

is also an advantage because there are always two highly skilled and

interchangeable operators working on the line, who can organise and take turns.” The technology, therefore, does not replace the operators’ experience but enables it to be utilised more effectively: automation provides new tools for managing powder, reducing downtime, and maintaining consistent quality even in a production process characterised by frequent colour changes.

Growth built on people

Forty years in business have required Verniciatura Rosa to adapt constantly, not only in its equipment and the services it offers, but also in how it manages its workforce. This change is particularly evident in the relationship with the most experienced operators, who are used to intervening directly on the plant to resolve faults. “Thanks to the experience gained over the years with the previous technology, we had become accustomed to stepping in personally because we knew every single detail of how it worked. With this technology, we can no longer do that, because automation has introduced a different approach to production: practical experience remains fundamental, but it must be complemented by the ability to interpret more complex systems, understand how they work, and identify the causes of faults without always having to resort to direct intervention on the plant.” This is yet another aspect of the transformation of skills that is currently accompanying the technological evolution of industrial coating. Today, Verniciatura Rosa is also investing in generational renewal by bringing new staff into production. This is a necessary step in a company where some of the experience gained over the years must be gradually passed on to younger generations. “As some of our staff are approaching retirement, we have started to take on new personnel. It is important that they gain experience and get to know the line.” This is perhaps the most significant achievement over forty years in business: the ability to evolve without losing the wealth of knowledge accumulated through production. Technology can increase flexibility and improve process management, but its value also depends on people’s ability to understand how it works, adapt it to specific production needs, and turn the experience gained over time into new skills.

N. 101 - SEPTEMBER/OCTOBER 2026 - ipcm®

The air extraction system.

101 AND BEYOND...

FILTRATION QUALITY - CUSTOMIZATION - INNOVATION

HIGHLIGHT OF THE MONTH

100 years of FreiLacke: a look back and key milestones Interview with Dr. Rainer Frei Managing Director at FreiLacke – Emil Frei GmbH & Co. KG., Bräunlingen-Döggingen - Germany

ince 1926, FreiLacke has been developing innovative paints and

milestones that have shaped its development, as well as its approach to

coatings for a wide range of industrial applications. Today, the

innovation, sustainability and the challenges facing the coatings industry.

third-generation family-run company employs more than 650

He also explains how FreiLacke combines its long-standing family-

people at its headquarters in Döggingen, in Germany’s Black Forest,

business tradition with continued investment in technology, its people and

and serves customers worldwide through an international network of

future-oriented solutions — including the new Product Technology Centre

subsidiaries and partners. Its product range covers the entire spectrum

scheduled to open in spring 2027.

from industrial coatings, powder coatings and electro-deposition coatings

FreiLacke’s commitment to its people has also been recognised in 2026

to composite solutions, with customised coating systems developed for

with several Great Place to Work® awards, including ‘100 Best Employers in

sectors including vehicle manufacturing, wheels, mechanical and plant

Germany’ and ‘Best Employers in Manufacturing & Industry 2026’, as well as the

engineering, rail vehicles, wind power and functional furniture.

‘Great Start’ award for its apprenticeship training. With trainees and students

As FreiLacke celebrates its 100th anniversary in 2026, ipcm® spokes with

accounting for around 8–10% of its workforce, the company continues to invest

Managing Director Dr. Rainer Frei about the company’s history and the

strongly in developing the next generation of skilled professionals.

FreiLacke has already received several awards from the Great Place to Work® Institute. © Emil Frei GmbH & Co. KG

HIGHLIGHT OF THE MONTH

Dr. Frei, FreiLacke can look back on a century of company history – an

development. For us, this means fostering long-term relationships with

extraordinary milestone that your company is celebrating this year.

staff, customers and suppliers, continuously improving our processes and

What has been your personal highlight?

using resources responsibly.”

Dr. Rainer Frei: “My personal highlight is meeting with customers, our staff, suppliers and business partners. Our centenary has impressively

FreiLacke is regarded as a highly innovative company in the coatings

demonstrated that our success and our continuous growth are the result

industry. Which current product developments or technological

of a trusting and long-term partnership. Together, over the years, we have

innovations do you currently regard as particularly ground-breaking –

built a strong foundation on which we can look back with pride today –

and in your view, how do these solutions differ from the competition?

and which, at the same time, motivates us to shape the future together.”

“From our perspective, it is above all customised and application-oriented coating solutions that are leading the way. Our focus is on working with

Longevity is about thinking long-term – from the lifespan of products

our customers to develop solutions that are optimally tailored to their

and the responsible use of resources to the health of employees and

specific requirements and processes. In doing so, we support them

customers. What role does this approach play at FreiLacke, and what

throughout the entire customer journey – from the initial consultation,

specific initiatives are you pursuing to promote long-term value creation

through development and sampling, right through to series production.

and sustainability?

Another key area of focus is on process-reliable system coatings,

“As a medium-sized family-run business with a long history, we have

where different coating systems can be combined in horizontal or

traditionally been a values-driven company. Acting in a responsible manner

vertical configurations. This allows the respective strengths of the

with a long-term perspective has always been part of our corporate

individual systems to be utilised in a targeted manner and tailored to the

identity. In doing so, we take economic, environmental and social aspects

requirements of the application.”

into account and gear our decisions towards sustainable corporate FreiLacke has its headquarters in Döggingen-Bräunlingen in the Schwarzwald-Baar district. © Emil Frei GmbH & Co. KG

ipcm® - SEPTEMBER/OCTOBER 2026 - N. 101

HIGHLIGHT OF THE MONTH

For many years, FreiLacke has stood for high quality and technical

development and our manufacturing processes.

expertise in the coatings industry. In your opinion, what particular

What sets FreiLacke apart is the high standard of training, a strong

strengths or unique selling points distinguish FreiLacke products? Why

focus on performance and long-standing service with the company.

do customers consciously choose your company?

This combination of experience and specialist knowledge creates a solid

“From our perspective, customers choose FreiLacke because they see

foundation for preserving tried-and-tested methods whilst simultaneously

us as a reliable partner for comprehensive coating solutions. In addition

driving new ideas forward. We do not view tradition and a spirit of

to the high quality of our products, they particularly value our customer-

innovation as opposites, but rather as complementary. Our roots provide

focused approach, our high level of delivery reliability and the technical

direction, whilst continuous investment creates the conditions for future

expertise of our contact persons.

success. A current example of this is the construction of our new Product

Furthermore, we place great importance on close, partnership-

Technology Centre, which is scheduled to open in spring 2027. The

based collaboration. We aim to gain a thorough understanding of our

three-storey building brings together development, application technology,

customers’ requirements and to support them with our know-how in

product presentation and customer training, thereby offering the ideal

the development and implementation of suitable coating solutions. In

conditions for conveying the concept of system coatings in a practical

our view, this combination of product quality, personalised support and

way, as powder and liquid coatings can be applied together at a single site

technical expertise forms the basis for long-term, trust-based customer

for the first time.”

relationships.” In light of the growing shortage of skilled workers: What importance The company has continued to develop successfully over generations.

do training and the promotion of young talent hold at FreiLacke, and

What role do your employees and the corporate culture play in this, and

what measures do you employ to attract and retain young talent for the

how do you manage to combine tradition with a spirit of innovation?

company in the long term?

“Our staff are the key factor in the continued success of FreiLacke. That

“Training and nurturing young talent is a top priority at FreiLacke.

is why we make targeted investments in their training and personal

With trainees and students making up around 8 to 10 per cent of our

development – as well as in modern technologies, new product

workforce, we are consciously investing in our own future talent and

The opening of the new Product Technology Centre is scheduled to take place in spring 2027. © Schmelzle+Partner MBB Architekten BDA

HIGHLIGHT OF THE MONTH

laying the foundations for long-term staff development. We offer a wide

partnerships throughout the entire value chain form the basis for us

range of career opportunities and interesting roles within an innovative,

to overcome challenges together and capitalise on opportunities.

internationally active family-run business. At the same time, we place

Strategically, we will continue to focus on quality, cost-effectiveness,

great emphasis on a customer-focused and employee-oriented corporate

delivery performance and service. At the same time, we take sustainability

culture that promotes personal responsibility, collaboration and personal

considerations into account as part of our corporate and product

development. Through employee surveys conducted by the internationally

development and are continuously refining our solutions. Furthermore,

active institute Great Place to Work®, the working culture and positive

we see further internationalisation and a consistent focus on customer

team spirit at FreiLacke are regularly recognised with the accolade of

benefit as key areas of action for the future. Our aim is to continue

being named one of the best employers. We are very proud of this and

supporting our customers as a reliable partner with high-performance and

see this recognition as an incentive to continuously develop our corporate

application-oriented coating solutions.”

culture further.” The paint and coatings industry is heavily influenced by global developments such as supply chains, raw material prices and regulatory requirements – most recently felt acutely in connection with the Strait of Hormuz, for example. How does FreiLacke address these challenges, and which strategies have proved particularly effective in this regard? “Global developments such as volatile commodity markets, geopolitical uncertainties and increasing regulatory requirements present challenges for the entire industry. This makes it all the more important to identify these issues at an early stage and to act proactively in collaboration with our partners. A key component of our strategy is close cooperation with our strategic suppliers. We maintain long-term, trust-based partnerships that have proven their worth both in the joint development of forwardlooking solutions and in ensuring a reliable

GA 1

supply. Furthermore, we rely on continuous dialogue throughout the entire value chain so that we can respond flexibly to changing conditions and provide our customers with reliable support, even in challenging times. Looking ahead to the future: What strategic priorities and technological developments will be crucial to ensuring that FreiLacke remains successful well into the next century? “Our future success will continue to depend largely on working together with our customers, suppliers and other partners on a longterm basis and in a spirit of trust. Fair Dr Rainer Frei, now leading the company into its third generation.

ipcm® - SEPTEMBER/OCTOBER 2026 - N. 101

FOCUS ON TECHNOLOGY

Greenfield Engineering: raising the bar in powder coating – a strategic investment in quality, consistency and sustainability Edited by J. Wagner GmbH Markdorf, Germany

neil.bourne@wagner-group.com

Greenfield Engineering has transformed its entire powder coating operation by investing in WAGNER’s advanced automation and IPS technology, boosting consistency, efficiency and sustainability in a high-mix manufacturing environment.

reenfield Engineering continues to strengthen its position as one of the UK’s leading contract sheet metal manufacturing businesses through

significant investment in advanced manufacturing technology. Operating from more than 80,000 sq ft (approximately 7,430 m²) of production space located across two facilities in Holsworthy in the South West region of the UK, the company provides precision sheet metal fabrication, powder coating, assembly and integrated manufacturing solutions to customers operating across a wide range of sectors including furniture, lighting, laboratory equipment, transport, electronic enclosures and industrial technology. As customer expectations continue to evolve, Greenfield Engineering recognised the need to modernise a powder coating facility that had served the business reliably for more than 25 years.

Greenfield Engineering is one of the UK’s leading contract sheet metal manufacturing businesses. The company provides sheet metal fabrication, powder coating, assembly and integrated manufacturing services for customers across a wide range of industries.

N. 101 - SEPTEMBER/OCTOBER 2026 - ipcm®

FOCUS ON TECHNOLOGY

The new powder coating line at Greenfield Engineering, with IPS powder centre (on the right side), S-Cube booth and recovery system.

While the existing plant had supported many years of successful

implemented a complete line modernisation incorporating a fully

production, increasing product complexity, growing customer

automated five-stage pre-treatment process, advanced drying and curing

requirements and the company’s wider investment in advanced

ovens, new conveyor systems, intelligent powder recovery technology,

manufacturing technologies highlighted the opportunity to create a

and state-of-the-art powder application equipment. Installation was

finishing facility capable of matching the standards achieved throughout

completed during late 2025, with production commencing in January

the rest of the business. The result is one of the most advanced powder

2026.

coating installations in the UK, delivered in partnership with TD Finishing and WAGNER.

Creating a future-proof finishing operation

Why WAGNER?

Selecting the right technology partner was a critical part of the project. Following a detailed review of available systems, Greenfield Engineering

The powder coating project forms part of a wider programme of

selected WAGNER’s latest generation IPS powder application technology,

strategic investment across Greenfield Engineering’s manufacturing

supported by the company’s established UK presence and after-sales

operations. Recent investments have included fibre laser cutting

support infrastructure. “This project was not simply about replacing

technology, automated punching systems, robotic bending solutions,

equipment,” Director Daniel Green commented. “It was about creating

advanced quality assurance equipment, renewable energy generation

a future-proof finishing operation capable of supporting increasing

and digital manufacturing systems. The objective was clear: create a

customer expectations, greater product complexity, and our long-term

powder coating operation capable of delivering exceptional finish quality,

growth plans. WAGNER’s commitment to the UK market, combined with

repeatability and efficiency while supporting future growth. Frank Green,

the capabilities of the IPS platform and strong after-sales support, made

Founder of Greenfield Engineering, explains: “Our customers expect

the solution a natural fit.”

consistently high standards. We wanted a process that delivered the

The installation includes WAGNER’s S-Line automatic powder coating

same high-quality finish every time, regardless of operator experience.

system with S-Cube booth technology, designed specifically for

This investment establishes the benchmark for the future of our finishing

manufacturers operating high-mix production environments where

operations.” Working alongside TD Finishing and WAGNER, Greenfield

flexibility and efficiency are equally important.

ipcm® - SEPTEMBER/OCTOBER 2026 - N. 101

FOCUS ON TECHNOLOGY

Built for high-mix manufacturing

utilisation without the need for manual programming. The system also

One of Greenfield Engineering’s key requirements was the ability to

recognises gaps between components and automatically disables

manage frequent colour changes while maintaining productivity and

powder delivery when no product is present, reducing unnecessary

finish quality. With more than ten colour changes regularly occurring

powder consumption and improving overall process efficiency. For

during a shift, minimising downtime was essential. The self-cleaning

Greenfield Engineering’s high-mix manufacturing environment, this

S-Cube booth technology significantly reduces cleaning times,

technology delivers consistent coating thickness across a wide variety

enabling rapid transitions between colours while maintaining stable

of product shapes while minimising overspray and reducing waste.

airflow conditions and consistent coating performance. The system incorporates twelve automatic PEA-X1 powder guns alongside dedicated guns for underside coating, ensuring complete coverage of larger

The UK’s first WAGNER IPS powder centre

A key feature of the installation is the IPS powder centre, the first

and more complex components. A dedicated manual coating station

system of its type installed within the United Kingdom. The IPS

equipped with WAGNER PEM-X1 controlled by the new Sprint 2 Expert

platform combines powder feeding, conditioning, sieving, and colour

controllers provides additional flexibility for intricate geometries and

change management within a single integrated system. Intelligent

specialist finishing requirements. Together, these technologies allow

sensors continuously monitor powder flow, weight, pressure and fill

Greenfield to maintain exceptional coating quality across a diverse

levels to ensure optimal performance throughout production. The

product range while supporting efficient production flow.

system’s Smart Feeding Technology maintains a stable powder

Intelligent automation through 3D coating technology

transfer rate even during extended production runs, helping to eliminate process variation and improve consistency. For Greenfield Engineering,

At the heart of the installation is WAGNER’s advanced 3D coating

this represents a significant advancement in process control and

technology. Each component entering the booth is scanned

repeatability. As Frank Green explains: “We’re finding with our new

automatically, allowing the system to identify the geometry of

system that the standard is set by the system, not by the operator.

the workpiece in real time. Automatic gun positioning technology

We’re now achieving a level of consistency that simply wasn’t possible

continuously adjusts spray distances to optimise coverage and powder

before.”

N. 101 - SEPTEMBER/OCTOBER 2026 - ipcm®

FLAT BED CUSTOM REUSABLE MASKING WITHOUT TOOLING COST © J. Wagner GmbH

Sustainability and operational efficiency Sustainability was a key consideration throughout the design of the new facility. The installation incorporates WAGNER’s Energy Efficiency Package (EEP), combining an optimised mono-cyclone recovery system and advanced filtration technology to reduce energy consumption while maximising powder recovery performance. The improved airflow design reduces pressure losses throughout the system, helping to lower operating costs and reduce environmental impact. At the same time, improved powder management and recovery minimise waste and improve material utilisation. These benefits complement Greenfield Engineering’s broader sustainability strategy,

From left to right:

• 3D Masks by cutting Silicone • Max precision • Multiple materials for multiple uses and industries • No minimum order quantities

A 3D scanner detects the geometry of each workpiece as it enters the booth. The system automatically adjusts the Z-axes so that every gun maintains the optimal distance to the surface. The system is equipped with twelve automatic PEA-X1 powder guns and dedicated guns for underside coating, ensuring complete coverage of large and complex components. One of Greenfield Engineering's key requirements was the ability to manage frequent colour changes while maintaining productivity and finish quality.

PASSION FOR MASKING SOLUTIONS

which includes significant investment in on-site solar generation, waste reduction initiatives, and internationally recognised environmental management systems.

Delivering measurable results

Since commissioning, Greenfield Engineering has experienced significant improvements across multiple aspects of the finishing process.

info@global-mask.com www.global-mask.com

FOCUS ON TECHNOLOGY

Key benefits include:  Improved coating consistency and repeatability.  Enhanced finish quality across complex product ranges.  Reduced powder waste and overspray.  Increased process control and visibility.  Improved productivity through faster colour changes.  Reduced operator dependency.  Lower environmental impact through improved energy efficiency and recovery performance. “It’s a win-win situation. We’re achieving improvements in productivity while simultaneously reducing waste and supporting our environmental objectives. The performance of the installation has exceeded expectations,” Managing Director Gary Burnard commented.

Looking to the future

The success of the project has reinforced Greenfield Engineering’s commitment to continuous investment in advanced manufacturing technologies. As customer requirements continue to evolve, the company remains focused on expanding its capabilities, increasing automation, and further enhancing quality, efficiency and sustainability throughout its operations. “The results achieved through this investment have given us confidence to continue investing in the future. Our focus remains on delivering world-class manufacturing solutions and creating long-term value for our customers,” Gary Burnard concludes. For Frank Green, the project represents an important milestone in the company’s ongoing development: “The investment has transformed our finishing capability. The consistency, appearance and overall quality of the coated product have exceeded expectations and further strengthened the service we provide to our customers. It has taken our powder coating operation to another level.”

From top left, clockwise: For particularly complex geometries, the line includes a double manual coating station. The final filter operates with a smaller fan motor thanks to WAGNER’s Energy Efficiency Package (EEP). Coated metal sheet parts entering the pre-treatment.

N. 101 - SEPTEMBER/OCTOBER 2026 - ipcm®

YOUR SOLUTION PROVIDER

SUCCESS STORIES

Datalec Precision Installations: rethinking the entire powder coating process through sustainability Sustainability is more than a commitment at Datalec Precision Installations (DPI); it is a guiding principle in operational decision-making. So when the company set out to establish a new in-house powder-coating facility at its UK headquarters, it looked beyond conventional approaches. The widely used phosphating pretreatment process offered proven results, but fell short of DPI's environmental and operational ambitions.

or many companies, sustainability is now an objective to pursue. For Datalec Precision Installations (DPI), a UK manufacturer of data centre infrastructure, it has become the guiding principle

behind every new manufacturing investment. When the company decided to establish an in-house powder coating facility at its UK headquarters, the objective was not simply to bring the coating process under its own control to improve quality and lead times. The real challenge was to build a finishing department aligned with the company’s ESG strategy, significantly reducing its environmental impact without compromising performance, reliability, or competitiveness. To achieve this goal, DPI chose to challenge one of the most established stages of the coating process: conventional phosphating pretreatment.

Rethinking pretreatment by addressing its limitations

Growing demand from the hyperscale and colocation data centre sectors required DPI to gain greater manufacturing autonomy. Before designing the new powder coating line, however, the company carried out a detailed assessment of the operational and environmental impact of incorporating a conventional pretreatment process. The analysis highlighted well-known drawbacks associated with traditional phosphating: high water consumption, substantial energy demand to heat process tanks, sludge generation requiring disposal, intensive maintenance, and a significant carbon footprint due to the multi-stage nature of the process. For a company that had made emissions reduction, resource efficiency, and sustainable manufacturing key strategic objectives, installing a © DPI

N. 101 - SEPTEMBER/OCTOBER 2026 - ipcm®

conventional phosphating line would have represented an unacceptable compromise.

SUCCESS STORIES

This led to a partnership with Metavate, the exclusive UK distributor

environmental, operational, and economic benefits.

of Chemtec technologies, whose objective was clear: identify a

At the heart of the project is Toran 3®, a single-stage, ambient-

pretreatment technology capable of delivering outstanding performance

temperature pretreatment technology developed by Chemtec, based

while eliminating most of the environmental impacts associated with

in Corbetta (Milan, Italy). Unlike conventional pretreatment systems, it

conventional phosphating.

requires neither pre-degreasing nor rinsing. The anhydrous process uses

A solution built around two complementary approaches

high-boiling organic fluids that simultaneously clean and protect the metal surface against oxidation, incorporating the contaminants removed from the substrate into a polymeric film that cross-links during the

The project developed with Metavate went far beyond replacing the

subsequent drying stage.

pretreatment chemistry.

Unlike conventional phosphating processes, Toran 3® completes

The entire coating department was redesigned by focusing on two

degreasing, cleaning, polymerisation, and metal surface protection in a

fundamental aspects of the process:

single 90-second operation.

 the implementation of Toran 3 pretreatment technology;

Its most innovative feature, however, lies in what the process eliminates:

 the complete optimisation of the component hanging system

 no heated tanks;

throughout the powder coating line.

 no rinsing stages;

The integration of these two approaches delivered measurable

 no water consumption;

ipcm® - SEPTEMBER/OCTOBER 2026 - N. 101

SUCCESS STORIES

 no sludge generation;

manufacturing without compromising

By completely eliminating water usage

 no chemical or wastewater effluent.

performance.”

and rinsing stages, the new pretreatment

Despite its simplified process, Toran 3 delivers

process reduced water consumption for

excellent corrosion protection, achieving more than 1,000 hours of salt spray resistance,

Water savings and lower carbon emissions

pretreatment to zero. For DPI, this translates into annual savings of approximately 1.6

One of the project’s most significant

million litres of water, supporting both local

phosphating systems in terms of performance.

achievements concerns water consumption.

resource conservation and the company’s ESG

“We are proud to support DPI in improving both

Calculations carried out during the design

objectives.

the quality and sustainability of its projects,”

phase showed that, at DPI’s expected

Removing heated process tanks also has a

says Rachel Stevens, Director of Metavate.

production volumes, a conventional

direct impact on carbon emissions. According

“Toran 3® has enabled the company to produce

phosphating system would have required

to DPI’s analysis, Toran 3® pretreatment

higher-quality finished products while delivering

approximately 33,000 litres of water per week,

alone reduces CO₂ emissions by up to 92.7%,

measurable environmental benefits, helping

equivalent to more than 1.59 million litres

corresponding to annual savings of more than

DPI meet the growing demand for responsible

annually.

168 tonnes of CO₂.

enabling it to compete with traditional

These benefits are further enhanced by the second key element of the project: the © DPI

complete redesign of the component hanging system.

More components per metre of conveyor

Alongside the introduction of the new pretreatment technology, DPI completely redesigned the way components are hung on the coating line. The objective was to increase loading density without changing conveyor speed or increasing staffing levels. The result was a substantial increase in the number of components processed per linear metre of conveyor, reaching more than 15 aluminium profiles per metre and over 78 small components per metre in dedicated configurations. A more efficient component layout also improved powder transfer efficiency, reducing overspray and limiting powder losses to approximately 1.2% per coated component. The optimisation of the line also generated significant energy savings. Energy consumption per coated component fell from approximately 2.97 kWh to as little as 0.45 kWh, representing reductions of up to 85% in the most favourable configurations and typically ranging between 48% and 69%, depending on component geometry.

N. 101 - SEPTEMBER/OCTOBER 2026 - ipcm®

SUCCESS STORIES

Importantly, these gains were achieved while maintaining the same

At the same time, the project demonstrates how sustainability can

conveyor speed and without increasing the number of operators.

become a driver of industrial innovation, simultaneously improving

Sustainability that also improves profitability

environmental performance, manufacturing efficiency, and economic competitiveness.

Although the project was primarily driven by DPI’s environmental

The collaboration between DPI and Metavate clearly shows that

objectives, the economic benefits have proved equally significant.

rethinking a coating process—starting with pretreatment and extending

Eliminating water consumption, dramatically reducing energy demand,

to production-line organisation—is not simply about reducing

removing sludge disposal requirements, lowering powder consumption,

environmental impact. It is about building a more efficient, resilient

and reducing maintenance activities have all generated substantial

manufacturing model capable of meeting the growing demands of a

operating cost savings.

market increasingly focused on responsible industrial production.

Analysis of the new production system shows cost reductions per coated component generally ranging between 34% and 73%, with savings reaching 80% under the most favourable production conditions. For DPI, the new powder coating department represents far more than a manufacturing investment. Bringing the process in-house enables the company to offer customers shorter lead times, tighter quality control, improved ESG data traceability, and reduced project risk by limiting dependence on external

www.lechler.eu

suppliers.

IVE and Lechler Tech bio-based finishes bring a natural caress to your furniture, indoors and outdoors.

BRAND-NEW

UltiCoat unites Wisconsin and Arizona industrial finishing operations under one brand Scott’s Industrial Coatings and Perfection Industrial Finishing combine powder coat, liquid paint, chemical processing and media blasting capabilities across three facilities by consistent certifications and demanding

vendors and two qualification processes. Now

quality standards across every facility.

that’s one relationship, with the same people

Day-to day operations remain unchanged,

they already know doing the work.

with customers continuing to work with the

“The certifications our teams have built over

same teams, at the same facilities, using the

the years – AS9100D, Nadcap, ITAR – are

same processes, while also gaining access

difficult to earn and harder to maintain, and

to additional capabilities and locations to meet

they’re what let us serve commercial, aerospace

a broader range of needs.

and defence customers with confidence,”

Combined capabilities

finishing capacity. For customers in demanding

access:

markets, that combination matters.”

and specialty applications

Joaquin “JQ” Salas, CEO of UltiCoat.

alongside a Midwest operation with large-scale

Under the UltiCoat brand, customers can  Powder coating – high-volume production © UltiCoat

Salas continued. “Those qualifications now sit

 Liquid paint – including high-performance

Scale and reach

UltiCoat operates three facilities across

industrial and protective coatings

Wisconsin and Arizona, including 64,000

adison Lake Capital today introduced

 Chemical processing – anodizing and

square feet of coating operations in Green

UltiCoat, a single brand bringing together

conversion coatings

Bay, 32,000 in Phoenix and 15,000 in Tucson.

Scott’s Industrial Coatings and Perfection

 Media blasting and surface preparation

Scott’s Industrial Coatings was established in

Industrial Finishing industrial coating and

 Cerakote application – ceramic-based

2000 and grew from a single pole shed to its

finishing operations in Green Bay, Wisconsin,

protective coatings.

current footprint. Perfection Industrial Finishing

and Phoenix and Tucson, Arizona. The new national platform combines Midwest and Southwest operations to deliver end-to-end

Certifications and qualifications (site and process specific)

traces its origins to a Tucson garage paint shop in 1991 and has served manufacturers across Southern Arizona since.

 AS9100D and ISO 9001:2015 Certified

The Midwest and Southwest footprint shorten

industrial customers under the leadership

 Nadcap accredited

freight lanes for customers on both sides of

of a single CEO. The combined organization

 ITAR registered

the country and adds capacity and redundancy

gives manufacturers and OEMs access to a

 Cerakote certified applicator

across the network.

broad range of finishing processes across

 Approved supplier to defence primes

UltiCoat serves manufacturers and OEMs in

two regions – Scott’s high-volume, large-

including BAE Systems, Lockheed Martin,

defence, aerospace, marine, transportation,

scale industrial coating capacity in the Upper

Northrop Grumman and Honeywell Aerospace

energy, fire and rescue, construction and

Midwest and Perfection’s aerospace- and

 Approved supplier to commercial

industrial fabrication.

defence-qualified metal finishing in the

companies including Caterpillar and Oshkosh

Southwest – under one name and one point of

Corporation.

contact. The rebrand reflects a broader shift in

“Bringing these two companies together under

customer expectations rather than a change

UltiCoat gives our customers something

driven solely by the companies’ individual

neither of us could offer alone,” said Joaquin

histories. Under UltiCoat, customers gain a

“JQ” Salas, CEO, UltiCoat. “A manufacturer

single, trusted partner with national reach and

that needed powder coat in Wisconsin and

a full range of finishing capabilities, backed

anodizing in Arizona was managing two

metal finishing for aerospace, defence and

N. 101 - SEPTEMBER/OCTOBER 2026 - ipcm®

For further information: www.ulticoat.com

BRAND-NEW

Krautzberger GA 1: Reliable automatic spraying for abrasive and high-viscosity materials Krautzberger presents the GA 1, a compact automatic spray gun designed for abrasive and highly viscous materials, combining reliable spray performance, reduced maintenance requirements and flexible integration into automated coating systems.

ndustrial coating processes involving abrasive or

cross-sections also enable the reliable processing of

highly viscous materials place particularly high

larger material quantities and highly viscous media.

demands on spray equipment. Wear, maintenance

Another key advantage is the compact design of the

requirements and process stability can have a

GA 1. It allows improved access to complex

significant impact on production efficiency and coating

component geometries and therefore provides

quality. With the GA 1, Krautzberger has developed a

greater flexibility when integrating the spray gun into

compact automatic spray gun specifically designed

automated systems and robotic applications. Different

to meet these challenges. At the heart of the GA 1

adapter configurations, optional material circulation

is a pneumatically controlled diaphragm shut-off

and a robot adapter allow the GA 1 to be adapted to

system. Unlike conventional designs, the GA 1 operates

various production concepts. Its design also supports

without a needle and needle packing in the material

fast cleaning and straightforward maintenance, helping

section. This significantly reduces mechanically

to reduce downtime in daily production.

stressed components and helps minimise wear

The GA 1 is particularly suited to automated glazing

and maintenance requirements – particularly when

and coating applications in the ceramics and glass

processing abrasive materials.

industries, as well as other industrial processes

For users, this means longer service intervals, reduced

involving abrasive or high-viscosity materials.

maintenance effort and reliable operation in demanding

With the GA 1, Krautzberger combines reliable spray

automated coating processes.

performance, low maintenance requirements and

The integrated Krautzberger XLINE nozzle system

flexible system integration in a compact automatic

ensures a uniform and reproducible spray pattern,

spray gun.

supporting consistent coating quality throughout the production process. High air capacity and large internal

For further information: www.krautzberger.com

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BRAND-NEW

Max Paint: high-efficiency filtration for spray coating Defil recommends Max Paint, a high-efficiency honeycomb filter for spray coating systems, designed to maximise overspray removal capacity, reduce the frequency of filter replacements, and keep operating costs low.

elled by Defil (Sesto San Giovanni, Milan,

the inlet of the airflow to be filtered. This

and lead to higher energy consumption. To

Italy), a company specialising in air

positioning promotes effective pre-filtration,

monitor the filter’s wear and tear, it is advisable

filtration and dust removal since 1985, the Max

trapping larger particles on the surface and

to install pressure gauges or differential

Paint filter offers an advanced solution for

reducing the risk of premature clogging of the

pressure switches. These instruments

industrial filtration, optimising spray coating

inner layers.

measure the pressure difference between the

processes across a range of sectors, from

Although the synthetic fibres used are

airflow inlet and outlet: reaching the critical

the automotive industry to metalworking

chemically inert and non-inhalable, safety

threshold indicates that the filter needs

and cosmetic packaging. Thanks to its

remains essential. The filter must therefore be

replacing to maintain the flow rate within the

honeycomb design and multi-layer synthetic

handled while wearing appropriate personal

limits specified by the system and applicable

fibre construction, the filter maximises its

protective equipment (PPE), including gloves,

regulations.

capacity to capture overspray – up to 27 kg/

lab coats, and face masks.

A further distinctive feature of Max Paint is its

m², depending on the coating product – while

Maintenance and efficiency management

maintaining filtration efficiency of up to 99.84%. Compared with traditional systems, this increased capacity reduces the frequency

Scheduled maintenance is not only good

self-extinguishing honeycomb structure, which is classified as UL 2.

End-of-life management

of filter replacements and, consequently,

practice but also a fundamental requirement

operating costs.

for ensuring a system’s efficiency and for

aspect. Once saturated with paint, the

helping to comply with applicable regulations.

filter must be classified and disposed of in

The filter’s service life is considered over when

accordance with the regulations applicable to

Correct installation is the first step towards

the maximum pressure drop permitted by the

the type of coating product used; it is therefore

ensuring high performance: the filter must

ventilation system is reached: a saturated filter

essential to consult the relevant safety data

be positioned with the lower-density side,

causes an increase in pressure drop, which

sheet. Depending on the paint accumulated

often identifiable by its different colour, facing

may require the booth’s fans to work harder

and the storage conditions, the spent filter

Tips for optimal use

End-of-life management is another important

may pose flammability risks and, if exposed to high temperatures, may release volatile substances. The material must therefore be stored correctly until disposal, in accordance with the environmental regulations governing the management of industrial waste. For further information: www.defil.it

Max Paint’s unique honeycomb design enables it to remove significantly more overspray than traditional filters.

N. 101 - SEPTEMBER/OCTOBER 2026 - ipcm®

We convey the future since 1959

Future-proof and reliable overhead

and floor MONORAIL and P+F CONVEYOR systems that can be perfectly integrated into your production processes.

We take care of all your requirements and create a tailor-made and cost-optimized concept for you.

segreteria@conveyors.it

HIGHLIGHT OF THE MONTH

The power of 100 ipcm® issues. The excitement of a future yet to be written Alessia Venturi ipcm®

An exclusive cocktail party for more than 100 clients, suppliers, and friends from across Europe to celebrate 100 issues chronicling the industry’s evolution.

N. 101 - SEPTEMBER/OCTOBER 2026 - ipcm®

n 29 July, we did not simply celebrate

attuned to the everyday reality of companies.

the publication of ipcm ’s first 100

That is why the cocktail party organised at

issues. We celebrated the history of a

Villa Le Libellule in Lazzate (Como, Italy) was

publishing project launched seventeen years

conceived as a cultural manifesto, reflecting

ago with a clear ambition: to report on the

the role ipcm® has built up over the years: not

surface treatment industry with a new, more

merely to describe change but to be present

dynamic and authoritative approach, better

where that change takes shape.

Precisely this sense of presence was the theme of the evening. Around 100 long-standing customers from across Europe, along with suppliers and friends, accepted our invitation to join the celebrations, contributing to a magical atmosphere of warmth, trust, and joy.

Engineering specialized in the supply of systems for surface treatment, painting and coating

The evening also echoed the concept behind the stand that has distinguished ipcm®’s participation in PaintExpo, the leading international trade fair for our industry, for years: an informal, welcoming setting featuring the ever-present table football. It was a way of showcasing once again our approach to professional relationships: expertise and substance, as well as conviviality, interaction, and pleasure in being together. Contributing to making the event so special was Bruno Vanzan, an internationally renowned bartender and two-time world champion, who has been at the helm of BB Holding since 2017, a company active in the beverage industry and committed to bringing quality, professionalism, and a focus on high-quality ingredients to the sector. His creativity joined forces with our team to create a selection of signature cocktails, including the ipcm® Americano, with its deep, brilliant red colour, built on a balance between bitter and red vermouth – a symbolic drink created to celebrate an important milestone and, above

E-COAT SYSTEMS

all, to be shared with the people who helped make it possible. Another highlight of the evening was a creation by Patrizia De Lazzari,

LIQUID PAINTING SYSTEMS

the cake designer behind Patrizia’s Cake. More than a decorative feature, it was a visual narrative of our first 100 issues. The structure, built in several levels and traversed by a spiral, reproduced all the magazine’s

POWDER COATING SYSTEMS

covers in sugar paste, from the first issue of January/February 2010 to issue 100, dated July/August 2026, placed at the very top; and even

SELF-LEARNING ROBOTS FOR AUTOMATED PAINTING

higher up, the world, with one specific point marked: Cesano Maderno, the place where it all began.

SYSTEMS FOR THE TREATMENT OF VOCs EMISSIONS Photo credit © Yari Favaro

HIGHLIGHT OF THE MONTH

From there, lines branched out, crossing borders and connecting people, ideas, and expertise. It embodied what ipcm® has become over the years: a project born of a vision and grown issue by issue, journey by journey, until it built an international network. Looking back, those 100 issues are much more than a series of magazines: they reflect obstacles and successes, difficult choices and exhilarating moments, responsibility, hard work, and an unending enthusiasm. Not to mention all the kilometres travelled, the airports, the hotels, the trade fairs, the interviews, the articles written late at night, the photographs, the revisions, the phone calls, and the deadlines met. The first 100 issues of ipcm® are a milestone, but above all, the start of the next chapter. The issue you are reading marks the beginning of a second cycle of 100 issues, bringing new ideas, new generations, new markets, new customers, and new frontiers to explore. This accomplishment belongs to everyone who has helped build it: employees, customers, partners, readers, and friends who, over the years, have believed in our vision. Perhaps this is the truest meaning of this milestone: not to stop and look back at what has been achieved, but to draw on what we have built together to find the energy to continue our journey.

Photo credit © Yari Favaro

N. 101 - SEPTEMBER/OCTOBER 2026 - ipcm®

ANALYSIS

Uncertainty as a driver for process optimisation through automation Adriano Antonelli Tecno Supply - Ibix Srl, Lugo (Ravenna) – Italy adriano.antonelli@tecnosupply.com

In a socio-economic context marked by instability and rising energy and raw-material costs, improving process efficiency is a key means of minimising cost impacts. Beginning with an analysis of consumption and, consequently, production-line costs, this article identifies hanging optimisation as one of the most practical strategies for increasing load density, reducing lead times, and streamlining process-related expenses.

N. 101 - SEPTEMBER/OCTOBER 2026 - ipcm®

he uncertainty surrounding this period in history is fuelled by a constantly evolving geopolitical situation and a stream of contradictory news reports, following one another without a

clear common thread. Conflict scenarios are complicating an economic landscape of contrasts, where instability is causing widespread concern and driving up the prices of raw materials, energy, and semi-finished products. All of this is affecting our market segment, surface coating, which is characterised by high energy consumption. Although we cannot influence international processes, we can certainly take action on our own production processes, keeping costs under control and promoting efficiency measures.

ANALYSIS

A much-discussed topic in this context,

introduced by HangOn, a company specialising in smart solutions for the hanging, masking, and handling of parts, is the “Green Effect”1. What is it? It is an opportunity to achieve three results: reducing energy consumption and the carbon footprint while increasing the profitability of coating lines. But how can these results be achieved in routine operations within a company? What tools can HangOn and its distributor Ibix provide? First of all, it is necessary to analyse the energy consumed by

the coating plant: as we know, 80-90% of energy consumption is constant and does not vary with the number of parts treated, and there are sources of inefficiency within each system that must be managed and taken into account (Figs. 1 and 1bis). Calculating the actual cost per part by also considering energy consumption and the costs of pre-treatment, powder, and labour is therefore essential for making informed and sound decisions. To increase profit margins, savings must be achieved in line costs without compromising quality standards. This involves, where possible, increasing hanging density to optimise the impact of fixed costs and reduce variable ones (Figs. 2 and 3). The CCC is a tool

Fig. 1 and 1bis – As the surface treatment sector is among the most energy-intensive, reducing energy consumption is key to improving process efficiency.

for calculating and comparing various hanging solutions: it is a spreadsheet available on the website www.hangon.com, which users can

employ to calculate the costs and benefits of different options for their coating plants. So, what options are available for implementing such continuous improvement on a line? Let us explore them in detail.

The latest developments in Ibix-HangOn’s hanging systems HQW D system

One example is the HQW D system, a 2 mmdiameter tree-shaped frame with fixed hanging points. The range is extensive, allowing every customer to choose their ideal pitch. To keep the frame compact, even during packaging, the upper hanging point must be fitted with a dedicated hook.

Fig. 2 and 3 – To increase profit margins, line costs should be reduced while maintaining quality standards by increasing hanging density where possible and thereby optimising the mix of fixed and variable costs.

1 A.Venturi, “Understanding the real drivers of coating economics and sustainability: HangOn’s Coating Cost Calculator takes a major leap”, in ipcm® March/April no. 98 (March/April 2026), pp. 98-102 https://www.ipcm.it/en/open/ipcm/2026/98/108-112.aspx

ipcm® - SEPTEMBER/OCTOBER 2026 - N. 101

ANALYSIS

Fig. 4 – The new HQW D tree-shaped frame has a 2 mm diameter and fixed hanging points, compared with chain hanging. Fig. 5 – Inserting the HQW D frames into a dedicated bar prevents them from swinging during movement within the plant and during pre-treatment. Fig. 6 – The 2 mm-diameter hook and the reinforcement along the frame’s entire length ensure hanging stability. Fig. 7 – The frame is designed to increase hanging density. Fig. 8 – The new HCL FS CDV bar is compatible with the universal frame and is designed to hang medium-weight items. Fig. 9 – The new straight and 145° twisted arrow hooks expand the range of applications for the Ibix-HangOn hanging systems, accommodating a wide variety of configurations.

Fig. 10 – The arrow hooks can be inserted into BH hook holders for handling heavier items and into BHL holders for lighter loads.

N. 101 - SEPTEMBER/OCTOBER 2026 - ipcm®

The frame is designed for urgent situations and to avoid hook-to-hook hanging operations: this is critical because “chain-style” hanging, in addition to taking longer to set up, allows significantly fewer items to be hung than the HQW D solution (Fig. 4). The cost per hanging point is comparable to that of a single hook, so the total cost of the frame remains well below €1 without requiring regeneration. Frame swinging during movement within the plant or during pretreatment can be resolved by inserting the HQW D frames into a specially designed bar that ensures stability, correct earthing, and protection against contact (Fig. 5). HQW S system Unlike the system described above, the new HQW S system is fitted with an adjustable upper hook that can be set to 0° or 90°. The hooks are spaced at variable distances. This economical and versatile frame eliminates the need for makeshift hanging arrangements using additional hooks, which can reduce load density and process efficiency. The 2 mm-diameter hook and reinforcement along the frame’s entire length guarantee hanging stability. The frame is designed for a load capacity of 2 kg per hook (Figs. 6 and 7). HCL bar Among our new products, the HCL FS CDV bar is certainly worth noting. Designed to hang medium-weight items, it can be fitted to our universal frame. Some of the main features of this bar, which is fitted with spring steel hooks, are as follows:  sturdiness and lightness: it can support up to 20 kg per hook while remaining lightweight thanks to its hollow tubular structure;  spring steel hooks: manufactured on CNC machines and subsequently inserted into the bar;  central attachment point;  the option to produce customised bars to meet specific requirements (Fig. 8). Ever seeking to offer simple innovations to optimise line loading, Ibix-HangOn has improved its arrow hooks for hanging components with holes, ensuring parts remain aligned and stable throughout the process. This solution allows water to drain more easily during pretreatment, avoiding the need for subsequent blow-off, and enables parts to be positioned closer together without touching. Hanging with a

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single hook would not guarantee adequate stability in these cases. By supporting the component at two points along its circumference, the arrow hook ensures optimal, wide grounding and prevents oscillation during operation. The new straight and 145° twisted arrow hooks can be used for a wide range of tasks. They can be fitted into BH hook holders for heavier parts and BHL holders for lighter ones (Figs. 9 and 10).

Via Strà, 164/4A - 37030 Colognola ai Colli (VR) +39 045 6151417 | info@veronaimpianti.com www.veronaimpianti.com

ANALYSIS

The horizontal or vertical HCL bar has slots into which springs and

example, the HQL 800X33 bar has 46 hooks over a length of 800 mm. This

hooks (made from round rods or sheet metal) can be inserted. Its ends

bar can be fitted into the HCF universal frame, making the resulting system

are protected with silicone caps that allow easy removal and ensure

modular. Bars can be selected according to the length of the component

conductivity. The bar can have either single or double slots to increase

to be treated. Moreover, the HQL G6 caps ensure perfect electrostatic

hanging density, resulting in an extremely flexible system that reduces

compatibility. A 1.5 mm-hook bar, also made from spring steel, is now

the number of special frames that need to be built for the various parts

available for heavy workpieces, particularly in the small parts sector. The

to be coated. Special accessories can be custom-made to suit specific

range also includes triple-bend configurations, which prevent parts from

parts. Two springs can be housed within a hook holder, each with a four-

falling off during pre-treatment. The HQL bars, on the other hand, are ideal

way outlet. This bar can also be used for cataphoresis coating, thanks

when parts need to be hung from one side only, avoiding shading effects

to a system of caps that protect the ends and prevent the cataphoresis

and other issues during the process.

solution from flowing upwards.

The advantages of using this bar are numerous:  time-saving: up to 30 times faster than using single hooks;

HCF universal frame

 minimal mark left by the hook;

The flexibility of the HCF universal frame allows the use of load bars that

 spring steel hooks;

integrate with the various new products constantly being introduced,

 special hook configurations available on request;

further expanding its versatility and making it truly universal. This

 smart packaging to reduce transport costs (Fig. 11).

significantly reduces the number of frames required for different components, the storage space needed, and handling issues. The

H11B bar

universal frame can also be used for cataphoretic coating: the structure

It is a perforated bar into which the hooks are inserted, ensuring a clean,

remains the same, but the bars and accessories are changed to ensure

secure fit at all times and allowing the hanging hooks to be replaced

maximum conductivity. The range includes bars pre-welded with square

when necessary. It can accommodate standard or twin hooks, which

hooks to minimise contact.

fit between two punched holes and remain securely in place. For twin

Other solutions already available in Ibix-HangOn’s range

hooks, any configuration can be designed for even greater flexibility. Even more robust H2B, H25B, and H3B versions are also available. These bars

HQL bar

can accommodate hooks up to 10 mm. Hooks can be welded at their

HQL bars are produced entirely automatically, reducing costs and

ends to form a T-shaped frame. This guarantees part stability, while the

eliminating the need for regeneration. Hooks with a diameter of 1 mm can

system’s modularity allows hooks to be inserted where needed without

be inserted in pairs into the bar to hang workpieces symmetrically. For

compromising electrical conductivity.

N. 101 - SEPTEMBER/OCTOBER 2026 - ipcm®

ANALYSIS

HQC bar For positioning parts in a “cross” pattern, the HQC bar, which

thick and 18 mm high. It is also possible to create different configurations:

accommodates 1.5 mm diameter hooks on one side only, can be chosen.

slats on one side only (i.e. cut-off), in a zig-zag pattern, or bent from 0 to

A special coupling allows it to be connected to a central 10 mm diameter

180°. This type of frame was also designed to avoid single-item hanging.

hook. The R 58 bar holder ensures the bar remains stable and allows for

As the frame is produced automatically, it is cost-effective, on a par with

easy removal, thanks in part to the BH G 20 cap. The resulting frame is

a single hook. The new configurations on offer allow users to find the

cost-effective and flexible, with the option to skip levels. The hooks have

right hook shape for each component to be hung. Another new feature

a pitch of 50, 75, or 100 mm. This bar type was also designed to avoid

is the adapter that allows the HQS frame to be extended using standard

utilising individual hooks, significantly reducing hanging times, as the

or other available products. The HQS frame can be used for a wide range

frame is ready for use and does not require handling individual hooks. It

of applications, from small components to parts of varying weights and

also allows for easy off-line pre-hanging. Its main advantage, however, lies

profiles (Fig. 13).

in the possibility of achieving a wide range of workpiece configurations. Furthermore, the bar’s manufacturing technology keeps its cost at a

Trolleys

level similar to that of a single hook, meaning that purchasing the frame

Ibix-HangOn offers a range of trolleys designed to streamline the coating

does not incur any additional costs compared with the standard solution.

process, with the primary aim of reducing processing times and increasing

Additionally, to further increase the frame’s versatility, a new metal adapter

load density. Hanging parts directly on the line reduces density and

has been developed that also allows H11B bars to be employed so that, by

efficiency, as short handling times do not allow the available space (in

using the same central hook, it is possible to accommodate a bar allowing

cubic metres) to be fully utilised.

the use of hooks of up to 4 mm, thus achieving greater horizontal flexibility

Trolleys, on the other hand, allow for a pre-hanging stage and the

(Fig. 12).

movement of parts within the factory, enabling the load to be prepared in advance and optimising line utilisation.

HQS frame

The Ibix-HangOn trolleys are modular and designed to suit different

Part of our Quick range, the HQS frame is fitted with metal slats that allow

frame types, ensuring maximum flexibility. If the frame changes, e.g. with

both individual workpieces and profiles to be hung. The central hook,

different attachments or dimensions, the trolley can be easily adapted to

available in 4 or 5 mm sizes, enables the frame to support loads of up to

the new requirements. The trolley serves a dual purpose: it enables pre-

100 kg. The HQS frames come with various types of hooks, ensuring that

hanging and transport of all load bars to the coating line, as well as the

every customer can choose the configuration best suited to its specific

orderly storage of unused frames. Special trolleys can also be designed to

needs. Their length can be up to 2400 mm; the sheet metal is 1.0 mm

meet specific requirements using the available components (Fig. 14). From left to right: Fig. 11 – Hang On's patented products. Fig. 12 – HQC bar with a 15 mm hook. Fig. 13 – The HQS frame has a wide range of applications, from small parts and components of varying weights to profiles. Fig. 14 – Ibix-HangOn’s trolleys streamline the coating process, reducing cycle times and increasing load density.

ipcm® - SEPTEMBER/OCTOBER 2026 - N. 101

ANALYSIS

From left to rght: Fig. 15 – New EPDM plug that can be used for different hole sizes. Fig. 16 – GDF plug can be used to mask threaded holes on both sides. Fig. 17 – Special MDF masking to which magnets can be applied.

New Ibix-HangOn masking devices

cleaned. Its softness makes it easy to insert the plug and ensures a secure

Our company has also introduced new products to its range of masking

grip. Where necessary, it can be bonded with solid silicone.

solutions:

 magnetic silicone, 1 mm thick: its magnetic properties allow it to adhere

 the GSPE stepped plug is a metric plug with multiple steps, allowing it

to ferrous surfaces, eliminating the need for disposable adhesive tape.

to fit holes of different diameters. It is a disposable product for powder

It withstands temperatures up to 250 °C, is easy to clean, and, where

coating processes and can be used with five different metric hole sizes

necessary, can be bonded to the materials mentioned above.

(Fig. 15).

 MDF: it has some limitations compared with the materials mentioned

 the GAQ…H cap can be used both as a plug and as a cap. The masking

above. Firstly, it cannot be fitted before chemical pre-treatment because it

device is ventilated and features a handle for easy grip and quick removal.

would absorb water, and it is less flexible, making it more difficult to clean.

Designed as a plug, it utilises the end ribs to ensure correct positioning.

However, it is more economical and withstands temperatures of up to 200

In addition to conical plugs and caps, many other solutions can be adopted

°C, so it can also be used for powder applications.

depending on the specific requirements: the GDF plug, for example, allows

 cork, 2-25 mm thick: this is compressed cork for liquid applications,

a nut to be covered at both ends in a single operation. For blind nuts welded

another cost-effective material that withstands temperatures up to 150 °C

to sheet metal, the Qbolt, fitted with a screw, allows the masking solution to

and can be bonded to other materials.

be screwed on directly. The silicone cover makes cleaning easier. Both GAP

Finally, magnets can be added to these masking devices to improve

and GVM caps are vented, i.e. they allow air to escape without letting dust

stability and grip on workpieces (Fig. 17).

or water in during pre-treatment cycles (Fig. 16). In addition to moulded products that can be manufactured to specific designs, Ibix-HangOn can combine different types of silicone:

Masking solutions tailored to customer needs

Our wide range of materials enables us to consistently identify the most

 solid silicone, 1-6 mm thick: it has the same characteristics as the

suitable masking solution based on part characteristics, timeframes, and

silicone used in coating plants. It is supplied in sheets that can be die-cut to

the machining method. The design of each masking device begins with an

size and bonded together to increase thickness. Pull-out handles can also

analysis of the component to be protected and takes into account various

be fitted.

factors: permissible tolerances, attachment methods, ease of application

 expanded silicone, 2-20 mm thick: it comes in sponge form. Being

and removal, storage conditions, expected lifespan, the available budget,

silicone-based, it is resistant to high temperatures and can be easily

and cleaning methods.

N. 101 - SEPTEMBER/OCTOBER 2026 - ipcm®

errors and ensures that no areas are left unprotected. Although the initial investment may be higher than with simple tape, the cost is recouped through the greater ease and speed of applying and removing the protection. The risk of operator error, which could result in the masking device being applied to unintended areas, is also minimised. The production of masking kits, particularly for components requiring the protection of multiple areas, is an efficient and reliable approach.

www.apengroup.it export@apengroup.it

A correctly designed and positioned masking solution helps prevent

A further advantage is flexibility in terms of quantity: the absence of minimum order quantities means we can produce only what is needed. Furthermore, should a company’s technical department modify the dimensions of some of its components, we can produce new masking devices without incurring any further fixed costs. Similarly, damaged or worn masking devices can be replaced individually, without any additional costs associated with redesign.

Conclusions

To summarise, the key steps for reducing process costs are as follows:  using the HangOn calculator to analyse a line’s energy consumption and costs;  treating hanging as a strategic decision, as it directly affects plant utilisation, work organisation, and production management;  streamlining operations and focusing on high-volume products to increase hanging density and make optimal use of the line’s capacity;  identifying more efficient working methods, e.g. by maximising the quantity of product per metre of conveyor, through solutions that increase hanging density, preferably with off-line pre-hanging operations. The time saved in this way can be allocated to maintenance or used to make the line available for other products to be coated;  remembering that halving the time required for hanging through effective solutions can have a significant impact on process costs. Indeed, efficiency depends not only on the plant’s performance, but

Apen Group S.p.A. Milan - Italy

also on how the activities around it are organised and managed.

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ARCHITECTURE and DESIGN

ipcm® - SEPTEMBER/OCTOBER 2026 - N. 101

HIGHLIGHT OF THE MONTH

SPECIAL ISSUE ON ARCHITECTURE & DESIGN

New finishes and decorative options for powder-coated aluminium coils Edited by Decoral Group Arcole (Verona) - Italy

info@vivdecoral.it

The aluminium coil coating industry is evolving towards increasingly high-performance, versatile solutions focused on aesthetic customisation. Decoral Group is driving this evolution through the development of new matt and textured finishes, expanded colour options, front-and-back surface combinations, and large-format coils up to 2 metres wide, further expanding the material’s application potential.

N. 101 - SEPTEMBER/OCTOBER 2026 - ipcm®

n recent years, aluminium coil coating has undergone profound technological advances. Originally developed to ensure the protection, uniformity, and durability of metal

surfaces, this continuous-flow process has now evolved into a solution that combines technical performance, aesthetic appeal, and greater design freedom. Market demands have, in fact, changed: alongside the properties traditionally associated with coil coating, such as weather resistance, colour stability, and long-term reliability, there is now growing

HIGHLIGHT OF THE MONTH

demand for surfaces that offer new decorative options, customisation,

integrity even after the material has been bent is a major step forward,

and aesthetic value.

broadening the range of applications for this type of product without

Pre-painted aluminium thus becomes integral to design, contributing to

limiting design possibilities.

a project’s visual and architectural identity. For this reason, architects, designers, and companies are increasingly seeking finishes that combine high performance with a distinctive aesthetic, in line with current trends in contemporary architecture and design.

The popularity of matt and textured finishes

The evolution of colour in coil coating

Alongside the development of surface textures, colour research is also taking on an increasingly central role. In recent months, Decoral Group has expanded its colour range for coil coating with new tints and innovative effects, designed to meet the growing demand for customisation through

Growing interest in matt and textured finishes is one of the key trends

deeper shades, special finishes, and contemporary effects that create

shaping the coil coating market. These finishes meet demand for more

distinctive surfaces and enhance the harmony among the building, its

natural, sophisticated-looking materials, in line with current architectural

surroundings, and the materials used.

trends. In particular, matt finishes reduce light reflections and give the surface an elegant, understated effect, while crinkled finishes add a textural element that enhances the substrate’s character.

Double-sided finishing and new design possibilities A further development has enabled the creation of different finishes

One of Decoral Group’s most significant innovations in this context has

on both sides of a coil. This solution increases design flexibility and

been the development of textured coil coatings compatible with bending

offers new opportunities for applications where both surfaces of the

operations. The ability to preserve the finish’s aesthetic and functional

treated material are visible or require different aesthetic characteristics.

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SPECIAL ISSUE ON ARCHITECTURE & DESIGN

HIGHLIGHT OF THE MONTH

The option to customise both front and back surfaces enables the simultaneous fulfilment of functional and decorative requirements, making coil coating an even more versatile tool for designers and manufacturers.

Growing demand for large-sized coils

The evolution of application requirements is also reflected in the dimensions of the materials demanded by the market. In recent years, interest in large-sized coils has grown, with a significant increase in demand for coils up to two metres in width. This trend is closely linked to the development of large-scale architectural applications, where wider formats allow for optimised processing, reduce the number of joints, and ensure more uniform aesthetic results.

An increasingly versatile solution for a wide range of applications © Decoral

Thanks to its technical and aesthetic evolution, powder coil coating is now used across a range of sectors: architecture, especially for façades, cladding, and roofing; residential and commercial construction; doors and windows; interior design; contract work; and industry, particularly in component manufacturing. Decoral Group will also soon showcase its latest innovations at two major international trade events: Aluminium, taking place at the exhibition centre in Düsseldorf, Germany, on 6–8 October (Stand 3H69), and VETECO, to be held in Madrid, Spain, on 10–13 November (Stand 9E05). At both events, company representatives will be on hand to discuss these new coilcoating solutions in more detail and to engage with industry professionals and operators.

From top to bottom: With its powder coil coating plant, Decoral can coat aluminium coils up to two metres in width. Textured surfaces add a tactile quality that enhances each material’s character. © Decoral

N. 101 - SEPTEMBER/OCTOBER 2026 - ipcm®

Matt finishes reduce light reflections and give the surface an elegant, refined look.

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Young GSB: a bridge between generations in aluminium and steel coatings Edited by GSB International e.V. Düsseldorf, Germany info@gsb-international.de

GSB International is addressing generational change by involving young industry professionals in the association’s activities through Young GSB. Established in 2019, the working group provides a platform for developing new ideas and practical solutions while gradually integrating the next generation into the association’s committees and decision-making processes.

enerational change and future competitiveness are major

are elected for a four-year term, with the possibility of re-election. Those

concerns for many companies. These issues become even more

GSB executive bodies are:

complex when it comes to an association. This was the starting

 The Board, which handles strategic and economic issues

point for the creation of Young GSB, a working group created by GSB

 Quality Committees for the aluminium and steel and galvanized steel

International, the leading quality association for surface coatings on

substrates: the Quality Committees are responsible for technical matters

aluminium and steel in the building sector.

such as the further development of quality guidelines, testing, research

Bringing together young professionals from coating manufacturers, pre-

and round-robin tests.

treatment and coating companies, and testing laboratories, Young GSB was established to encourage fresh ideas, develop new approaches and prepare the next generation to take an active role in the association’s work. Since its first meeting in 2019, Young GSB has evolved into a platform where the next generation of

Many members of these bodies have decades of experience in the coatings industry and in the GSB’s area of activity. But nothing is as constant as change, and generational transition is by far one of the most discussed forms of change in many companies—especially now, at a time when generations of high birth rates

industry professionals can work

are retiring.

independently on topics that

This trend was also discussed

matter to them, develop practical

at the GSB Board meetings in

solutions and contribute new

2019, and it was thus decided to

perspectives to the GSB’s

launch Young GSB.

activities. At the same time, it has become a valuable bridge between generations, gradually

Composition and functioning

integrating its members into the

The idea was to bring together

association’s committees and

young professionals from the

giving them the opportunity to gain

membership as part of a working

first-hand experience of its decision-

group. The group’s composition

making processes.

was intended to reflect the structure

The beginning

on the Board and the Quality Committees.

As is common in many associations, the GSB’s executive bodies are composed of volunteers who

N. 101 - SEPTEMBER/OCTOBER 2026 - ipcm®

of the membership—just as is the case The group was composed of manufacturers of pre-treatment chemicals and coating materials,

HIGHLIGHT OF THE MONTH

as well as coating companies themselves. Representatives from testing laboratories were also brought on board. At the same time, the Board and the Quality Committees agreed that the organization needed fresh ideas and a more modern approach to its operations.For this reason, the overarching guiding principle was immediately clear: The working group should work on the topics that matter most to them—and do so independently. The working group met for the first time in 2019 and quickly established a shared understanding of its objectives. The initial topics were identified, prioritized, and actively advanced, while practical concepts for their implementation were developed. Of course, this has been the approach since the very first meeting and continues to this day, in the field of precompetitive activities.

Results

The GSB concepts were revaluated, and here and there, this fresh and unbiased perspective revealed one or two opportunities for optimization. For example, single-layer systems that had previously been approved by the GSB only for aluminium can now also be used on steel or galvanized

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The Young GSB working group: some members have already exceeded the age limit for Young GSB and have involved their successors.

POWDER COATINGS E-COAT

SPECIAL ISSUE ON ARCHITECTURE & DESIGN

HIGHLIGHT OF THE MONTH

steel, provided that the material manufacturer

This allows Young GSB members to gain first-

they merely provide a broad overarching and

grants approval and the coater demonstrates

hand experience with the Board’s work and

strategic framework without influencing the

the performance of its coating (GSB, 2026) .In

to present the concepts they have developed

creative technical discussion. This ensures that

addition, a training portal and remote training

directly.

the groups’ findings can be presented to the

courses were proposed and subsequently implemented. Since then, these training programs have become a well-established and

Quality Committees and the Executive Board

How Young GSB operates today

in a form that is already highly comprehensive,

With such an innovative working group, it was,

highly valued offering among GSB member

of course, particularly important to find an

companies.

organizational structure that would be practical

New Committee members

for everyone involved. Since everyone has a

practical and ready for implementation.

The network

But far beyond GSB matters, Young GSB

full-time job in the industry, the challenge was to

has become the go-to platform for young

As a positive side effect, experienced young

find an efficient way to collaborate. The working

professionals in coatings for architecture. As

specialists and managers are becoming

group meets in person twice a year. The meeting

part of Young GSB, members have the unique

integrated into the GSB’s structures and are

locations are rotated so that each member gets

opportunity to sit down with a wide variety

ready to take on roles within its committees

to enjoy a short commute at least once. During

of experts. Where else can you find such a

almost without any transition period—provided

the meetings, current topics are addressed by

diverse group of experts from the coatings

they are elected by the members.

focus teams of about five people and presented

industry gathered around one table? This allows

Many members of Young GSB have now

at the end of each session. These focus teams

problems to be addressed holistically right

joined the various committees, where they are

then continue working on the topics until the

away, leading to innovative solutions.

bringing a new perspective. In addition, the

next meeting, using video conferences.

Board has granted a guest seat to Young GSB.

To provide technical and strategic support, representatives of the GSB—Thomas Lendl,

GSB (2026). GSB ST 663-6. Coater Steel + Galvanised Steel.

Available from: https://gsb-international.de/wp-content/ uploads/2025/12/06-GSB-QR-ST-663-6-Coater-Steel-2026-01-01en.pdf [29.07.2026]

What´s next?

The Young GSB is also constantly evolving.

Chair of the Aluminium Quality Committee,

Some members have already outgrown the

and Philipp Mader, Managing Director—are on

age range for the Young GSB and have brought

hand at every meeting in an advisory capacity

their successors on board. Furthermore, as

to support the individual groups. In doing so,

the Young GSB matures as a working group, its members are increasingly finding their way into the GSB’s bodies. In addition, the current projects are continuing at full speed, and the industry can already look forward to the following activities.

N. 101 - SEPTEMBER/OCTOBER 2026 - ipcm®

Young GSB has evolved into a reference platform for young professionals in the architectural coatings sector, bringing together diverse expertise and creating unique opportunities for knowledge exchange and cross-sector collaboration.

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From the laboratory to the production line: a new product for the pre-treatment of aluminium coils Martina Stucchi ipcm®

Three years of development and industrial trials have enabled DN Chemicals to perfect DollCoat AL 108, a new pre-treatment system for aluminium coils implemented by Luxe Coat (L’Aquila, Italy). Developed and validated directly on production lines, it is the result of a genuine co-development process between the formulator and the end user, aimed at improving performance, increasing process efficiency, and reducing consumption.

n continuous-flow coating, process

industrial plant. The availability of Luxe Coat’s

development increasingly depends on the

facilities, production lines, and staff to conduct

ability to test and validate new solutions

tests under real production conditions was,

directly under real production conditions.

in fact, crucial to fine-tuning and verifying the

This principle has also inspired collaboration

performance of the new chemical formulations

between Luxe Coat (L’Aquila, Italy), a company

developed.

belonging to the Spanish group Luxe Perfil, and

This collaboration between the two companies,

DN Chemicals (Caleppio di Settala, Milan, Italy),

which has been ongoing for over fifteen years,

which has gradually evolved from a traditional

has entered a particularly intensive phase

technical and commercial relationship into

over the past three years, with numerous tests

a genuine co-development initiative. Indeed,

carried out directly on the production lines

the experience gained by Luxe Coat on its

at both the L’Aquila plant and a few Spanish

continuous-flow coating lines, combined

sites belonging to the group. These activities

with DN Chemicals’ know-how in formulating

have contributed to the development of a new

pre-treatment products, has enabled research

generation of treatments for coated aluminium.

to move directly from the laboratory to the

The latest addition is DollCoat AL 108, currently

Luxe Coat’s coil coating department for aluminium strips in L’Aquila, Italy. © ipcm

N. 101 - SEPTEMBER/OCTOBER 2026 - ipcm®

FOCUS ON TECHNOLOGY

The coil coating line.

Tank containing the DollCoat AL 108 treatment bath.

undergoing industrialisation at Luxe Coat’s premises. Rather than the

“When we met in 2018, we had only just restarted our continuous-flow

simple development of a new chemical product, this project reflects the

powder coating line, as we had initially been working solely with a liquid

evolution of a working method: starting from application requirements,

coating line,” explains Alfredo Calvano, technical and plant manager at

experimenting directly under industrial conditions, and progressively

Luxe Coat. Since then, the company has acquired, recommissioned, and

refining the formulation. The aim is to achieve ever-higher performance,

revamped several systems to expand its production capacity. “In 2020,

particularly in terms of protection against filiform corrosion, and the use

we commissioned a rolling mill, which has enabled us to bring an ever-

of pre-treated materials in highly corrosive environments such as marine

increasing share of our production process in-house, from raw materials

areas, while maintaining a focus on efficiency and reduced consumption

through subsequent treatments to coating operations. This development

in the pre-treatment process.

was accompanied by a significant expansion of our production space: we

A story of corporate growth and evolution

acquired two new buildings, bringing our covered area to approximately 55,000 m² and creating the conditions for introducing further processes to

Based in Valencia (Spain), the Luxe Perfil group has been a leading player

better integrate the various stages of the aluminium processing workflow.”

in the aluminium coating sector for many years. Its structure includes

However, this relaunch is not yet complete: Luxe Coat also plans to

Luxe Coat, an Italian company specialising in coil coating of aluminium

gradually recommission the remaining facilities and expand its production

using both liquid and powder products. We have featured the Luxe Perfil

capacity, thereby broadening the range of products it offers in European

group several times in our magazine : our first visit to the Luxe Coat

and global markets.

plant dates back to 2018. Over the past eight years, the company has

This type of industrial growth inevitably also creates the conditions for

undergone a profound transformation, marked by the recommissioning of

developing new technological solutions. In particular, collaboration with

plants, the expansion of production capacity, and the gradual insourcing of

DN Chemicals has taken on an increasingly important role in recent years,

production phases.

leading to the development of new pre-treatment formulations. Innovation

in the coating process has thus become part of a wider project aimed not only at increasing production capacity but also at continuously improving 1 B. Pennati, “Advanced technology, process renewal, and industrial research on pre-treatment:

Luxe Coat’s strategy for its business relaunch” in ipcm no. 53, Vol. IX September-October 2018

the performance, efficiency, and quality of end products.

https://www.ipcm.it/en/open/ipcm/2018/53/108-114.aspx

Pre-treatment as a key stage in coil coating

2 A. Venturi, “Luxe Perfil: the experts in the impossible rely on the new PrimeCoat® A109

The partnership between DN Chemicals and Luxe Coat began when

re-treatment product’s high performance” in ipcm® no. 89, Vol. XV September-October 2024 https://

the latter joined the Luxe Perfil group and has since deepened through

www.ipcm.it/en/open/ipcm/2024/89/104-110.aspx

ipcm® - SEPTEMBER/OCTOBER 2026 - N. 101

SPECIAL ISSUE ON ARCHITECTURE & DESIGN

FOCUS ON TECHNOLOGY

The pretreatment tunnel using DollCoat AL 108 developed by DN Chemicals after 3 years of research and testing on the production line and a coated coil exiting the curing oven.

increasingly close collaboration to meet the requirements of the company’s coating process. In recent years, the partnership has particularly focused

Coil pretreated with DollCoat AL 108.

Improved anti-corrosion performance on aluminium

“The primary objective in developing this new generation of pre-treatment

on evolving the pre-treatment stage, seeking solutions to improve its

products was to improve protection for coated aluminium, with a

performance. “Their current setup includes using DollCoat TZ 73 on the

particular focus on filiform corrosion, one of the most critical issues for

liquid coating line, where it is applied in the final stage of the cycle, i.e. the

products intended for architectural applications and characterised by high

conversion stage, and DollCoat TZ 75 on the powder coating line, where

durability requirements,” notes Calvano. “Together with DN Chemicals’

it is applied by spraying,” explains Mara Pege, the head of DN Chemicals’

technical team, we set up a testing programme combining EIS and

laboratory.

ACET electrochemical analyses (see the Technical box) with accelerated

It was precisely on the basis of the experience gained with these systems

corrosion tests. The trials covered various aluminium alloys and coating

and Luxe Coat’s specific production requirements that DN Chemicals

technologies, so we worked with both powder and liquid coating lines.

began developing a new generation of products. “The project arose

“The test methods adopted included electrochemical impedance

from direct consultation with Alfredo’s team, which highlighted the need

spectroscopy (EIS), carried out on pre-treated but still uncoated material,

to combine higher performance with greater process efficiency while

enabling the electrochemical behaviour of surfaces to be characterised

reducing chemical consumption,” adds Pege. “The first result was

and the effectiveness of the protection provided by the treatment to be

DollCoat IL 101, developed to meet the requirements of the L’Aquila plant’s

assessed. We also carried out salt spray tests on coated material, which

line by integrating with the latest product range and the conversion system

are still ongoing, to assess corrosion resistance over time. We are very

already in use. However, tests have shown that the application method

pleased with the results obtained, which are particularly encouraging: the

affects the treatment’s performance: spray application and application

analyses conducted have shown the system to perform well on various

via a chemcoater, as used, for example, on the Valencia site’s line, yield

alloys and with both coating technologies. In particular, in the tests carried

different results under different conditions.”

out so far, filiform corrosion appears to be largely confined to the small

After about three years of research, DollCoat AL 108 was launched.

portion of unprotected material at the notch.”

Designed as a product of the same generation as DollCoat IL 101, it was

A particularly significant point is that these results are not derived

specifically developed for spray application on the L’Aquila plant’s liquid

exclusively from laboratory tests. “The cooperation of the Luxe Perfil

aluminium coil coating line. Therefore, it is not simply a replacement for

group was invaluable,” states André Bernasconi, the general manager of

TZ 73 but the result of a development process closely aligned with the

DN Chemicals, “because validation was carried out progressively on its

plant’s characteristics, application process, and production requirements.

production lines, two in Italy and one in Spain. This enabled our lab to

The transition from TZ 73 to AL 108 is now complete, following months of

test the product under different application conditions and to refine its

industrial trials that enabled data to be collected directly from production

formulation until it met the requirements.”

and the new technology to be progressively optimised.

N. 101 - SEPTEMBER/OCTOBER 2026 - ipcm®

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SPECIAL ISSUE ON ARCHITECTURE & DESIGN

André Bernasconi, on the left, with Alfredo Calvano.

From experimentation to industrialisation

The development of DollCoat AL 108 therefore marked a milestone in a broader process that saw Luxe Coat and the chemical manufacturer transfer production requirements directly into research and development activities. “The ability to combine laboratory expertise, testing on production lines, and trials repeated under industrial conditions has enabled us to progressively refine the process, taking into account not only corrosion resistance properties but also specific application methods and production requirements,” says Bernasconi. “The result is a pre-treatment process designed entirely to the customer’s specifications. The phase currently underway will be crucial for completing the validation of the new product and consolidating the results obtained in the preliminary tests. Extending the test campaigns and collecting further data will enable us to define the treatment’s long-term behaviour with greater precision and to guide the product towards final qualification.” For the Luxe Perfil group, the project forms part of a broader strategy to modernise its facilities and gradually integrate its production processes with the aim of offering the market highly durable materials for the new LUXE INFINITY product family. For DN Chemicals, on the other hand, it is a concrete example of how a formulation can be developed from real-world application conditions and, through continued dialogue with the customer, evolve into an industrial solution. This close interaction between chemistry, process, and production is one of the most interesting aspects of the project: a demonstration that innovation does not arise solely from the product itself, but from the ability to develop and test it directly within the context in which it is intended to operate.

SPECIAL ISSUE ON ARCHITECTURE & DESIGN

FOCUS ON TECHNOLOGY

DollCoat AL 108: the next-generation product for aluminium pre-treatment The new generation of DollCoat continues to evolve, offering tailored solutions for a range of application requirements, including the pre-treatment of aluminium alloys. Although DollCoat GP 107 has already delivered significant results, development work has continued to further enhance its performance. This has led to the creation of DollCoat AL 108, which is currently undergoing certification in accordance with QUALICOAT requirements. DollCoat AL 108 shares several characteristics with the other solutions in the new DollCoat series:  it is formulated with resins modified using synthetic oligomers derived from silanes (POS T8, fig. 1);  it can be applied in dipping, spraying, or atomisation systems;  it operates at low temperatures, 20 to 35 °C;  it contains no chromium or other heavy metals;  it does not require high curing temperatures and is already effective at 60 °C;  it does not generate sludge. From the earliest applications, its use in industrial plants has shown a marked improvement in pre-treatment quality. For example, characterisation of 3000-series aluminium alloys using electrochemical impedance spectroscopy revealed high polarisation resistance (Rp) values, significantly higher than those obtained with ‘traditional’ processes. The test also reported a corrosion current density (Jcorr) of 1.77 × 10-7 A/cm² and a corrosion rate of 0.0021 mm/y, associated with a polarisation resistance (Rp) of 2,600 Ω. The ACET characterisation of the same coated aluminium surfaces revealed a high level of protection, a particularly significant result given that the coil was painted with liquid products to a maximum film thickness of 25 µm. The reduced thickness, in fact, made the ACET test particularly demanding. Compared with previous applications, the results show a marked improvement, attributable to the use of a pre-treatment product containing a resin modified with FLG-LD graphite engineered by ENI (fig. 2). Characterisation measurements showed a paint thickness of 25 mm, with impedance values ranging from 2.68 × 10⁹ to 5.22 × 10⁹ Ohm·cm² (Z min and Z max, respectively). The measured ΔZ was 2.97%, while water uptake was limited to 0.08%. Performance in acetic salt spray tests has improved significantly, as shown by the results reported in this article. In summary, DollCoat AL 108 and the forthcoming DollCoat IL 101 for chemcoater applications offer significant improvements over ‘traditional’ benchmark technologies.

Fig. 1: POSS are synthetic oligomers derived from silanes and characterised by a cage-like structure. Thanks to the properties inherited from silanes, they act as adhesion promoters and anti-corrosion agents, helping to enhance the barrier effect.

N. 101 - SEPTEMBER/OCTOBER 2026 - ipcm®

Fig. 2: In the new DollCoat products, the POSS-modified resins are further additivated with FLG-LD graphite, engineered by ENI.

SPECIAL ISSUE ON ARCHITECTURE & DESIGN

BRAND-NEW

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N. 101 - SEPTEMBER/OCTOBER 2026 - ipcm®

BRAND-NEW

SPECIAL ISSUE ON ARCHITECTURE & DESIGN

SurTec to showcase aluminium surface treatment solutions at ALUMINIUM 2026 At ALUMINIUM 2026, SurTec will showcase high-performance aluminium surface treatment solutions combining resource efficiency and sustainability for demanding automotive, aerospace and defence applications.

t ALUMINIUM 2026 in Düsseldorf, SurTec will present its comprehensive portfolio for aluminium surface treatment. The

focus will be on sustainable and high-performance technologies for demanding applications for the automotive, aerospace and defence industries. “The requirements for aluminium surface treatment continue to evolve. At the same time, resource efficiency and sustainable processes are becoming increasingly important,” explains Dr. Torsten Koerner, Director

Scan

Spray

Global Product Management, SurTec International GmbH. “Our portfolio comprises advanced surface treatment solutions for a wide range of applications – from passivation and etch-passivation solutions for sealing, corrosion protection, and adhesive bonding in the automotive industry to high-performance passivation for copper-containing aluminium alloys with QPL approval for the aerospace and defence industries. In this way, we help our customers to make their processes more efficient, sustainable, and ready for the future.” SurTec’s complete portfolio of anodizing process solutions provides customers with coordinated solutions from a single source. The portfolio covers the entire anodizing process, from surface preparation and anodizing to colouring and a wide range of sealing technologies. SurTec’s Global Center of Competence for Anodizing in Italy combines extensive application and process expertise to support customers worldwide with tailored solutions across the entire anodizing process chain. “My colleagues at the Global Center of Competence in Italy look forward to talking with visitors about innovative nickel-free cold and mid-temperature sealing technologies, as well as additional solutions

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for optimizing their anodizing processes,” says Raffaele Cadorna, General Manager, SurTec Italia Sas di Externa Holding Srl. The SurTec experts look forward to welcoming visitors from around the world at Booth 3G52 and discussing current challenges and practical solutions for aluminium surface treatment. For further information: www.surtec.com Gema Europe Srl | Via Goldoni, 29 20090 Trezzano s/N | Italy T +39 02 48 400 486

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ADVANCEMENTS

SPECIAL ISSUE ON ARCHITECTURE & DESIGN

SurTec 650: one chemistry, four critical functions for aluminium surfaces Fabio Vincenzi SurTec International – Bensheim, Germany fabio.vincenzi@surtec.com

Pre-treatment, bare-metal passivation, anodic oxide sealing, and anodic flash sealing: four functions performed by a single trivalent chromium technology to protect aluminium against corrosion and simplify surface treatment process management.

is worth stating plainly: SurTec 650 is not chromium-free, and was never meant to be. It is built on trivalent chromium, Cr(III), a chemically different species from hexavalent chromium, Cr(VI). Cr(VI) is the toxic, carcinogenic and strictly regulated form that REACH and RoHS target; Cr(III) is a non-toxic, naturally occurring form of chromium — an essential trace nutrient, in fact — and is not subject to those restrictions. The point of the technology is to deliver the corrosion performance once associated with Cr(VI) chromating using the benign Cr(III) chemistry instead. What is less widely appreciated, even among surface finishers who use it

sk a surface finisher what keeps them up at night and, sooner

every day, is how many different jobs this single chemistry is asked to do.

or later, aluminium comes up. It is light, it is everywhere from

Depending on the process sequence, SurTec 650 can act as:

aircraft fuselages to battery housings, and it corrodes in ways

 a pre-treatment before painting, replacing chromate conversion

that are hard to predict and hard to stop once they start. For decades, the

coatings ahead of liquid or powder coating;

industry’s default answer was hexavalent chromium: chromate conversion

 a stand-alone passivation for bare metal corrosion resistance and

coatings and dichromate seals that worked extremely well but came with

electrical conductivity;

a heavy regulatory and environmental price tag.

 a sealing treatment for anodised aluminium, closing the porous oxide

SurTec 650, a trivalent chromium technology originally developed from a

layer left after anodising;

NAVAIR (US Naval Air Systems Command) patent, was created to remove

 a sealant for a thin anodic “flash” grown specifically as a pre-treatment

Cr(VI) from that equation without giving up performance. One distinction

before painting.

SurTec 650 has protected uncoated aluminium aerospace components for decades — one of four distinct functions performed by the same chemistry. © AdobeStock

ADVANCEMENTS

This article walks through all four functions, with a particular focus on

and REACH-compliant, and contains no hexavalent chromium at any stage

sealing, the application that, in our experience, is still the least understood,

of the process or on the finished surface.

even though corrosion resistance is exactly where it delivers its biggest

It is worth noting, since the term “tri-chrome” sometimes invites the

benefit.

question, that SurTec 650 is formulated and qualified specifically for aluminium and its alloys, wrought or cast. The one documented exception

How SurTec 650 works

is magnesium: SurTec 650’s technical data sheet also lists it as suitable

SurTec 650 is a liquid, trivalent-chromium-based concentrate. When

for use as a conversion coating on magnesium alloys, a detail that is

aluminium is immersed in the working bath (typically at pH 3.5–4 and

genuinely useful in lightweight mixed-metal assemblies, aerospace

30–40 °C), the main chemical reactions occur rapidly: the bulk of the

brackets or e-mobility structures that combine aluminium and magnesium

material exchange — dissolution of the native aluminium oxide and of

components in the same sub-assembly. For every other base metal,

metallic aluminium at the surface — takes place within the first one to ten

SurTec offers dedicated chemistries (steel, for example, is treated with

seconds of immersion. Because the process is reductive at the aluminium

phosphate-free SurTec 609 EC); SurTec 650’s identity remains firmly

surface, the formation of hexavalent chromium during this critical step

anchored to light alloys.

is actively suppressed, not just avoided downstream. After about five minutes, the final layer has fully formed: a mixed oxide of chromium(III), zirconium(IV) and aluminium, a few tenths of a micron thick, that is

Function 1 — Pre-treatment before painting

The most widely recognised use of SurTec 650 is also the one closest

chemically inert and provides a genuine barrier against corrosive attack,

to its historical origin: a Cr(VI)-free replacement for hexavalent chromate

not merely a sacrificial or cosmetic film. The resulting passivation layer is

conversion coatings ahead of liquid paint, powder coating or e-coat. Here

inorganic and heat-resistant up to around 100 °C with only minimal loss in

the conversion layer does two jobs at once, it protects the bare metal

corrosion resistance, a useful margin for parts that see moderate service

during transport and intermediate storage, and it provides the chemical

temperatures or downstream curing.

anchor that the subsequent coating bonds to.

In practice, the result depends as much on surface preparation as on the

In architectural and construction applications (window and door frames,

passivation step itself. A typical sequence is degreasing, then deoxidising

curtain walling, façade profiles) this combination has become the de

or desmutting to remove the smut left by alloying elements, an alkaline

facto benchmark (Figure 1). SurTec 650 is QUALICOAT-approved and

etch where the silicon content is low (below roughly 1%), the SurTec 650

recognised by SurTec as the technology of choice in this segment

immersion or spray step itself, and a final rinse in deionised water, with a

specifically because of its outstanding resistance to filiform corrosion,

rinse stage after each step. The surface must be water-break-free before

the thread-like creeping corrosion that can develop under powder-coated

it reaches the passivation bath; everything the conversion layer does well

aluminium profiles in humid, coastal or de-icing-salt environments. Paint

downstream depends on that.

adhesion to powder coatings remains best-in-class even after artificial

Performance varies with the alloy being treated, which is itself a useful

weathering, which is precisely the property façade fabricators are tested

diagnostic for the finisher (Table 1).

against.

Table 1: Corrosion resistance of bare metal treated with SurTec 650 according to alloy type (neutral salt spray, ISO 9227). Alloy type

Bare corrosion protection (NSS, ISO 9227)

Non-heat-treated wrought and rolled alloys

up to 500 h

Heat-treated wrought and rolled alloys

up to 336 h

High Cu- and high Zn-containing alloys

120 – 168 h

Cast alloys, Si > 1%, Cu < 0.1%

up to 240 h

Cast alloys, Si > 1%, Cu > 0.1%

24 – 120 h

The pattern is consistent with what every anodiser already knows from experience: the more alloying elements an aluminium grade carries — copper for strength, silicon for castability — the more second-phase particles and micro-galvanic cells it contains, and the harder it is to protect with a conversion coating alone. SurTec 650 meets MIL-DTL-81706B (classes 1A and 3) and MIL-DTL-5541F, is QPL-listed, REACH-registered

Figure 01 - Aluminium for façades and curtain walls: SurTec 650 is the QUALICOAT-approved benchmark for filiform corrosion resistance and powder-coating adhesion.

ipcm® - SEPTEMBER/OCTOBER 2026 - N. 101

ADVANCEMENTS

The same logic extends across automotive aluminium body and trim parts, aluminium wheels, and general industrial components destined for liquid, powder or e-coat finishing. It is also the segment where the role of SurTec 650 within a wider portfolio becomes clearest: on a mixed-metal line it handles the aluminium, while dedicated phosphate-free chemistries handle the steel, so the finisher can run a coherent, Cr(VI)-free pre-treatment strategy across both substrates rather than compromising on one to suit the other.

Function 2 — Passivation for bare metal corrosion resistance and conductivity © AdobeStock

Many aluminium components are never painted at all, and for those, SurTec 650 is used as a stand-alone passivation rather than a paint base. Two industries illustrate why this matters. In aerospace, SurTec 650 has been the benchmark replacement for chromate passivation on uncoated aluminium for decades, precisely because it solves a requirement profile that is unusually demanding: excellent bare metal corrosion resistance, low electrical contact resistance (below 5,000 µΩ per square inch, i.e. below about 32 mΩ·cm²), and a markedly reduced tendency toward contact corrosion where it meets adjoining metal components — passivation lowers the driving force for galvanic attack and slows it considerably, though it cannot eliminate it outright where dissimilar metals stay in direct contact. Avionics housings, in particular, need to stay electrically conductive while remaining corrosion-resistant, a combination that

hexavalent chromate coatings achieved, and that SurTec 650 was engineered to match without the Cr(VI) liability. The same conductivity profile has made it the reference technology for 5G antenna and mast hardware, where reliable, low-resistance grounding has to survive years of outdoor exposure (Figure 2). In electromobility, the requirement looks different but the underlying chemistry is identical. Battery pack housings and Electronic Control Unit (ECU) enclosures combine a gasket seal with the SurTec 650 passivation layer to prevent corrosive seal creepage — the slow ingress of moisture along a sealing line that, left unchecked, eventually compromises the battery compartment (Figure 3). Because SurTec 650 already delivers

Figure 02 - 5G antenna and mast hardware: corrosion resistance and reliable grounding conductivity on the same surface. Figure 03 - EV battery and powertrain housings: SurTec 650 helps prevent corrosive ingress along gasket lines. Figure 04 - Aerospace components in 7075 aluminium: anodised and sealed with SurTec 650, this high-zinc alloy achieves a level of corrosion resistance that the anodic layer alone cannot provide.

N. 101 - SEPTEMBER/OCTOBER 2026 - ipcm®

best-in-class bare metal corrosion protection, some OEMs are able to consider additional e-coating of the battery housing redundant, simplifying the process chain rather than adding a layer to it. SurTec has also built a dedicated Applicator Qualification Process around SurTec 650 together with leading automotive, electronics and aerospace OEMs, so that end customers can identify coaters whose process is specifically qualified for a given requirement.

SPECIAL ISSUE ON ARCHITECTURE & DESIGN

Function 3 — Sealing the anodic oxide layer

This is the function this article wants to bring forward, because it is where corrosion resistance is won or lost on some of the most demanding aluminium parts in the industry, and yet it is rarely discussed with the same depth as pre-treatment or passivation. Why anodised aluminium needs sealing at all Anodising grows a layer of aluminium oxide that is hard and wearresistant, but also porous: at the microscopic level it looks like a honeycomb of open cells. Left unsealed, that porosity is an open invitation for moisture, chlorides and other contaminants to reach the metal underneath. Sealing closes the pores — historically with boiling water (slow and energy-intensive), with nickel salts (effective but carrying nickel-related restrictions in some regulatory frameworks), or, for the best corrosion performance available, with hexavalent chromium dichromate. The dichromate option is the one the industry has spent the last two decades trying to leave behind: the corrosion performance was excellent, which is exactly why it was so hard to replace. A widely cited case from US military history makes the point well — anodised 7075T6 fasteners used without an adequate seal suffered catastrophic exfoliation corrosion in service, and dichromate sealing was the fix; that same fastener family is precisely the kind of high-strength, high-zinc aluminium alloy where unsealed anodising is most vulnerable. Where trivalent chromium sealing fits in Trivalent-chromium sealing technologies — the same chemical family as SurTec 650 — emerged directly out of the effort to match dichromate’s corrosion performance without its toxicity. The mechanism is analogous to passivation but applied to an alreadyanodised surface: Cr(III) and associated mixed oxides deposit within and across the pore structure of the anodic layer, occluding it and forming a continuous, inert barrier. Independent corrosion testing on trivalent chromium seals has repeatedly shown protection comparable to traditional dichromate sealing — and, in favourable alloy and anodising combinations, fully matching it — while removing Cr(VI) from both the process bath and the treated part.

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Why this matters most on impure and cast alloys The alloys that benefit most from sealing are exactly the ones that are hardest to protect by passivation alone — the same high-copper, highzinc wrought alloys (2024, 7075) and the impure die-cast and pressurecast alloys that show up at the lower end of the NSS table above. Copper- and silicon-rich intermetallic particles create localised galvanic cells that passivation alone cannot fully neutralise; on castings, porosity and flow lines compound the problem further (Figure 4).

www.verind.com

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Figure 05 - Architectural aluminium profiles: a pre-anodised flash sealed with SurTec 650 combines the corrosion resistance of the anodic layer with a surface ready for painting.

Figure 06 - Automotive: a single base-metal protection strategy for aluminium body panels, trim, wheels and structural components.

Sealing an anodised layer on these alloys with SurTec 650 adds a second,

quality itself is verified with the dye-stain test (ISO 2143 / ASTM B136)

independent barrier on top of the anodic film itself, and the results show

or, where a quantitative result is required, acid dissolution or admittance

it: corrosion resistance of up to 720 hours in neutral salt spray has

testing (ASTM B680, ISO 2931) — the standard methods the industry uses

been demonstrated on die-cast alloys when SurTec 650 is used as the

to confirm that the pores have actually closed. That is a distinct check

sealing step, with qualification from multiple leading automotive OEMs

from the water-break test used earlier in the line to verify the surface is

and Tiers. For pressure die-cast aluminium structural parts in particular

clean before treatment, or the cross-cut adhesion test applied where a

— increasingly common in automotive and e-mobility platforms, where

subsequent coating follows; each test answers a different question at a

large, complex castings are anodised for wear and corrosion resistance

different stage.

on functional surfaces — sealing is the step that decides whether the part meets its corrosion specification in the field, not just on the test panel. On die-cast components specifically, getting a reliable seal starts even further upstream: the release agent used in the casting process has to leave a

Function 4 — Sealing the anodic flash from a pre-anodising pre-treatment

The fourth function is, in a sense, the bridge between Functions 1 and 3

surface that responds predictably to the cleaning, anodising and sealing

— and it is the one most often overlooked. Alongside chemical conversion

steps that follow. That is why SurTec works directly with release-agent

coating, there is a second, electrochemical route to preparing aluminium

specialist Chem-Trend, a sister company under Freudenberg Chemical

for painting: a thin, deliberately grown anodic layer, only a few microns

Specialities, to keep the casting and surface-treatment ends of that

thick, produced in an anodising tank specifically as a pre-treatment before

process chain compatible.

coating. This is variously called pre-anodising, thin-layer anodising or an “anodic flash” — flash because it is a short, rapid anodising step that builds

Process compatibility

just a few microns of oxide, not the 10–20 µm of a typical decorative

Because SurTec 650 is liquid, nickel-free and operates without the

anodised finish, or the up to 100 µm of a hard-anodised (hardcoat) layer.

temperature and time penalty of hot-water sealing, it integrates cleanly into

It is important not to confuse this with the native oxide that forms

existing anodising lines as a cold or mid-temperature sealing step. Seal

spontaneously on any aluminium surface in air.

N. 101 - SEPTEMBER/OCTOBER 2026 - ipcm®

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The anodic flash is an induced, controlled and intentional oxide,

In other words, this is Function 3 (sealing an anodic layer) applied to the

electrochemically grown to a defined thickness, and it is a recognised

specific case of a thin anodic layer that exists only to serve Function 1

alternative to chemical conversion coating as a pre-treatment ahead

(pre-treatment before painting). It is the clearest illustration of why SurTec

of powder or liquid painting. Its great strength is corrosion resistance:

650 is best understood as a single chemistry with several jobs rather than

a thin anodic layer is one of the most effective barriers against filiform

four separate products: the same Cr(III) oxide is being asked to passivate,

corrosion known in architectural aluminium, often outperforming a

to seal porosity, and to leave behind a surface the paint will bond to — and

conversion coating at the cut edges and weak points of a powder-coated

it does all three at once.

profile, which is exactly where filiform attack tends to start (Figure 5). There is a catch, however. To preserve the mechanical keying that gives the subsequent powder coat its grip, the anodic flash is left with its

Across every industry that relies on aluminium

The functions described above recur, in different combinations, across

pores open rather than fully sealed in the conventional sense. The risk

virtually every sector that builds with aluminium:

this creates is not only porosity for corrosion: residual acid electrolyte

 Automotive: pre-treatment for aluminium body panels, trim and

from the anodising bath stays trapped inside those pores, and if it is

wheels; passivation and sealing for battery housings, ECU enclosures and

not addressed before painting, it can react or outgas during the paint’s

structural die-cast components in electrified platforms (Figure 6).

baking and curing cycle, causing blistering in the finished film. This is

 Aerospace: bare metal passivation for avionics and electronic housings;

the gap SurTec 650 fills. Applied immediately on the anodic flash, it

oxide sealing on anodised structural and fastener-related parts, where

stabilises the anodic coating and reduces these residual acid inclusions

decades of qualification history give specifiers confidence.

in the pore structure — protecting against both corrosion and paint

 Transportation and rail: pre-treatment of brake callipers and discs,

blistering — while still leaving a surface ready to bond with the coating

where corrosion protection must survive extreme thermal cycling without

that follows.

compromising safety-critical performance (Figure 7).

SPECIAL ISSUE ON ARCHITECTURE & DESIGN

ADVANCEMENTS

Figure 07 - Rail: rolling-stock components require corrosion protection that can withstand extreme thermal cycling and continuous exposure to outdoor conditions.

 Construction and architecture: façade profiles, window and door fittings, where filiform corrosion resistance and long-term paint adhesion

One chemistry, fewer process headaches

The case for SurTec 650 has never really been about replacing one

define product warranties.

chromate step with one trivalent chromium step. It is about recognising

 Electronics and electrical: 5G antenna and mast hardware, electronic

that pre-treatment, passivation and oxide sealing are facets of the same

enclosures, anywhere conductivity and corrosion resistance have to

surface chemistry problem, and that a single, well-characterised, Cr(VI)-

coexist on the same surface.

free technology can be qualified once and then deployed wherever

 Healthcare and lifestyle: aluminium housings for electro-medical

aluminium needs protecting — whether the part is about to be painted, left

equipment, where cleanliness and long-term corrosion resistance both

bare, or has just come out of an anodising line. For finishers managing

matter.

multiple aluminium alloys, multiple industries and an increasingly

What ties these sectors together is not the end application but the

demanding regulatory environment, that consolidation is, in itself, a

underlying material: aluminium that has to perform — untreated or

meaningful part of the value.

anodised, painted or bare — in environments that will eventually try to corrode it.

ABOUT THE AUTHOR Fabio Vincenzi is Global Anodizing Engineer and R&D Specialist at SurTec International, where he focuses on the development and industrial qualification of pre-treatment, passivation, and anodising sealing technologies for aluminium.

N. 101 - SEPTEMBER/OCTOBER 2026 - ipcm®

TIGER Drylac®

Beyond time. Beyond expectations.

TIGER Drylac® Super Durable Powder Coatings deliver long-term color and gloss stability, enhanced UV resistance and reliable protection for demanding architectural applications - where performance must endure for decades.

www.tiger-coatings.com RAL 9010 Pure White 68/10066

QUALICOAT class 2 GSB Florida 3

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Beyond extrusion: Estral builds a comprehensive service with support from its paint supplier Alessia Venturi ipcm®

Since 1974, Estral has progressively expanded its expertise, processes, and services, evolving from a company specialising in extrusion into a partner capable of managing aluminium profiles across most of the supply chain. The implementation of powder coating operations marked the latest step in this vertical integration strategy, with supplier selection also playing a strategic role: Estral’s partnership with TIGER Coatings enables it to broaden its product range, address challenges, and better meet customer needs.

“M

oving towards meeting almost all of our customers’ requests and requirements for the

production and finishing of aluminium profiles seemed to us to be the most natural path of development for our company, which has been applying its expertise to this industry for the past fifty years.” These words, spoken by Giancarlo Alberti, the CEO of Estral, during his interview with ipcm®, describe a growth

trajectory common to an ever-increasing number of manufacturing companies today: progressively expanding their expertise and services to meet customer needs in a more comprehensive manner. Anticipating, embracing, understanding, internalising, and meeting the needs of their target markets are values embedded in the DNA of all contract businesses: as they do not have a product of their own, they help other companies complete, finish, enhance, and promote theirs. After all, the line between manufacturer and service provider is gradually blurring.

N. 101 - SEPTEMBER/OCTOBER 2026 - ipcm®

Estral vertical powder coating line for profiles up to 7.5 mt was designed by Euroimpianti (Valeggio sul Mincio, Verona, Italy).

FOCUS ON TECHNOLOGY

On the one hand, industrial companies are now expected to offer not

production processes, enabling it to offer increasingly comprehensive

just products but also solutions, customisation, refinement, and after-

services. The implementation of powder coating operations, together

sales support. On the other hand, contractors and service providers

with the establishment of solid partnerships with coating producers,

have gradually expanded their scope of activity, investing in technology,

was a further statement of intent to maintain a focus on quality and

expertise, and processes to play an increasingly significant role in the

delivery times, and to continue growing from a technical perspective. The

creation of end products.

collaboration with TIGER Coatings is a concrete example of this.

That is where the right choice of suppliers and partners becomes strategically important. To guarantee flawless service, it is essential to build a supply chain of reliable providers selected not only for the quality

Specialising in shaping aluminium

Estral, an acronym for Estrusione Alluminio (meaning ‘aluminium

of their products but also for their ability to share standards, values, and

extrusion’), was founded in 1974 in Manerbio, within one of Italy’s most

corporate vision. As the distinction between product and service blurs, so

prolific industrial districts: an area in the Lombardy region that stretches

does the separation between suppliers and partners.

between the provinces of Bergamo and Brescia and is home to numerous

Estral is a concrete example of this evolution: its fifty-year history reflects

companies specialising in the extrusion, die-casting, machining, and

the gradual expansion of its expertise and the vertical integration of its

finishing of aluminium for architectural and industrial applications.

From left to right: Entrance and exit of the profiles from the drying and curing ovens; The coating booths are housed in a pressurised clean room; Application of TIGER Coatings powders in glossy white, Estral’s flagship colour.

ipcm® - SEPTEMBER/OCTOBER 2026 - N. 101

FOCUS ON TECHNOLOGY

In its 50-year history, the company has expanded its original core

aluminium alloy profiles. We operate five extrusion presses with an annual

activities, extrusion and subsequent machining operations, by integrating

production capacity of 40,000 tonnes of profiles, ranging from small to

into its corporate structure a foundry, Deral SpA, adjacent to its original

large sizes. We carry out all types of machining operations, collaborating

plant, which manufactures billets for extrusion by collecting, sorting, and

with our customers to bring their ideas, designs, and innovative products

smelting scrap, with a production capacity of 70,000 tonnes per year; a

to life. We also handle thermal break assembly, film lamination, screen

retail distribution centre, Alu-Brixia Srl, which delivers 5,000 tonnes per

printing, heat-shrink packaging, pre-assembly, and packaging with

year of profiles on a just-in-time basis; and, five years ago, a new powder

bespoke kits tailored to each requirement,” says Giancarlo Alberti, CEO of

coating department certified to Qualicoat Seaside standards.

Estral. “The latest process we have introduced is powder coating. The goal

Rather than mere scale expansion, this reflects a clear strategy of vertical

was to manage the entire aluminium production chain and thus provide

integration, aimed at extending control over the supply chain and, above

a comprehensive service, including ensuring the availability of the raw

all, enhancing the company’s ability to meet customer needs through

material right from the start thanks to our foundry. This is particularly

an integrated offering. “Since 1974, we have been working alongside

valuable today, in light of the global situation characterised by significant

our customers to design, develop, and manufacture custom extruded

uncertainty regarding procurement.”

One of the two Optispeeder powder centres WITH Smart-In-Line technology supplied by Gema Europe (Trezzano sul Naviglio, Milan, Italy).

The powder coating application booths are equipped with the Polifluid system by Eurosider (Grosseto, Italy) which controls temperature and humidity of compressed air.

N. 101 - SEPTEMBER/OCTOBER 2026 - ipcm®

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“Estral is a company with a strong focus on quality – a word that recurs countless times in all our day-to-day communications, both internally and externally – and is totally dedicated to serving its customers. We do not have our own range of branded products: we manufacture exclusively to the specifications of our customers, which come from a wide variety of industries, ranging from furniture to the automotive sector, for which we have a dedicated, IATF 16949:2016-certified department,” adds Alberti. “One of our key strengths is innovation: we invest heavily in technology, equipment selection, and product development.” “Another strength is our extreme flexibility, in terms of both the processes we perform and the industries we serve. In this journey towards complete vertical integration of our operations, the only process we are not currently carrying out in-house is anodising. I do not rule out the possibility that we may integrate this finishing technology as well in the future, but for the time being, we have noticed a market trend favouring coating. Our decision was also supported by the availability of a wide range of powder coatings with an anodised effect, which are remarkably realistic while offering far greater colour consistency and environmental sustainability. TIGER is a great help to us in this regard, thanks to its wide range of colours and special effects, particularly in the range of anodised-effect finishes.” “In 2017, TIGER Coatings developed the first colour chart for Stumpfmatt (ultra-matt) effects, when demand for super-matt finishes – including anodized effects – was beginning to emerge, and would soon become an architectural trend,” explains Marzia Brambilla, COO at Tiger Coatings Italy (Bergamo). “Today, these effects are the solution many coating contractors turn to whenever possible. TIGER boasts one of the most extensive colour collections on the market, thanks to its long-standing, close relationship with the worlds of design and architecture.” The choice of the right coating supplier thus becomes an integral part of Estral’s service promise: it is not merely a matter of sourcing a raw material, but of securing high-quality, consistent standards, continuity, and responsiveness that match the requirements of its customers.

Consistent quality and technical guidance at the heart of the supplier-customer relationship “In the extrusion market, we are recognised as a company that

places the utmost emphasis on product quality,” states Alberti. “Fifty years of history could not be ‘tarnished’ by failing to apply the same approach to coating. It was therefore essential for us to be meticulous and rigorous in both the process and the selection of suppliers.”

FOCUS ON TECHNOLOGY

“We have been working with TIGER since installing our powder application

specified by our customers but also the standard RAL finishes. We

plant in 2021, initially responding mainly to specific customer requests,”

currently use several exclusive TIGER products, ranging from special

notes Devid Battagliola, planning manager for Estral’s coating department.

finishes, of which we can purchase as little as a single box, to standard

“The quality of its powder coating products, and above all their consistent

colours and high-turnover finishes. These include, for example, glossy

quality from one batch to another, make TIGER one of the company’s most

white, our flagship colour, which we selected from TIGER’s range to ensure

widely used suppliers. Over the past five years, TIGER has reorganised

the highest quality even on ‘simple’ finishes, if we can call them that.”

internally at both technical and commercial levels, and the addition of

“We have not developed any exclusive colours with TIGER, as the wide

more customer-focused staff has enabled our relationship to evolve,

range of products they offer means that we can almost always provide

establishing a partnership that now encompasses not only the finishes

what the customer is looking for,” Battagliola continues. “We have drawn

Unloading of glossy white profiles.

N. 101 - SEPTEMBER/OCTOBER 2026 - ipcm®

One of the 5 extrusion presses operated by Estral at its Manerbio (Brescia, Italy) site.

SPECIAL ISSUE ON ARCHITECTURE & DESIGN

Coatings according to GSB: on TIGER’s expertise on several occasions whenever we have had to address specific customer requests or technical requirements that we were unable to handle on our own or that would have required much longer lead times. Their support has enabled us to resolve these issues quickly, helping us identify the nature of the problem

Long-lasting attractiveness

and find a solution."

of facades, buildings and

“We have established a solid partnership with Estral, in line with our company’s primary commercial objective,” remarks Marzia Brambilla

industrial products

from TIGER. “Its team understands that our products’ higher costs

made of aluminium, steel and galvanized steel

ve d P r e t r e a t me p ro

a te r

A p p rove d C o

Coated Aluminium & Steel.

Approved Quality.

e ri

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

From the left: Alessia Venturi of ipcm®, Devid Battagliola of Estral, Marzia Brambilla of TIGER Coatings Italy and Giancarlo Alberti of Estral.

WE ARE EXHIBITING Visit us on stand 3F70-03 06 - 08 October 2026 Exhibition Centre Düsseldorf, Germany

SPECIAL ISSUE ON ARCHITECTURE & DESIGN

FOCUS ON TECHNOLOGY

are more than offset by the resulting performances, their consistent

as Estral,” says Brambilla.This partnership, therefore, goes beyond the

quality, and our assistance and problem-solving capabilities. What I find

selection and supply of powders; it is integral to how Estral has built its

particularly interesting about working with Estral is its ability to guide

new coating department, a technological solution designed to serve its

customers in making technical choices about which powders to use,

customers and help them stand out in the market through the high-

suggest alternatives, and steer them towards options with higher added

quality finishes of their profiles.

value.”

Prompt responses to enhance service delivery

Product quality, however, is only one of the necessary conditions for providing a comprehensive service: for Estral, paint suppliers must also be able to meet its needs in terms of logistics and service speed. “Delivery times for powder products have a significant impact on our own lead times,” says Giancarlo Alberti. “Upstream of our coating plant, we have installed a compactable, mobile warehouse with a capacity of 1,500 tonnes for storing both our own extruded products and our customers’ profiles, allowing material to be immediately available as and when required, in quantities ranging from a single bar to several tonnes. This has accelerated our turnaround times, making it essential that our powder supplier guarantees the same speed of delivery." “All the steps in TIGER’s ongoing development – including the opening of the new logistics hub in Dalmine planned for 2027 – are bringing the company increasingly closer to meeting the needs of customers such

Technical notes on Estral’s coating line The coating line, designed and installed by Euroimpianti (Valeggio sul Mincio, Verona, Italy), has a production capacity of 800 bars per hour (approximately 100 tonnes per week) with a maximum length of 7,500 mm. As Estral is Qualicoat Seaside certified, the pre-treatment phase comprises a two-stage acid process and Henkel’s Bonderite® nanotechnology-based conversion, sprayed via a PNR system. The line incorporates two application booths fitted with Gema spray guns and a powder coating unit featuring Smart-In-Line Technology. These booths ensure 99.9% powder recovery and operate simultaneously, one for light colours and the other for dark ones. The booths are connected to a Polifluid nitrogen generation system from Eurosider (Grosseto, Italy), which enhances film stretching and application consistency, particularly for metallic colours. The drying and curing ovens are adjacent, and an energy recovery and recycling system uses heat from the latter to warm the former. The coating plant is completed by an in-line laser paint stripping machine for the hanging hooks, also supplied by Euroimpianti, and a water treatment system from Italplant.

N. 101 - SEPTEMBER/OCTOBER 2026 - ipcm®

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EcoDie: innovation and sustainability in aluminium extrusion die cleaning Edited by ALSAN - Alvarez Schaer Paterna – Valencia, Spain

marketing@alsan.es

ALSAN, a company specialising in the development and production of chemical products for anodizing and powder coating lines, has developed EcoDie, an innovative system for recovering and reusing caustic soda from spent aluminium extrusion die cleaning baths, significantly reducing raw material consumption and waste management costs while contributing to a favourable return on investment.

egular die cleaning is an essential operation in an aluminium extrusion plant to ensure consistent process quality. The dies are cleaned

by immersion in caustic soda (NaOH) baths, which remove aluminium deposits embedded in the internal die surfaces without damaging the die steel. Over time, dissolved aluminium gradually accumulates in the form of sodium aluminate. This progressively reduces the cleaning capacity of the baths and eventually makes it necessary to renew them. As a result, highly alkaline spent die-cleaning baths are generated which, due to their corrosive nature, require specialised waste management and the preparation of new caustic soda solutions. As an indication, a plant producing 10.000 tonnes of extruded aluminium per year can generate more than 300 tonnes of this waste annually. Across the European aluminium extrusion sector, the total is estimated to exceed 120.000 tonnes per year. This situation highlights the need for solutions to recover and reuse the caustic soda contained in these baths, thereby reducing both raw material consumption and waste generation.

N. 101 - SEPTEMBER/OCTOBER 2026 - ipcm®

SPECIAL ISSUE ON ARCHITECTURE & DESIGN

Figure 01 - Cyclic operation of the EcoDie system. Diagram of the caustic soda recovery process through the precipitation of aluminium as aluminium hydroxide.

From research to industrial application At ALSAN, the development of this solution began

with laboratory-scale research. This work provided the basis for studying and evaluating different technological approaches aimed at removing dissolved aluminium from spent die-cleaning baths, which is the main cause of the loss of system activity,

making it the most promising technology from both an operational and industrial perspective.

EcoDie: an industrial solution for caustic soda recovery from spent die-cleaning baths

The research carried out by the ALSAN team has led

as well as recovering the caustic soda contained in

to the development of EcoDie, an industrial solution for

the baths. This work has led to the development of an

recovering caustic soda from spent die-cleaning baths.

industrial-scale system based on the results obtained

EcoDie is a process designed to remove aluminium

in the laboratory.

from spent caustic soda baths and recover the caustic

During the development of the project, different

soda for reuse. The core of the system is a reactor

methods for recovering caustic soda from spent die-

in which the aluminium is precipitated as aluminium

cleaning baths were investigated. First, alternatives

hydroxide. In the first stage, the system is fed with

based on the addition of external reagents, such

spent caustic soda baths, which are allowed to cool

as CO₂, lime or sodium silicates, were evaluated.

naturally to room temperature and are continuously

These methods convert the dissolved aluminium

stirred to promote the formation and precipitation

into insoluble compounds that are subsequently

of aluminium hydroxide while facilitating caustic

separated by filtration. Although these options provide

soda recovery. The process continues until chemical

satisfactory aluminium removal, they also result in the

equilibrium is reached between the free caustic soda

generation of large quantities of sludge and require a

and the aluminium in solution. Once this state has

continuous supply of reagents.

been reached, the reactor regenerates caustic soda

A technology based on the solubility equilibrium of

that can be reused in new cleaning baths. When these

aluminate was also investigated. This approach allows

baths become spent, they are returned to the EcoDie

CONVEYOR SYSTEMS

the recovery of caustic soda through the controlled

system, restarting the recovery cycle.

precipitation of aluminium as aluminium hydroxide.

ACCESSORIES

The treatment time for a spent caustic soda bath,

It eliminates the need for external reagents and

corresponding to one complete cycle, is approximately

enables the caustic soda to be recovered and reused,

24 hours (Fig. 1).

ENGINEERED FOR MATERIAL HANDLING CHAINS

CUSTOM SOLUTIONS

DISCOVER SE.PO.

www.sepoitalia.it

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Figure 02 - EcoDie system operating sequence for caustic soda recovery.

Figure 2 illustrates the different stages of the EcoDie process. The

material has potential for valorisation and could generate additional

process begins with the spent caustic soda being transferred from the die-

economic returns for the plant, this potential income has not been

cleaning bath to the system and then into the reactor, where the dissolved

included in the analysis.

aluminium is precipitated as aluminium hydroxide. The system then

As shown in Figure 3, this approach significantly reduces both raw

separates the precipitate by filtration, allowing the regenerated caustic

material consumption costs and waste management costs. In addition,

soda to be recovered. Finally, the regenerated caustic soda is returned

the only by-product generated is high-purity aluminium hydroxide, which

to the die-cleaning bath for reuse, thereby closing the complete bath

can potentially be recovered and used as a raw material in other industrial

regeneration cycle.

sectors.

A real aluminium extrusion plant with an approximate production capacity

In conclusion, ALSAN introduces the EcoDie system as an industrial

of 20.000 t/year has been considered for the study. The plant uses caustic

solution for recovering caustic soda used in die cleaning, with an

soda in die-cleaning operations. In the scenario evaluated with EcoDie, the

estimated recovery efficiency of at least 80%. This performance results

caustic soda is recovered, with aluminium hydroxide being the only waste

in a significant reduction in raw material consumption and waste

generated in the process.

management costs, contributing to a favourable return on investment.

For the economic assessment, a conservative scenario has been adopted

With this technology, ALSAN further promotes process efficiency in the

in which the aluminium hydroxide is managed as non-hazardous solid

aluminium industry while supporting the principles of the circular economy

waste, considering the current waste management cost. Although this

and reducing the environmental impact of die cleaning operations.

Figure 03 - Representation of the EcoDie system and the associated cost savings in raw materials (caustic soda) and waste management.

N. 101 - SEPTEMBER/OCTOBER 2026 - ipcm®

Powder from Nature Advanced solutions for metal surfaces treatment

S I N C E 1 9 8 2

EUROPOLVERI S.p.A. - Sandrigo (VI) Italy - Ph. +39.0444.750643 - info@europolveri.it - www.europolveri.it BRANCH OFFICE: Cernusco sul Naviglio (MI) Ph.+39.02.92148001 - Erbusco (BS) Ph.+39.030.7704158 - DEPOT: Iori Colori, Reggio Emilia Ph.+39.0522.327248

Zaniolo CdA-01.26

The strength of Europolveri powder coatings comes not from the carefully selected blend of raw materials alone, but from the people who study, shape and formulate these products thanks to more than 40 years of experience, and provide customers with a range with more than 1.000 products available in stock and over 40.000 already formulated.

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9 metres of flexibility: the new frontier for vertical coating lines with Coroxal Alessia Venturi ipcm®

The investment in a vertical powder coating line for bars up to 9 metres in length, designed by SAT, equipped with an in-line brushing machine and a Visicoat profile recognition system, and integrated with an automated profile storage facility upstream and an automatic packaging machine downstream, has marked a further step in Coroxal’s development strategy, focused on automation, efficiency, and quality. Indeed, it has resulted in a highly integrated production system capable of meeting the demands of an increasingly competitive and dynamic market.

N. 101 - SEPTEMBER/OCTOBER 2026 - ipcm®

FOCUS ON TECHNOLOGY

From left to right: A full view of the new vertical powder coating line for aluminium profiles up to 9 m in length, designed by SAT and in operation at Coroxal since March. On the right, the automatic packaging machine to which one of the plant’s two unloading bays is connected. Raw and coated bars entering and leaving the coating line.

“C

The automated warehouse for profiles, with a capacity of 2,500 units, is integrated with the coating line to ensure a continuous, orderly, and efficient production flow.

ombining coating with anodising, first with a horizontal line

Experience in aluminium treatment has enabled Coroxal to develop

and now with this state-of-the-art, high-productivity vertical

specific expertise in surface protection and enhancement processes

system, has been a forward-thinking decision. We aim to

by integrating a range of technologies over time. While anodising has

provide a comprehensive service to our customers who use aluminium

always been at the heart of its operations, it has now turned its attention

with both finishes and prefer to rely on a single supplier for all processing

to coating, aiming to provide its customers with a comprehensive service

phases required for their products, whether machining, anodising, or

by removing the challenge of dealing with multiple points of contact

coating. Companies today are seeking lean processes, streamlined

in the production of a single item. The main results achieved include

administrative and logistical management, and consistent, uniform

increased production capacity and reduced processing times thanks to the

treatments for aluminium.

integration of an automated warehouse and a packaging machine, greater

At the same time, this material’s industrial and architectural applications

uniformity and quality of finishes, enhanced process reliability, and, last

call for perfect colour matching, harmonious textures, special effects, and

but not least, the optimisation of energy resources.

consistent resistance and durability across the various treated surfaces. That is why being able to source from a single supplier is a significant competitive advantage for our customers, as well as a guarantee of

History, growth, and target markets

The history of Coroxal S.r.l. began in 1961 in Ospitaletto (Brescia, Italy),

quality,” states Guglielmo Corradi, a partner at Coroxal alongside his

when the late industrialist Guglielmo Corradi, together with his wife Maria

brother Gianluca, commenting on his company’s latest investment in a

Gogna, founded a business offering highly specialised services for treating

state-of-the-art vertical powder coating line from SAT (Verona, Italy).

aluminium and its alloys, with particular expertise in anodic oxidation.

ipcm® - SEPTEMBER/OCTOBER 2026 - N. 101

FOCUS ON TECHNOLOGY

From the outset, Coroxal has distinguished itself for the quality of its

investment in technological innovation, the modernisation of facilities, and

workmanship, attention to detail, and ability to develop technical solutions

the continuous improvement of production processes, with a particular

that meet the needs of a constantly evolving industrial market. Experience

focus on quality and efficiency. In 2008, Coroxal took a further step

in aluminium surface treatments has enabled the company to build,

forward with the complete revamp of its oxidation plant at the Ospitaletto

over time, a solid reputation based on reliability, technical expertise, and

headquarters. The project implemented cutting-edge technologies and

attention to customer needs.

installed 27 new in-line steel tanks, increasing production capacity,

In 2000, Guglielmo Corradi, the founder’s grandson, joined the company,

improving process control, and ensuring ever-higher quality standards.

bringing new energy and entrepreneurial drive that revitalised its growth.

The founder’s second grandson, Gianluca Corradi, joined the company in

His arrival marked a period of expansion characterised by significant

2016, contributing to the further development of its business structure.

The in-line brushing machine can be activated either automatically by the Visicoat system if this phase is included in the treatment recipe, or manually by the operator if defects are detected during loading.

N. 101 - SEPTEMBER/OCTOBER 2026 - ipcm®

The seven-stage cascade pre-treatment tunnel performing nanotechnology-based conversion through atomisation.

SPECIAL ISSUE ON ARCHITECTURE & DESIGN

Under his guidance, an in-house mechanical workshop was established to enhance customer service and enable Coroxal to provide complete finished products by integrating machining with surface treatments. This strategic decision enabled Coroxal

EnvironmEnt SuStainablE GrEEn

to handle an ever-increasing proportion of its workflow in-house, ensuring greater quality control, reduced processing times, and a more comprehensive and competitive service. In 2020, Coroxal opened a new site in Rovato, near Brescia. This major investment was intended to increase production capacity and support the company’s growth. A new oxidation plant was installed, featuring tanks up to 8 metres in length (longer than those at the Ospitaletto site, which are up to 7 metres, and twice their depth), automatic overhead cranes, and a control room for remote plant management. At the same time, the company invested in a horizontal coating line to provide customers with a full range of services. In 2021, the new plant reached full capacity, with production organised across three shifts, allowing greater flexibility and a better response to market demands. In 2022, the company renewed its commitment to sustainable innovation, focusing on reducing energy consumption and utilising renewable sources by installing a photovoltaic system with a total capacity of 2 MW. In 2026, Coroxal reached another significant milestone in its growth journey with the launch of the new vertical coating plant designed and built by SAT. This strategic investment, once again, aimed to increase the company’s production capacity and introduce advanced technologies into its surface finishing process. To complement the new vertical coating department, an automated warehouse for aluminium profiles, with a capacity of 2,500 units, was installed in line with the SAT system. This integrated solution enables automated management of profiles, from storage to feeding the coating line, ensuring a continuous, orderly, and efficient production flow. It optimises internal material handling, reduces manual operations, improves material traceability, and ensures greater continuity in the production process. “Coroxal’s market is very broad: it is not limited to the architectural envelope sector. We cover 99% of products made from anodised or coated aluminium,” explains Claudio Pozzi, from the technical department of Coroxal’s Rovato site. “Offering both anodising and coating means we can quickly and efficiently meet the needs of companies that need profiles to be anodised or coated and then processed, or vice versa, as well as those requiring pre-treatment with flash anodising and powder coating, particularly in the shipbuilding and architectural sectors. While in 2020 powder coating was introduced as a complementary process to the company’s main

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anodising operation, with the system installed in 2026 we adopted a different approach, expanding our coating capacity to vertically

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FOCUS ON TECHNOLOGY

SPECIAL ISSUE ON ARCHITECTURE & DESIGN

integrate production, attract new customers, and enhance the services

position, they pass under the Visicoat camera system, which detects their

offered to existing ones. Today, production volumes are still higher for

shape; the brushing machine can then be activated according to their

anodising, but having installed such a high-performance vertical coating

specific characteristics and treatment requirements.”

line as the one supplied by SAT, which is already operating in three shifts,

“The Visicoat system is integrated with our MES, and the brushing

five days a week, we expect to soon reach the same volumes for coated

machine can be activated either through production orders or manually

materials as well.”

at the loading stage,” confirms Pozzi. “This feature is particularly useful

A vertical system designed for flexibility and automation

in a contract coating context, where profiles arrive at our company after extrusion and may have issues that can only be identified during loading.” The chemical pre-treatment following mechanical brushing has been

The launch of the new vertical coating plant in 2026 was a major

designed to achieve Qualicoat Seaside certification. The cycle, a cascade

technological investment for Coroxal. The system was designed to meet

process except for the final conversion stage, comprises seven stages.

the demands of modern production, characterised by high volumes,

It starts with two acid degreasing (deoxidation) stages, unlike more

production flexibility, and the need to maintain consistent quality

traditional set-ups that include only one acid degreasing stage. These are

standards, particularly in terms of coating consistency and uniformity. It

followed by corresponding rinses with mains water, an alkaline degreasing

therefore enables Coroxal to further strengthen its offering by combining long-standing expertise with industrial innovation. “We chose SAT as our technology partner because we wanted to work with a firm with extensive experience in designing and installing advanced industrial coating systems,” comments Guglielmo Corradi. “Thanks to its extensive technical expertise and in-depth knowledge of the sector, this collaboration has provided us with bespoke plant design, reliable technology, support during the installation and commissioning phases, optimised production performance, and the valuable prospect of future development and upgrades.” “SAT designed the plant’s technological and flexibility-oriented features to enable us to process even materials that competitors cannot handle. Indeed, one key distinguishing feature is the ability to coat profiles up to 9 metres in height,” notes Claudio Pozzi. The line was fitted with multiple devices to improve both production performance and quality consistency. Among these, the Visicoat vision system plays a central role, automatically detecting each profile’s shape, linking it to the corresponding coating recipe preset by the technical department, and adjusting the booth’s application parameters to match the profile’s geometry, thereby ensuring treatment repeatability and reducing the margin for operator error. In addition, a brushing machine was installed directly on the line. “We can brush profiles without pre-treating them and without stopping the line,” indicates Pozzi. “In the brushing area, a ‘festoon’ system mounted on the monorail conveyor keeps the five hooks involved in the operation stationary while the rest of the system continues to operate. This means that the surface treatment can be carried out without interrupting the production flow.” As SAT’s CEO, Andrea Trevisan, explains, “This is the first brushing machine we have built for 9-metre profiles, although we have now installed around fifty of them worldwide. That meant we had to make some modifications to the loading area: since Coroxal processes profiles ranging from 3 to 9 metres, we fitted a roller shutter system that guides the profiles and prevents them from jamming. Once they reach a vertical

N. 101 - SEPTEMBER/OCTOBER 2026 - ipcm®

SPECIAL ISSUE ON ARCHITECTURE & DESIGN

FOCUS ON TECHNOLOGY

stage, a final rinse with demineralised water with a conductivity of less

with Gema CM40 units and dense-phase powder feeding systems using

than 30 µS, and a Henkel no-rinse, nanotechnology-based conversion

Smart-In-Line technology. The booths are fitted with high-efficiency

stage, where the product is mixed and atomised using a PNR system.

cyclone filters for very rapid colour changes and are configured to

However, the plant is also designed to accommodate a traditional cascade

facilitate opening, inspection, and cleaning during the most critical colour

conversion process, complete with the associated rinse. The system

change operations. The Visicoat vision system plays a critical role in the

features automatic dosing of chemicals and monitoring of process

application phase as well. “Under normal conditions, operators simply feed

parameters, which are checked daily; operators can view the measured

powder into the system,” illustrates Andrea Trevisan.

values in real time. The dosage is adjusted according to the preset parameters, while the alkaline degreasing process is controlled based on pH. The probes are regularly inspected and maintained. Automatic replenishment of the tanks ensures that concentrations remain constant. Downstream of the pre-treatment stage, there is an independent drying oven with its own burner, followed by two SAT C-Expert coating booths, one dedicated to light colours and the other to dark colours, each equipped

The two SAT C-Expert coating booths are housed within a cleanroom. The coating booths are equipped with Gema CM40 units and dense-phase powder feeding systems featuring Smart-In-Line technology.

SPECIAL ISSUE ON ARCHITECTURE & DESIGN

FOCUS ON TECHNOLOGY

“By contrast, SAT automation allows for a more precise definition of

speed is approximately 2 m/min. For profiles with critical coverage issues

the quantity of powder to be dispensed, preventing over-dosing and

or specific customer requirements, it can be adjusted to the profile’s

making consumption more controllable, thereby ensuring greater coating

characteristics and finishing requirements, reducing it to 1.8, 1.6, or, more

consistency. Automatic adjustment effectively minimises the variations

rarely, to 1.4 m/min. Here too, the use of the Visicoat vision system is

that can arise when different operators manually set different parameters,

crucial.”

helping to ensure consistent product quality.” The line ends with a polymerisation oven in SAT’s standard configuration, with fans at the bottom and separate inlet and outlet. “The oven’s design

Visicoat for adjusting working speed

“The Visicoat system plays a major part in this plant’s performance,” states

keeps the polymerisation chamber extremely well sealed from the external

Claudio Pozzi, “one of the most interesting aspects being the relation

environment, promoting a flat temperature curve even at the system’s

between the line’s speed and the coating recipes.”

high operating speeds,” explains Andrea Trevisan. “The standard cycle

“For example, if the loading of profiles is slowed by the presence of very

Coated profiles entering and exiting the polymerisation oven.

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Unloading of the coated profiles.

SPECIAL ISSUE ON ARCHITECTURE & DESIGN

FOCUS ON TECHNOLOGY

heavy or complex-shaped parts that are difficult to hang without the

and unloading operations without requiring manual intervention in the

operator in the booth realising it, the Visicoat system automatically adjusts

process.”

the coating recipe by changing the parameters to suit the new scenario,

Dual unloading for continuous-flow operation

thus reducing the risk of errors during coating application,” confirms Andrea Trevisan. “A set of photoelectric cells detects the length of the

The plant’s flexibility also extends to the final stage of the cycle. The

incoming profiles and enables the system to adjust the recipe parameters

unloading area has been designed with a dual configuration: on the one

according to their actual size, in order to achieve the same results

hand, an automatic unloading system consisting of a series of chains,

regardless of the workpieces’ length.”

capable of safely handling profiles of varying lengths and weights,

This approach is particularly advantageous for a coating contractor.

transfers them directly to the packaging machine; on the other, a

Profiles with different requirements can be processed simultaneously

traditional unloading bay with an inclined arm creates a small buffer zone

within the same booth: if some require a lower speed and others a higher

downstream of the line and ensures the process is not interrupted when

one, the plant automatically adjusts the treatment programme. The spray

the material is not destined for the packaging machine. This applies to

guns are controlled individually, so the recipe adapts to each profile, even

profiles that require the application of protective film, a sublimation phase,

when different shapes are loaded next to one another. “At SAT, we describe

or a different type of packaging. “Packaging is currently the bottleneck of

it as a dynamic system,” summarises Andrea Trevisan. “The coating

our line,” says Pozzi. “The ability to temporarily divert material to trolleys

requirements are continuously monitored and adjusted to the profiles

via the conventional unloading system therefore allows production to

present in the booth, and the recipes are automatically adapted. This

continue at 2 m/min, with the time required for packaging made up later

allows the plant to accommodate any variations caused by the loading

without affecting the coating cycle.”

Saving energy

during anodising

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FOCUS ON TECHNOLOGY

SPECIAL ISSUE ON ARCHITECTURE & DESIGN

The automated warehouse as an integral part of the production line

The investment in the coating line was accompanied by the implementation of an automated storage system for aluminium profiles and powder products. A traditional drawer system is used for powder coatings, while the profile storage area was designed to make better use of space, reduce handling, and minimise the risk of damaging materials. The line is currently fed by roughly 50% of material from the physical warehouse, loaded by an operator using an overhead crane, and 50% from the automated warehouse. The latter houses profiles belonging to customers and, upon receipt of an order, automatically checks stock levels using its own algorithms, retrieves the required packages, and transports them to an area outside the storage department. Lights and monitors then guide operators in preparing the orders. The system also allows baskets for the various orders to be prepared in advance and made available directly at the loading area. The operator requests the necessary materials from their slots, and the warehouse system sends them directly to the loading bays, ready for transfer to the line. “The entire picking process is managed in a more streamlined way,” says Pozzi. “The materials reach the coating department already prepared, avoiding the manual handling involved in opening packages, removing parts, and arranging different orders. The result is smoother management of the plant’s feeding operations and greater overall production efficiency.”

Above-average performance and potential

The evolution of Coroxal, from its foundation in 1961 to its most recent investments, tells the story of a company that combines industrial tradition, technical expertise, and a constant pursuit of innovation. The installed plant was designed not merely as a practical solution but as a tool to support high production volumes while maintaining a high degree of flexibility: in contract coating, the ability to handle different colours, batches, and profiles simultaneously is essential. Under specific conditions, Coroxal’s capacity can reach up to 2.5 m/min, effectively treating profiles that are relatively short yet have a large surface area. “This figure certainly does not represent normal operating conditions, but we know we can achieve that level of performance, and that makes us extremely proud of our investment,” concludes Guglielmo Corradi.

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N. 101 - SEPTEMBER/OCTOBER 2026 - ipcm®

Claudio Pozzi (left) and Andrea Trevisan (right).

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ROAD TO 2050

SPECIAL ISSUE ON ARCHITECTURE & DESIGN

Modern process chemistry as a key to greater cost-efficiency: the relevance of energy efficiency in surface finishing Thomas Sondermann Alufinish GmbH & Co, KG – Andernach, Germany thomas.sondermann@alufinish.de

Optimised anodising processes and mediumtemperature sealing, enabled by solutions such as ALFINOX 510 and ALFISEAL 1960 developed by Alufinish, can reduce energy and resource consumption while maintaining high standards of quality, performance and process reliability.

104

N. 101 - SEPTEMBER/OCTOBER 2026 - ipcm®

ising energy costs, ambitious sustainability targets and growing demands on process quality are changing aluminium surface finishing for good. While many companies initially focused on

short-term savings, the holistic optimisation of production processes is now moving into the foreground. Energy efficiency has long ceased to be purely a cost issue – it is increasingly becoming a decisive competitive factor.

ROAD TO 2050

Stable process control in the anodising bath helps to combine quality and cost-efficiency. Modern process additives such as ALFINOX 510 support this approach.

Energy efficiency starts in the anodising process. Coordinated process chemistry and stable bath control can sustainably reduce resource consumption and operating costs.

Practical experience shows that considerable savings potential can often

innovation. In practice, it is far more often the result of numerous

be tapped not through individual measures, but through the interplay of

optimisations along the entire process chain. It is precisely the interplay of

plant technology, process control and modern process chemistry.

different measures that frequently opens up the greatest savings potential

Energy efficiency starts in the process itself

– and often without extensive investment in new plant technology.

In an anodising plant, energy is consumed at numerous points: in

The key levers include, among others:

particular through the high electricity demand of the anodising process

 Optimising process parameters

and of electrolytic brightening and colouring processes, through the

 Reducing the required process temperatures

continuous heating of process baths such as etching and hot sealing, and

 Extending bath service lives

through the cooling of certain baths. These are among the most energy-

 Reducing water and chemical consumption

intensive process steps.

 Intelligent process and plant control

At the same time, expectations regarding quality and sustainability are

 Regular analysis and continuous optimisation of existing processes.

rising. Customers expect reproducible surfaces, long bath service lives, effective processes and the smallest possible ecological footprint. The

Time and again it becomes clear that the greatest efficiency gains do

challenge is therefore to save energy without compromising on layer

not come from looking at individual process steps in isolation, but from

quality, decorative appearance or process reliability.

a holistic analysis of the entire anodising process. This is exactly the

This is precisely where the development of modern process chemicals

approach taken by Alufinish. The company does not regard process

comes in.

chemistry as an individual product, but as part of comprehensive process

Holistic optimisation instead of isolated measures Successful energy efficiency rarely results from a single technical

optimisation. The aim is to support customers in reducing energy and resource consumption, increasing process stability and, at the same time, meeting the highest quality requirements.

ipcm® - SEPTEMBER/OCTOBER 2026 - N. 101

105

SPECIAL ISSUE ON ARCHITECTURE & DESIGN

ROAD TO 2050

Optimised anodising processes with ALFINOX 510

With the medium-temperature sealing ALFISEAL

QUALANOD-approved systems are a good

1960, Alufinish offers an alternative that can

example of how resource efficiency and the

An important building block of this strategy

significantly reduce the energy demand of this

highest quality standards can be combined.

begins in the anodising process itself. Modern

process step. Lower process temperatures

anodising additives help to create stable

make it possible to cut operating costs without

process conditions and to improve the cost-

having to compromise on the high requirements

efficiency of the entire line.

for corrosion protection and layer quality

With ALFINOX 510, Alufinish offers an anodising

(QUALANOD-approved).

develop. New requirements in the areas of

additive designed for optimised process control,

Particularly at a time of rising energy

sustainability, energy efficiency and quality

which effectively saves cooling energy. Through

prices, processes of this kind are becoming

call for the constant adaptation of existing

stable bath control and reproducible process

increasingly important. They show that energy

processes.

conditions, the product supports economical

efficiency and high-quality surfaces no longer

For Alufinish, this means supporting customers

operation and can help to use resources more

have to be a contradiction.

not only with individual products, but developing

efficiently. Instead of considering individual parameters in isolation, the focus is placed on the entire anodising process – an approach that improves both process reliability and costefficiency.

Energy savings in sealing

Process optimisation as a continuous development process Aluminium surface finishing continues to

tailored solutions together with them. The

Thinking about quality and sustainability together

combination of modern process chemistry, technical expertise and a holistic view of the

Alongside energy savings, process reliability

process chain makes it possible to implement

plays a decisive role. New processes must

economical and sustainable improvements step

not only be economical, they must also deliver

by step.

reproducible results in the long term.

Conclusion

A particularly effective lever for energy

Alufinish therefore pursues a holistic

efficiency lies in the sealing of the anodic oxide

development approach. Modern pre-treatment

layer. Conventional hot sealing processes

systems and process chemicals are designed to

combining cost-efficiency, sustainability and

often operate at temperatures close to the

reduce energy consumption, chemical input and

the highest quality requirements. The greatest

boiling point of water and therefore cause

water demand without losing sight of the high

potential often lies not in individual innovations,

correspondingly high energy costs.

requirements of international quality standards.

but in the intelligent combination of many small

Aluminium surface finishing faces the task of

optimisations along the entire process. Solutions such as the anodising additive ALFINOX 510 or the medium-temperature sealing ALFISEAL 1960 are examples of how modern process chemistry can help to reduce energy consumption while ensuring stable, highquality processes. Energy efficiency is thus increasingly becoming an integral part of modern process development – and a decisive competitive advantage for companies in aluminium surface finishing.

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N. 101 - SEPTEMBER/OCTOBER 2026 - ipcm®

Sealing the anodic oxide layer is one of the most energy-intensive process steps. Modern medium-temperature processes can significantly reduce the energy demand without impairing the quality requirements for the surface.

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ENGINEERING, CUSTOM DESIGN AND CONSTRUCTION tailored TO your needs painting lines SINCE 1972 www.midue.it

ANALYSIS

SPECIAL ISSUE ON ARCHITECTURE & DESIGN

Durability and design freedom: how powder-coated aluminium is expanding façade possibilities Sencan Kizilkaya, Global Product Manager - Architecture AkzoNobel Powder Coatings – Amsterdam, The Netherlands

sencan.haydaroglu@akzonobel.com

The use of powder-coated aluminium in façades combines low weight, resistance to weathering and durability with extensive possibilities for finish customisation. The article examines how advances in powder coating technology are expanding the aesthetic and functional potential of aluminium, enabling the development of durable, maintainable façade systems with a wide range of decorative finishes.

This puts durability at the centre of the design conversation. Contemporary design tools are enabling architects to explore more detailed and expressive façade outcomes, but those ambitions still need to be matched by constructability, sustainability, user experience and long-term durability3. Powder coated aluminium offers a way to connect these priorities. Aluminium provides a lightweight and versatile base, while architectural powder coatings expand its visual range and support durable surface performance.

Aluminium provides a durable, practical starting point

Aluminium is already an established choice for façade design. Compared

with heavier façade alternatives, such as glass reinforced concrete (GRC),

whole-life value1. Recent research into façade design and material

simplify access and installation planning. Beyond installation, aluminium’s

selection reflects this balance: durability, wind-load resistance and thermal

established availability can support efficient project planning, with a

insulation rank among the most important criteria, alongside aesthetics

comparatively straightforward supply chain and potential for shorter

and weight2.

lead times. Its durability and recyclability further strengthen its whole-life

açades must do more than create a strong visual identity. For

stone and terracotta, its low weight makes panels easier to transport,

architects and specifiers, façades must also deliver durable

handle and position. Its use can reduce the need for heavy-duty site

performance, support buildability and maintainability, and provide

equipment, lower the load transferred to the building structure and

credentials. 1 https://ascelibrary.org/doi/10.1061/(ASCE)AE.1943-5568.0000335

3 https://www.tandfonline.com/doi/full/10.1080/13467581.2025.2458791

2 https://www.mdpi.com/2071-1050/16/11/4611

ANALYSIS

With the material fundamentals already proven,

use. The question is no longer simply whether

An aluminium panel with a terracotta-effect

the design opportunity lies in expanding what its

aluminium can support a premium aesthetic,

coating can therefore help achieve the intended

finish can achieve.

but in what ways the finish can support the

visual character while keeping handling and

performance expectations of a building. The

installation requirements more manageable.

Powder coatings broaden aluminium’s design language

coating therefore needs to be considered as part of the durability discussion, where colour

Why architects’ scepticism has shifted

Architects continue to draw on stone, terracotta,

and gloss retention, film integrity, resistance to

wood and other metals when developing façade

mechanical damage and a practical cleaning

concepts. These materials can bring colour,

regime all influence how a façade will look and

viewed by some architects as too synthetic to

warmth, texture and depth, but each also

perform over time.

reproduce the depth and character of natural

brings practical considerations around weight, handling, maintenance and durability. Powder-coated architectural finishes are broadening the design language of aluminium.

Aesthetic freedom, backed by durability

Powder-coated effects were historically

materials convincingly. That perception is changing as completed façades show how stone, terracotta and metal-inspired finishes can

Table 1 (in the next page) illustrates how

contribute to considered architectural identities

They allow designers to create visual

powder-coated aluminium performs against

in real-world conditions.

approximations of premium materials while

Glass Reinforced Concrete (GRC) and glazed

Two prominent examples in Canary Wharf

retaining aluminium as the base material. The

terracotta. It shows that specification decisions

in London, England demonstrate this. At

opportunity for architects and specifiers lies

are influenced not only by cost and weight,

one development4, real stone was originally

in expanding the range of colours, textures,

but also by durability, including mechanical

considered but its weight made installation

finishes and tones available within an

resistance, weathering and maintenance

on the 55 and 50 storey towers impractical.

aluminium façade system.

requirements. The cost and weight differentials

Instead, cantilevered wrap-around balconies

Within the Interpon brand, we are seeing

are however considerable. In the example above,

were coated in Interpon D2525 Stone Effect. A

growing demand for stone, terracotta

a powder-coated aluminium panel costs less

significant reduction in structural loading was

and wood-look effect coatings, which are

than half a GRC panel and weighs between

achieved by using powder-coated aluminium,

particularly relevant to this shift. Stone effects

three and nine times less. Similarly, glazed

bringing both architectural richness and

can give a façade a more grounded character,

terracotta comes in at nearly twice the cost

practical advantage, supporting a smoother

and terracotta-inspired finishes are particularly

of aluminium and weighs close to six times

installation process.

popular as they introduce a warmer, more

more. These figures demonstrate the economic

Another London Docklands residential

textured appearance than concrete. Wood

advantages of aluminium and why façade teams

development5 showcases how powder coatings

effects can add natural texture without requiring

need to assess more than the visible finish.

can bring warmth and texture to a large project.

a solid timber façade system.

Weight affects transport, lifting, access, labour,

Aluminium cladding panels across the 20-storey

As these powder-coated finishes appear on

safety planning and the supporting structure

building envelope were finished in superdurable

more completed buildings, architects and

required. It can also influence the equipment

Interpon D2525 Stone Effect in White Stone.

specifiers are becoming more confident in their

and manpower needed on site, as well as the

Closely reflecting the original GRC design intent,

complexity of future façade interventions.

the panels retain the feeling of depth, mass

Durability is part of the specification equation.

and solidity. The stone-inspired finish softens

The comparison highlights that powder-coated

the scale of the building and brings practical

aluminium is robust and hard-wearing, with

advantages by helping reduce weight and

resistance to structural cracking, while enhanced

material costs and supporting easier installation

resin technology supports colour and gloss

and simpler replacement over time.

retention. By contrast, natural terracotta can be

The shift is not only about improved visual

susceptible to cracking from mechanical impact

effects. It also reflects greater confidence that a

and thermal stress.

powder-coated aluminium system can address

the practical performance demands that accompany a more ambitious façade concept. Cladding panels across the building envelope were finished with superdurable Interpon D2525 Stone Effect as an alternative to Glass Reinforced Concrete (GRC).

4 https://www.interpon.com/gb/en/showcases/the-collective 5 https://www.interpon.com/gb/en/showcases/wardian-towers

ipcm® - SEPTEMBER/OCTOBER 2026 - N. 101

109

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ANALYSIS

What this means for specification

material. Designers can explore warmer, more textured and more varied

The specification conversation should begin with the whole façade

façade expressions while retaining a lightweight panel system that

system and its durability requirements, not with appearance in isolation.

can support durability requirements, efficient transport, handling and

Architects and specifiers need to consider how a material will respond to

installation. That balance is particularly important when comparing

its environment, how it will be handled and installed, how its appearance

aluminium with heavier or more brittle alternatives. A material that is

will be maintained, and what will be required if panels need to be removed

easier to handle can reduce complexity during installation and future

or replaced later.

intervention. A finish that retains colour and gloss can help preserve the

Powder-coated finishes can help aluminium move into richer visual

intended architectural identity, and a recyclable base material can also

territory without changing the fundamental advantages of the base

support a more considered whole-life approach.

Table 1: Comparison of the performance of powder-coated aluminium, Glass Reinforced Concrete (GRC) and glazed terracotta across key specification criteria.

Powder-coated aluminium panel

GRC

Glazed terracotta 300 x 600mm horizontal installation=€235/m²

3mm simple panel: €160/m²*

€300/m² panel + €80/m² bracket/grid: €380/m²*

3mm panel: 8kg/m²

25–75kg/m², depending on thickness

45kg/m²

Installation

Lightweight; requires less on-site machinery and equipment and is easier to handle.

Heavy, difficult to handle, extensive onsite machinery. The supporting framework is often complex.

Labour-intensive; large-format panels or shaped profiles may need mechanical handling, including crane lifting. Panels are brittle and can crack or chip during handling, lifting or cutting.

Repairability and replacement

Can be touched up and repaired on-site via suitable liquid coatings with strong match to solid and special-effect finishes. Individual panels/components can generally be removed without dismantling wider façade.

Local cracks, chips and minor surface damage can be repaired using compatible cementitious/GRC repair materials, but achieving colour and texture match can be difficult. Individual panels can be replaced, but access to concealed fixings and supporting frames can make the operation more onerous.

Repairs are difficult to make visually and technically equivalent to the original glazed surface. Individual units can be replaced, but removal may risk damage to adjacent units and existing supports.

Mechanical resistance

Robust and hard-wearing, and resistant to structural cracking. Suitable protective taping and loading prevents damage during transportation.

High flexural and impact resistance, but remains susceptible to cracking, local damage from severe impact or poor detailing. Requires great care when transporting and installing.

Glazed surfaces may develop fine cracks (crazing) over time due to differential thermal expansion between the glaze and the terracotta body. Extra precautions required during transportation and installation.

Weathering

Enhanced resin maximizes colour and gloss retention. Strong film integrity minimizes the risk of ingress.

Longevity governed by matrix quality, fibre durability, panel thickness, crack control, drainage and exposure. Prolonged moisture exposure or cracking can lead to water ingress, staining and overall surface deterioration.

Water ingress presents significant risks. A welldesigned rainscreen system is required behind panels to avoid ingress; poor back-ventilation can lead to moisture accumulation, mould or freeze-thaw damage.

Maintenance

Cleaning frequency: 3–18 months, depending on the corrosivity of the environment. Water and mild detergent prolong and maximize colour and gloss retention

Textured or exposed-aggregate finishes are particularly difficult to clean uniformly, and prone to embedding atmospheric dirt. Any surface treatment must be reapplied regularly, and antigraffiti sealant lasts for 3–10 cleaning cycles depending on type.

Generally low maintenance. Routine cleaning is normally limited to periodic washing with water and mild detergent.

Environmental

Fully recyclable. Specifying high-recycledcontent aluminium can reduce the carbon footprint further.

CO₂-per-kilogram impact increases with thicker/heavier material grades; embodied carbon can be higher than aluminium in some detailed façade spandrel configurations.

Kiln-firing at 900–1100°C generates CO₂. Although recyclable, composition and thermal properties can make glazed terracotta difficult to regrind and re-fire.

Cost Weight

*Cost figures are marked as based on industry averages in 2025.

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300 × 1200mm vertical installation: €260/m²; profiled/sinusoidal tiles: €295/m²*

SPECIAL ISSUE ON ARCHITECTURE & DESIGN

ANALYSIS

A more expressive role for aluminium

Powder-coated aluminium does not simply imitate other materials, it gives architects more control over the relationship between appearance, durability and buildability. Stone, terracotta, wood and other premium references can inform a façade’s character, while aluminium provides a lightweight and adaptable base for delivering that intent. As powder-coated effects continue to demonstrate their potential at architectural scale, aluminium can take on a more expressive role without losing its practical foundation. Architects can pursue distinctive façades while keeping durability, maintainability, buildability and whole-life value at the centre of the specification. The result is not a choice between design ambition and dependable performance. It is an opportunity to use surface finishes to make durable performance part of a more ambitious architectural language.

Sencan Kizilkaya, Global Product Manager Architecture at AkzoNobel Powder Coatings. 3165-VentCor-IPCM-HalfPageAd1.qxp_Layout 1 2026-07-15 9:37 AM Page 1

CANADA’S LEADING SYSTEMS INTEGRATOR 93 Woodstream Boulevard, Suite 4 Vaughan, Ontario L4L 7Y7 | 905.760.8006

ventcor.com SERVICING

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SPECIAL ISSUE ON ARCHITECTURE & DESIGN

Gardo® Haze: the future of aluminium pre-treatment is already here. DFV’s success case: sustainability, innovation, and digitalisation Edited by Surventis Aluminium Competence Center Giussano (Monza e Brianza, Italy)

andrea.monti@surventiscoatings.com

High performance and sustainability can coexist, overcoming the traditional trade-off between quality and resource use. Integrating Gardo® Haze with the Full Acid Process reduces water usage, chemical consumption, and operating costs while improving process efficiency. At the same time, Gardo Vision enables the measurement and validation of results, transforming sustainability into concrete data and tangible benefits.

n the aluminium sector, sustainability is

high corrosion protection, compliance with

One concrete example of this is DFV, an

no longer merely a strategic objective but

architectural standards, and optimum surface

Italian company that has been operating in

a practical necessity. The growing focus

quality were thought to inevitably require high

the aluminium sector since 1972 and holds

on the consumption of natural resources, the

consumption of water, energy, and chemicals.

a leading position in powder-on-powder and

reduction of emissions, and the optimisation

Today, however, this belief is being challenged

sublimation coating, as well as wood-effect

of production costs is driving companies to

by technologies capable of combining quality

decoration services for aluminium profiles,

rethink their pre-treatment processes. For years,

and sustainability.

laminates, and building systems. Now a multinational group with plants in Italy, Australia, and Brazil, DFV integrates the entire production chain from extrusion through coating and decoration technologies to architectural systems, while offering advanced logistics and consignment stock services. Recently, it has adopted an integrated strategy based on Gardo® Haze, the Full Acid Process concept, and the Gardo Vision digital methodology, developed and refined by Surventis (formerly BASF Coatings), which has been active for 130 years in the treatment, protection, and sealing of metals and plastics across numerous industrial sectors. Headquartered in Münster (Germany), Surventis employs around 10,700 people and generated a turnover of approximately 3.9 billion Euros in 2025. Through brands such as Chemetall®, Glasurit®, and R-M®, Surventis, now controlled © Surventis

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by funds managed by Carlyle while BASF retains

SUCCESS STORIES

a 40% stake, works side by side with over 42,000 customers in more than

concentration is maintained at the minimum required to ensure the

140 countries, developing surface solutions capable of meeting the most

treatment’s effectiveness. This translates into:

complex challenges. DFV’s implementation of the Gardo Haze product,

 lower chemical consumption;

the Full Acid Process concept, and the Gardo Vision digital methodology

 greater operational stability;

is a success story demonstrating that it is possible to achieve high

 improved repeatability of results;

performance while reducing both consumption and environmental impact.

 reduced waste

Gardo Haze: a new application philosophy ®

Traditionally, conversion coatings are applied using high-flow spray systems, recirculation circuits, and storage tanks, all of which require ongoing maintenance. The Gardo® Haze technology introduces a different approach. Through an automatic dosing and control system, the product

 lower running costs. For a production manager, this means relying on a more predictable and controllable process.

Consistency and superior performance

Controlled atomisation ensures an extremely uniform distribution of

is continuously prepared at the correct concentration and applied via

the conversion coating across the entire profile surface. The technical

a controlled atomisation process that ensures an extremely uniform

documentation highlights that the process guarantees uniform coverage

distribution of the conversion coating. The solution is always fresh and

and consistent results across the treated surface, which is particularly

in optimal condition, avoiding the problems associated with continuous-

important in the architectural sector, where aesthetic uniformity, paint

flow recirculation systems. A good analogy is the difference between drip

adhesion, and anti-corrosion performance must remain consistent over

irrigation and a conventional sprinkler: with the former, water goes exactly

time. The main benefits are:

where it is needed, minimising wastage: Gardo® Haze applies the same

 improved coating adhesion;

principle to the pre-treatment of aluminium, using only the necessary

 greater treatment reliability;

amount of solution and ensuring uniform surface coverage.

 reduced production variability;

Reducing water consumption without compromising on quality

Water is now one of the most valuable resources for any industrial plant. In addition to the cost of supply, it is necessary to take into account waste water treatment, energy consumption, and increasingly stringent environmental regulations. Thanks to high-efficiency nozzles and controlled atomisation, Gardo® Haze requires significantly lower flow rates

 consistent corrosion protection performance. These benefits are often invisible to end customers, yet they are key factors in determining the quality and durability of a façade or window frame.

Full Acid Process: from electrochemical research to industrial innovation DFV’s choice was not limited to Gardo® Haze: in fact, it adopted the

than traditional spray systems. Its technical documentation highlights

Full Acid Process concept, developed to simplify pre-treatment, reduce

typical flow rates of around 4-5 litres per hour per nozzle, compared with

consumption, and improve the sustainability of the entire line. This

the 25-30 litres per hour normally used in conventional applications.

innovation is underpinned by work at the Surventis Aluminium Global

This difference offers several immediate benefits:

Competence Centre in Giussano (Monza e Brianza, Italy), where advanced

 reduced industrial water consumption;

electrochemical characterisation techniques, including Electrochemical

 lower volume of waste water requiring treatment;

Impedance Spectroscopy (EIS), have enabled a deeper understanding of

 reduced operating costs;

the interaction mechanisms between aluminium, chemical attack, and

 improved overall sustainability of the plant.

subsequent treatments. The knowledge gained has made it possible to

For lines that treat thousands of square metres of surface area each day,

rethink traditional pre-treatment and to develop fully acid-based cycles

the overall savings quickly become significant.

that combine high performance, ease of management, and a lower

Reduced use of chemicals and greater process stability

environmental impact. One of the main advantages of the Full Acid Process is its impact on

One of the main advantages observed by DFV is reduced chemical

wastewater management. Streamlining the cycle and reducing carry-over

consumption. In conventional systems, the treatment bath is constantly

effectively lower the load sent to the treatment plant, thereby improving

contaminated by carry-over from previous stages, necessitating top-

its overall efficiency. Another innovative feature is the use of acid attack

ups and causing fluctuations in operating conditions. By contrast,

formulations containing specific inhibitors to protect stainless steel

the Gardo® Haze technology relies on the continuous application of a

equipment. Thanks to the work carried out in Giussano, solutions have

solution prepared under correct and controlled conditions. The chemical

been developed that protect the plant without affecting the aluminium

ipcm® - SEPTEMBER/OCTOBER 2026 - N. 101

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SPECIAL ISSUE ON ARCHITECTURE & DESIGN

SUCCESS STORIES

etching rate, thus maintaining the process’

implemented at DFV has been supported

effectiveness. The integration of the Full

by the Gardo Vision methodology, a

Acid Process and Gardo Haze further

tool developed to objectively assess the

enhances the environmental benefits: on

environmental and economic performance of

the one hand, the acid cycle improves

surface treatment processes.

waste water management and reduces the

Gardo Vision enables the analysis and

line’s complexity; on the other, Gardo® Haze

comparison of key indicators, including:

minimises water and chemical consumption

 water consumption;

during the conversion phase.

 chemical consumption;

 energy consumption;

Qualicoat quality and sustainability: moving in the same direction

 operating costs;  CO₂ emissions;  the process’s overall carbon footprint.

For many years, sustainability and

This approach enables the client’s

performance have been considered

technological choices to be validated

conflicting objectives. DFV’s experience,

in practice and further opportunities

however, demonstrates the opposite. The

for improvement to be identified. For a

integration of the Full Acid Process and

plant manager, Gardo Vision provides a

Gardo® Haze enables the achievement

comprehensive assessment of the line,

of quality standards that meet the most

highlighting where resources are consumed

stringent specifications in the architectural

and which measures can yield the greatest

sector while maintaining a strong focus

economic and environmental benefits.

on sustainability. Assessments of projects developed using this approach

have highlighted the potential to achieve significant reductions in overall water

A new vision for the future of aluminium

DFV’s experience shows that the future

consumption compared with traditional configurations and, at the same

of aluminium pre-treatment lies not in a single innovation but in the

time, maintain the quality standards demanded by the market. These

combination of complementary technologies. Gardo® Haze reduces

results have been further supported by analyses carried out using Gardo

water and chemical consumption while improving process uniformity and

Vision.

stability. The Full Acid Process simplifies the line, improves waste water

Less maintenance, greater productivity

management, protects plant equipment, and maintains high performance. Gardo Vision enables results to be measured and validated by analysing

Line simplification also has a direct impact on maintenance requirements.

consumption, energy, costs, and emissions. Together, these three

The absence of large volumes of product being recirculated and the plant’s

solutions form a new generation of aluminium pre-treatment technologies

more compact configuration make it possible to reduce the maintenance

that integrate quality, productivity, and sustainability.

normally required for the management of tanks, pumps, and spray bars.

DFV’s success case proves that this future is already a reality, in which

The benefits are clear:

every litre of water saved, every gram of product optimised, and every

 greater operational availability;

kilogram of CO₂ avoided contributes to building a more efficient,

 fewer planned shutdowns;

competitive, and sustainable aluminium industry.

 lower maintenance costs; increased productivity. A solution developed to improve sustainability therefore also contributes to the plant’s economic competitiveness.

Gardo Vision: turning benefits into figures

Nowadays, simply declaring a process sustainable is no longer enough: this must be backed by concrete data. For this reason, the strategy

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N. 101 - SEPTEMBER/OCTOBER 2026 - ipcm®

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HIGHLIGHT OF THE MONTH

SPECIAL ISSUE ON ARCHITECTURE & DESIGN

From pre-treatment to coating: controlling aluminium surfaces Edited by DBM Tecnologie Casale sul Sile (Treviso, Italy)

info@dbmtecnologie.com

Lightness, machinability, and good mechanical properties make aluminium a key material across numerous industries. However, to achieve the required performance, its surface must be treated with specific processes. Pickling, chemical conversion, and brightening are among the most commonly used treatments for preparing, protecting, and enhancing the finish of aluminium components. The experience gained by D.B.M. Tecnologie in industrial cleaning and in managing chemical processes has resulted in a range of systems designed specifically for these applications.

Oxides, oily residues, and other contaminants left over from previous machining operations can compromise subsequent treatments and affect corrosion resistance, coating adhesion, and aesthetics. In this article, D.B.M. Tecnologie explores the role of the main surface treatments available for aluminium, i.e. pickling, chemical conversion, and brightening, and illustrates how experience in industrial cleaning has led it to develop specialised systems for these processes as well.

High-quality treatments start with cleaning

Before any chemical treatment is carried out, the components’ condition must be assessed on arrival at the plant. Parts that have undergone turning, milling, stamping, die-casting, or other machining processes may be contaminated with substances such as neat oils, emulsions, lubricants, particulates, or other residues. These must be removed uniformly, as a partially contaminated surface may respond differently to subsequent treatments. Even when the chemical parameters are correct, areas that

luminium is widely used in sectors such as automotive,

have not been adequately degreased can hinder contact between the bath

mechanical engineering, electronics, and technical components

and the substrate, leading to inconsistencies that may compromise the

manufacturing because of its favourable weight-to-performance

overall result. That is why cleaning and surface preparation go hand in

ratio, good machinability, and natural resistance to corrosion. However, its

hand and become key process variables in their own right, which should

final performance depends not only on the characteristics of the alloy or

be considered alongside subsequent chemical treatment stages right from

the heat treatments performed but also on surface quality.

the cycle design phase.

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HIGHLIGHT OF THE MONTH

Pickling, chemical conversion, and brightening in one treatment cycle

depends on the bath composition, initial

The main surface treatments for aluminium

rinse efficiency.

include pickling, chemical conversion, and

Finally, brightening primarily serves aesthetic

brightening, which serve different purposes but

requirements, as it enhances surface brightness

are often carried out as part of a single cycle.

and uniformity. The result is affected by the

Pickling removes oxides and impurities from

alloy, the initial finish, part geometry, and the

surfaces and prepares components for

correct management of the chemical process.

subsequent stages. Depending on the alloy

Therefore, although they serve different

and the required result, either acidic or alkaline

purposes, these operations require coordinated

solutions may be used, with carefully controlled

control of fluids, temperatures, times, handling,

times, temperatures, and concentrations:

and rinsing.

aluminium is particularly sensitive to excessive chemical attack and requires precise control of process parameters. Chemical conversion, or passivation, acts

workpiece preparation, treatment times, and

An integrated approach to cleaning and surface treatment It is precisely in these areas that D.B.M.

on the material’s surface layer, improving its

Tecnologie has applied the expertise it has

corrosion resistance and, where specified in the

gained in industrial cleaning to surface

production cycle, paint adhesion. The outcome

treatment.

The FLUOMATIC low boiling solvent-based cleaning system is particularly suitable for cleaning components with traces of neat oils, greases or other non-polar contaminants.

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www.waterenergy.it

SPECIAL ISSUE ON ARCHITECTURE & DESIGN

HIGHLIGHT OF THE MONTH

The LS is a single-chamber immersion system combining ultrasonics, hydrokinetics and rapid vacuum bubbling with basket rotation or tilting to treat internal cavities and blind holes typical of die-cast aluminium components.

The design principle is to regard cleaning, preparation, and chemical

In all cases, the starting point is the analysis of the component to be

treatment as parts of a common technological platform, configured

treated and the production cycle. The alloy, geometry, contamination

to each component’s characteristics and the required process. Tanks,

level, throughput, and required finish all determine the plant configuration

circuits, handling systems, and operating parameters can thus be adapted

and the sequence of the various stages. As a result, cleaning and surface

to incorporate degreasing, cleaning, pickling, chemical conversion,

treatment are managed as parts of a single process, with the aim of

brightening, rinsing, and drying stages as needed.

achieving uniform surfaces and repeatable results even across different

The configurations developed by D.B.M. include, for example, the KOMBI

components and applications.

multi-tank systems and the LS one-chamber solutions. The choice of architecture depends on the type and geometry of the parts, production volumes, initial contamination levels, and the treatment sequence. In multitank systems, the various stages are physically separated throughout a dedicated cycle; in one-chamber configurations, multiple operations can be carried out within the same unit according to a programmed sequence. When the nature of the contaminants requires it, preliminary cleaning can also be carried out using specific technologies. Alongside waterbased systems, D.B.M. develops solvent-based solutions such as FLUO and FLUOMATIC, as well as vacuum systems such as NYX, designed for applications where contamination control and drying are particularly important.

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Surface Finishing is our DNA

Professional shot blasting for the steel industry

before: scaled, rusted (rust grade A-B)

Rösler roller conveyor blast machines – the choice for continuous processing of long components

after: cleaned surface Sa 2,5

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SPECIAL ISSUE ON ARCHITECTURE & DESIGN

Robustness, LEAN and process intelligence in surface finishing: ALUMIL and SurfChem on the new powder coating vertical line at Kilkis Edited by Thomas Skylodimos Technical Director, Chemicals, Materials & Corrosion at SurfChem thomas@surfchems.com

At ALUMIL’s new vertical powder coating plant in Kilkis, process technology, productivity and sustainability come together in an integrated system. At the heart of the project is the long-standing partnership with SurfChem, combining high-performance chemical pretreatment, a LEAN approach and intelligent process control through Chematic.

urfChem, a well-known chemical manufacturer with more than 35 years of experience in metal pretreatment chemicals for aluminium, steel, galvanised steel, and actually any metal that can

be coated. Its passivation/conversion coatings hold the QUALICOAT, GSB International and QUALISTEELCOAT, while offering robustness, stability and sustainability along with innovative quality. ALUMIL, one of the world’s leading companies in architectural aluminium systems, places technological excellence and continuous innovation at the core of its strategy. Through advanced, AI-enabled production processes, the Group enhances operational precision, minimises production failures, and ensures consistently high-quality results. A tangible expression of this approach is ALUMIL’s new vertical powder coating line combined with a technologically advanced chemical pretreatment solution at the central factory in Kilkis, Greece, that doubles the coating capacity, replacing the old vertical line. Behind the visible investment with SAT Surface Aluminium Technologies Srl, a less visible decision: which aluminium pretreatment technology would carry the line for the years to come. After more than two decades of cooperation, repeated laboratory and production trials, and several generations of chrome-free conversion coating technology, ALUMIL once again selected SurfChem. This time with Chematic, its intelligent process management system, running the process.

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ALUMIL commissioned the new powder coating facility at Kilkis in 2025, with productivity in mind: the plant doubles the daily coating capacity. The line is a high-throughput vertical powder coating running at 2 m/min with profiles up to 8 metres, one of the largest aluminium extrusion and surface treatment operations in Europe. Fast colour changes, automatic online brushing of profiles with the brusher before painting, the unique Vision Recognition System Visicoat, is able to recognise the cross section of the profiles and conduct the coating process autonomously through one sophisticated AI solution.

SUCCESS STORIES

Oven and burners control with highest uniformity and energy saving

chemical process whose contact times were designed entirely around

technology. All of it visible, all of it measurable.

movement.

Powder does not stick to aluminium. It sticks to a conversion layer

 Sustainability: Measured the way a production line actually measures it

nanometre thick, formed chemically in a closed tunnel minutes before

- energy drawn per hour, water consumed per cycle, wastewater generated

the profile reaches the booth. That layer anchors the coating, and if the

per ton treated. Cascade rather than spray already tightens part of that

coating is ever cut, drilled or scratched on site, it is what stands between

before the chemistry is even chosen. Chemistry flows over the profile

the metal and the atmosphere for the remaining decades of the façade’s

under gravity instead of being driven at it through nozzles, which means

life. Which is why the pretreatment specification for the new line was

fewer nozzles to block and lower electrical demand than a spray line

written with the same care as the coating equipment, and why it was

carries.

written against four conditions that had to hold simultaneously:

 Trust: In the plainest sense, a partner still answering the phone when

 Performance & Quality: QUALICOAT SEASIDE licensing, which lifts

something drifts, and a process visible enough that nobody has to guess

the etching requirement from the 1.0 g/m² of standard aluminium

why. Two decades of cooperation count for something here, but a line

pretreatment to a minimum of 2.0 g/m². Two substrate routes through

running at this speed needs that trust proven in real time, not cited as

one bath, as well: the line processes pre-anodized profiles alongside

history.

conventionally pretreated material. The pre-anodizing / PREOX in the specification documents occurs in ALUMIL’s own anodising facility rather than in-line, and both routes then pass through a single conversion coating

A decision that had to be made again

Pretreatment suppliers do not change often. The qualification burden

stage. That is only possible if the conversion coating chemistry is qualified

is heavy, the QUALICOAT and GSB frameworks constrain what can be

for both.

substituted, and the cost of being wrong is counted in rejected production

 Productivity: More than 2 m/min, which changes the arithmetic

rather than in the price of chemistry. Most coaters evaluate once, early,

underneath everything else. A drifting bath produces more

and leave the question closed.

out-of-specification metal per hour. A stage needing descaling takes more

ALUMIL has never left it closed. Over more than two decades its laboratory

output offline. An unplanned stop leaves profiles standing inside an active

and production teams have tested virtually every major aluminium pretreatment alternative available, under both lab and industrial conditions. Its technical staff have worked through several generations of conversion

coating chemistry and can say precisely where each generation performed and where it ran out. That same span also covers the cooperation with SurfChem. It began when chromate conversion coatings were still the established answer for architectural aluminium, and around 2010 ALUMIL introduced SurfChem’s chrome-free pretreatment technology, at a point when the industry was still genuinely unsure whether chromium-free processes could match the corrosion protection and operating reliability that chromate chemistry had established over decades, on top of its environmental advantages. It continued through that transition and widened afterward. SurfChem pretreatment technology was introduced at several ALUMIL Group coating operations in Greece and Southeastern Europe, including Romania, Albania, and Serbia. The cooperation also moved outside coating altogether, into lubricants for high-speed billet and profile sawing. The interesting part of that history is not its length. It is how much changed inside it. Chromate gave way to chromium-free conversion coating. Line speeds rose. Environmental expectations tightened. Water

New vertical powder coating unit unloading unit – up to 8 meters pretreated and powder-coated aluminum profiles.

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SUCCESS STORIES

and wastewater became production metrics rather than utilities. Automation increased. Quality became datadriven. And the commercial conversation moved away from the price of a drum of concentrate towards the real cost of treating a ton of aluminium. Through every one of those shifts, ALUMIL kept evaluating alternatives. Which is what makes the Kilkis decision worth writing about: it was made by a buyer with somewhere else to go. “A long relationship gives you experience. It does not make the next decision automatic. On an investment of this size, we went back to what the line actually requires and evaluated against that. Performance, reliability,

Chematic intelligent pretreatment dosing system – remote control + alarm unit.

operating efficiency and the technical support behind them all had to hold together, and that combination is where most options separate”, says Giannis Tsoulfaidis, Corporate Production & Safety Director at ALUMIL. “ALUMIL has never made it easy for us. I would not want them to. You only progress when you are up for a good

Chrome-free pretreatment configuration, ALUMIL Kilkis vertical line Application: Cascade

challenge”, adds Dimitrios Skylodimos, CEO at SurfChem.

When the best pretreatment is the most boring one

Line speed: More than 2 m/min

Robustness is easy to undervalue, because on a line

Substrate routes: Conventional pretreatment and pre-anodised (PREOX), through a

that has it, robustness consists almost entirely of things

common conversion coating stage

that do not happen. The bath does not change character

Certification: QUALICOAT SEASIDE licensed, minimum 2.0 g/m etching degree,

halfway through a shift. Maintenance does not interrupt

GSB International Premium

production. A small parameter movement does not

STAGE 1 – DAL PF PLUS

continually correcting a process that wants to drift away

Function and operating behaviour: Combined acidic degreasing and etching. Meets

from target.

the enhanced SEASIDE etching requirement. No bath ageing; dissolved aluminium

immediately produce reject material. Operators are not

Underneath that behaviour are specific chemical

stable; etching degree constant across bath life.

properties, and they are worth naming rather than

STAGE 2 – DEOXAL PRO

aluminium stabilises rather than accumulating, which

Function and operating behaviour: Acidic deoxidising and activation. Removes etching smut and prepares a uniform, chemically active aluminium surface. Equilibrium below 3 g/L dissolved Al without overflow. No deposition on heat exchangers, nozzles

gesturing at. Dal PF Plus does not age. Dissolved means the etching degree the bath delivers in month eight is the etching degree it delivered in week one, a material point on a QUALICOAT SEASIDE line, where 2.0

or tunnel surfaces.

g/m² is not a nominal figure but a certified requirement

STAGE 3 – SURFPASS PA TMOC

Deoxal PRO reaches an operating equilibrium below

Function and operating behaviour: Chrome-free conversion coating. QUALICOAT approved for both conventional (A137), pre-anodised (AP137) substrates, and GSB International approved Zul-Nr. 262b.Rinse stages between and after the chemical stages as required by the process.

subject to inspection. 4 g/L dissolved aluminium and holds it there without overflow. The bath stays chemically active, and equally it stops depositing reaction products on heat exchangers, tunnel walls and pump internals. Descaling shutdowns do not get shortened. They stop occurring, because the deposits never form.

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SPECIAL ISSUE ON ARCHITECTURE & DESIGN

To SurfPass PA TMOC, QUALICOAT approved under A137 for conventional pretreatment, AP137 for pre-anodising and GSB International Zul-Nr. 262b, carries a conversion coating weight window of 2 to 20 mg/m2. That range is what absorbs the variation a real production line generates: conveyor speed adjustments, temperature drift across a shift, alloy variation between batches, all without anything leaving specification. This is not permission for a bath to wander; the process target stays controlled. The advantage is that normal variability around that target does not put the line over a cliff. Narrow windows rarely fail dramatically. They fail intermittently, and intermittent failures are the expensive kind, because nobody can trace them back to anything. The same product operates between 10 °C and 35 °C. At Kilkis that means minimized chilling in August and minimised heating in February, just enough to keep the bath inside range rather than running full climate control on it year-round. Most of the year it sits close to whatever temperature the building already is, which cuts the energy load and removes a control loop that would otherwise need constant correction. The line offered its own demonstration of what that tolerance is worth. During an extended stop, profiles stood stationary inside the pretreatment tunnel for approximately one hour. When the line restarted, the material continued through into coating as normal production: no adhesion loss, nothing scrapped. No line is immune to an unplanned stop, however advanced the equipment around it. The conveyor stops, a power outage, something upstream goes wrong: it happens even on the most technologically sophisticated production floors. What decides the outcome is not whether it happens but whether the chemistry can absorb it. High-speed production magnifies the cost of instability, and a chemistry that can absorb an abnormal event without converting it into a second problem — scrap, rework, bath recovery, an adhesion investigation — is worth considerably more to a plant than a favourable data sheet. That is true robustness. “The best pretreatment is the most boring one. The baths hold their values, I am not descaling equipment, and it behaves the same on a Monday morning as on a Friday afternoon. That means my people are running the line instead of watching the tunnel”, affirms Pavlos Toursidis, Powder Coating Division Manager at ALUMIL.

LEAN means taking work out of the process

The active chemistry at Kilkis is three stages, and the first of them is a consolidation rather than an addition. Dal PF Plus performs degreasing and etching in a single acidic bath. Combining two functions matters well beyond the chemical sequence, because every active stage in a pretreatment tunnel carries a footprint far larger than the tank it occupies. Chemistry has

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SPECIAL ISSUE ON ARCHITECTURE & DESIGN

SUCCESS STORIES

From left to right: Chematic intelligent pretreatment dosing system – shopfloor control + alarm unit. Vasilis Politidis – Alumil’s Laboratory Manager – supervising & controlling every function around pretreatment & passivation. From left to right: Kostas Gkogkos - SurfChem’s Head of technical support, Pavlos Toursidis – Alumil’s Powder Coating Manager, Vasilis Politidis - Alumil’s Laboratory Manager.

to be prepared, dosed and controlled. A bath has to be maintained and

cheap to buy: fresh water & wastewater per ton, maintenance hours,

monitored. Rinsing has to follow it. And eventually most of what entered

energy, downtime, and the cost of material that never becomes saleable

has to leave again as wastewater.

production.

That is what SurfChem’s LEAN approach actually means, and it is not

A bath that has to be discarded consumes its chemistry twice. Once

primarily about using fewer products. It is about removing work from

performing the work, once going to treatment.

the process: control loops, maintenance interventions, rinse volumes,

Read that way, sustainability and cost efficiency are no longer competing

corrective additions and disposal cycles that a differently designed

objectives. They are frequently the same engineering problem examined

chemistry would have made unavoidable.

from opposite sides of the balance sheet.

Water is the clearest example. Wet chemical pretreatment requires rinsing, and water entering the process does not disappear; the more fresh water a line draws, the more has to be managed downstream. Reducing rinse demand therefore has a direct consequence rather than a rhetorical one.

Performance is the part that cannot be negotiated

None of which matters if the coated aluminium does not survive.

Bath stability compounds it: chemistry that runs for long production

QUALICOAT sets the qualification threshold for a chrome-free conversion

periods without dumping or heavy corrective addition spends more of its

coating system at zero corrosion after 1,000 hours of acetic acid salt

life doing useful work and less of it being transferred to treatment. Across

spray testing and zero corrosion after 1,000 hours of filiform corrosion

the system, SurfChem’s chemistry delivers up to 80% less wastewater

testing.

volume than the technologies it displaces, and that figure was one of the

The SurfChem system meets both. That is what allows it onto a certified

reasons it was selected, not a benefit discovered afterward.

line. The testing was taken considerably further. After 3,000 hours of

So, what is chemical efficiency, actually?

AASS exposure without primer, maximum corrosion creep remained at 0.3

It is not the price per kilogram of concentrate, though that is what

mm. Filiform corrosion testing reached 1,500 hours with zero corrosion.

most quotations are compared on. The meaningful figure is chemical

Those figures are worth setting against the specification, because a creep

consumption per ton of aluminium successfully treated, and around it

number in isolation tells a reader very little.

sits the quantities that determine whether a line is cheap to run or merely

QUALICOAT’s acceptance criterion for acetic acid salt spray permits

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SUCCESS STORIES

explaining where it came from. A result that appears after powder application may originate in pretreatment, but it may equally trace back to incoming water, alloy, surface condition, rinsing, process temperature, line operation or something upstream of the chemistry entirely. Finding the answer requires rather more than knowing the concentration of a bath. That is why SurfChem’s technical people work alongside ALUMIL’s production personnel rather than arriving for scheduled analyses: production troubleshooting, bath optimisation, laboratory work, corrosion and materials expertise, and the ability to react while the problem is still alive. The relationship also extends into research. The two companies run projects, including the current work on corrosion performance over classic passivated and pre-anodised aluminium. Technical support solves the problem the plant has today. Research capability answers the question it will have in three years. Both sit

inside the same structure, and neither is visible on a technical data sheet. “You do not support a coating line from a infiltration of up to 16 mm² over a 10 cm

specimens taken from ALUMIL’s line and tested

datasheet. You have to know how it runs, how

scratch, with no single infiltration exceeding 4

at SurfChem’s own facilities. Approval testing

it changes through a shift, and what matters

mm. The qualification duration is 1,000 hours

establishes that a chemistry can perform.

when production is moving at full speed. Being

for most organic coatings and 2,000 hours for

Production specimens establish that it does.

close to ALUMIL means understanding their

Class 3 powder coatings, the most demanding

“Passing the corrosion requirement is the bare

process well enough not only to respond to

category, and one of the two classes this

minimum for us. The harder problem is holding

today’s challenges, but to anticipate what the

conversion coating is qualified to carry. The

that performance while the water consumption

line will demand next. That is the difference

SurfChem result therefore sits at one and a half

comes down, the bath stops ageing and the

between supplying a customer and working

times the exposure duration required of the

maintenance disappears, because those things

with a partner: you start tackling tomorrow’s

toughest coating class, with creep at one-eighth

normally trade against each other. And the

challenges before production has to answer

of the maximum single infiltration the standard

width of the window is what decides whether it

them”, affirms Kostas Gkogkos, Head of

allows. Without primer.

survives contact with a factory. Between 2 and

Technical Support at SurfChem.

All of those figures are for conventional

20 mg/m², and between 10 and 35 degrees,

pretreatment. The pre-anodised route performs

there is room for a line to move. Narrow either

substantially better again, and establishing

of those and you start producing rejects for

how much better, on real ALUMIL production

reasons nobody can trace”, says Thomas

Chematic, SurfChem’s intelligent chemical

material rather than laboratory panels, is one of

Skylodimos, Technical Director, Chemicals,

management system, developed in-house.

the joint research projects the two companies

Materials & Corrosion at SurfChem.

It replaces neither robust chemistry nor

are running now. The results also come from three separate directions, which is less common than

Support does not arrive in a drum

LEAN chemistry. Intelligent control. The Kilkis line adds one further element:

technical people. Its function is to make the process visible, and it does three different

There is a reason ALUMIL’s evaluation cannot be

things. The difference between them matters,

it sounds: QUALICOAT approval testing,

reduced to product specifications.

because digital process systems routinely blur

QUALICOAT re-approval testing, and production

A coating defect rarely introduces itself by

all three.

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SUCCESS STORIES

 Controls. Bath conductivity and temperature are held automatically,

There is technical support close enough to the line to arrive while the

which removes two variables from human attention entirely.

problem is still happening, not when the next order is due.

 Alarms. Anything moving outside specification triggers a warning —

There is R&D, running now, developing the process against requirements

pH, temperatures, low chemical level in the IBC, water quality — delivered

ALUMIL has not finished writing yet.

remotely as well as on the line. Alarming does not remove the variable. It

There is process intelligence through Chematic, putting monitoring,

removes the delay before anyone knows about it.

traceability and safeguards around the chemistry and the people running

 Logs. A full process data record, including line speed and stoppage

it.And underneath all of it sits the least technical word in this article, and

timelines, runs continuously. Logging removes the ambiguity afterwards.

the hardest one to earn: trust.

The plant works with it from a PLC screen on the line, from a PC in the

At Kilkis, it has been running for twenty years, and lately, at more than two

laboratory, and remotely, through a graphical representation of the coating

metres a minute.

line showing bath arrangement, dosing pump status and live values. Commands can be timed. The alarming is where the value tends to show up first, and the clearest cases involve utilities rather than chemistry. On one occasion, a deionised water system supplying a pretreatment process began delivering water at an alkaline pH. Nothing was wrong with the pretreatment chemistry at all. The problem originated upstream, in a system belonging to somebody else’s maintenance schedule, and without monitoring that kind of change stays invisible until its consequence surfaces somewhere further down the coating process. Chematic automation detected the problem and immediately notified with an alarm. The point is not that DI systems can malfunction; every plant contains utilities that eventually drift. The point is that the pretreatment process

Scan the QR code to discover our range of metal pretreatment products.

was being watched even when the problem did not originate in pretreatment. The historical record does something equally useful and less obvious. If a deviation occurs during a night shift, the engineer looking at it the following morning is not reconstructing events from recollection. What changed, when, what the rinse conductivity was doing, what the temperature was, whether the line was moving, which alarm came first: those are questions with answers. Access sits with ALUMIL; SurfChem’s technical staff are granted access when they are working on a problem, which means a support discussion starts from what the line actually did rather than from what somebody remembers it doing.

Forged in partnership. Proven in production.

Chematic is one part of the Kilkis story. It is not the conclusion. After more than twenty years, repeated qualification, laboratory testing, production trials and two complete changes of chemical technology, what SurfChem brings to ALUMIL now covers the whole problem that pretreatment presents to an aluminium producer. There is chemistry built for performance, robustness, sustainability and cost efficiency at the same time, which is harder than any one of them alone. There is a LEAN approach that looks past the price of a drum to the water, chemicals, wastewater, maintenance and production hours consumed for every ton of aluminium treated.

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Chematic at ALUMIL Kilkis Controlled automatically: Bath conductivity · Bath temperature Alarmed on deviation: pH · Temperatures · Low chemical level in IBC · Water quality · Any parameter outside specification · Remote alarm delivery Logged continuously: Full process data log · Line speed · Stoppage timelines Interface: Graphical view of the coating line: bath arrangement, dosing pump status, live values · On-site PLC screen · Laboratory PC · Full remote control · Timed commands Access: ALUMIL personnel. SurfChem technical support granted access when required.

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SPECIAL ISSUE ON ARCHITECTURE & DESIGN

Your product, its surface... you must design it, and we are responsible for making it perfect and maintaining it Edited by Lechler SpA

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This is where CLEARCOAT ESS&RE UHS (96302), the first bio-based Ultra

of surface hardness, resistance to solvents, gasoline, detergents, and

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finish for a piece of furniture doesn’t require the same

scratches, as well as a lower VOC content than required by Directive

performance as an industrial body shop, just as a sports item

2004/42/EC. Compared to a conventional clearcoat, this product offers

or a fashion accessory have different requirements in terms of

significantly higher surface hardness (140 König pendulum strokes), thus

resistance, aesthetics, and durability. The task of painting isn’t to even out

helping to preserve the surface’s appearance over time.

these differences, but to enhance them, while offering the right balance of

These characteristics allow it to meet a wide range of needs. In industrial

aesthetics, protection, and sustainability for each surface.

body shops, the high solids content helps create an effective barrier to

This is the philosophy that guides the development of Lechler’s ESS&RE

protect the manufactured item, while also ensuring excellent aesthetics,

line: starting from the designer’s objective and the final use of the article,

rapid drying, and solvent resistance. In the General Industry sector,

to identify the most suitable solution. In other words, it’s not the product

these same qualities translate into durable surfaces that maintain their

that defines the surface, but the desired surface guides the choice of

appearance over time even in the presence of aggressive detergents and

technology.

agents.

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ADVANCEMENTS

For the Sporting sector, where surfaces are constantly subjected to

More than just a clearcoat, CLEARCOAT ESS&RE UHS is therefore a

mechanical stress, the focus shifts to high scratch resistance and

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finish quality. Meanwhile, in the Habitat Interior sector, aesthetics and

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resistance to common cleaning products are key, essential for preserving

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it. Since every manufactured item expresses itself through its surface,

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environmental and regulatory aspects.

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RESEARCH BREAKTHROUGH

SPECIAL ISSUE ON ARCHITECTURE & DESIGN

A simple approach to rGO deposition on aluminium alloys for corrosion and wear protection Stefano Caporali* and Nicola Calisi Department of Industrial Engineering, DIEF, University of Florence, Florence, Italy, and Consorzio INSTM, Florence, Italy stefano.caporali@unifi.it * Corresponding author.

Aluminium and its alloys rely on a thin native oxide film for corrosion resistance; however, in chloride-containing environments this passive layer is prone to localized breakdown and pitting corrosion. Reduced graphene oxide (rGO) has emerged as a promising material for aluminium corrosion protection due to its excellent impermeability, and chemical and mechanical stability. When used as a coating component or nanofiller in paints rGO significantly enhances barrier properties. In this work rGO was obtained by simple reduction with L-ascorbic acid from GO solution and its direct application on commercial aluminium alloys, commonly used for structural applications, is investigated as an anticorrosion and anti-wear coating by means of electrochemical techniques and tribology. The results support the effectiveness and suitability of such simple, inexpensive, and environmentally friendly treatment, capable to enhance the stability of the surface passive layer.

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RESEARCH BREAKTHROUGH

luminium alloys are indispensable structural materials in modern

Historically, chromate-based conversion coatings have provided excellent

engineering due to their low density, high specific strength, and

corrosion protection for aluminium alloys. However, due to the toxicity

good formability. They are widely applied in aerospace, marine

and carcinogenicity of hexavalent chromium compounds, increasingly

and transportation sectors, and emerging energy technologies. The

stringent environmental regulations have driven intense research

corrosion resistance of aluminium originates from the rapid formation

into chromate-free alternatives. In this context, nanomaterial-enabled

of a thin, adherent oxide film (Al₂O₃) that passivates the surface under

coatings—especially those based on graphene derivatives—have attracted

neutral and mildly alkaline conditions [1, 2].

significant attention [4-6]. Among graphene-based materials, reduced

Despite this natural passivity, aluminium alloys are highly susceptible

graphene oxide (rGO) offers a unique combination of properties: high

to localized corrosion in the presence of aggressive anions, particularly

impermeability comparable to graphene, residual functional groups that

chloride ions [3]. Pitting corrosion represents the most critical

improve dispersion and adhesion, and scalable synthesis routes [7].

degradation mechanism, as it can initiate at microscopic defects,

Generally, the conversion from GO to r-GO requires a reducing agents

intermetallic particles, or inclusions and propagate rapidly with limited

[8-9] or thermal treatment [10-14], or even bacterial methods [15].

macroscopic warning. Once the passive film breaks down, localized

However, in order to propose a simple and easily scalable process for

dissolution is sustained by autocatalytic mechanisms involving local

industrial applications, several aspects need to be accurately taken into

acidification and chloride enrichment.

consideration, the most relevant of which are the use of water-based treatments and the use of inexpensive and benign reducing agents. Based on these concerns many commonly used chemical reductants, such as hydrazine, hydrazine hydrate, and NaBH4 need to be avoided. Green © AdobeStock

reductants, such as L-ascorbic acid (L-aa) [16-18], L-cysteine [19] and even various plant extracts [20-22], have been proposed. Despite inherent limitations—such as reduced deposition efficiency arising from the formation of graphene agglomerates that do not participate in film growth, and the requirement for moderately elevated processing temperatures (>60 °C), which restrict applicability to thermally sensitive substrates—this method remains the most viable and scalable approach for the deposition of rGO coatings on metallic substrates [23], including in industrial and artisanal manufacturing contexts.

Experimental procedures Samples preparation

Metallic substrates were prepared from commercially available bars of AA5754 and AA6068 aluminium alloys [their chemical composition, as determined by XRF-WDS (Rigaku ZSX Primus II), are depicted in Table 1 as 1 mm thick and 50 mm diameter tokens. The samples were than grinded with emery paper down to 1200 grit, rinsed in distilled water, acetone and then air dried letting the spontaneous oxidation film to be formed on the sample surface. Table 1: Designation, chemical composition (Wt%) of the aluminium alloys tested. Alloy designation

Composition (Wt%) Si

AA5754

0.35

0.26

0.40

3.2

0.10

0.18

0.25

0.1

0.01

balance

AA6068

0.40

0.34

0.57

1.1

0.10

0.20

0.30

0.1

n.d.

balance

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Reduced graphene oxide (rGO) coatings were deposited on the sample surface by immersing the metallic tokens in an aqueous solution prepared by diluting a commercial graphene oxide (GO) dispersion (0.4 wt%, Goodfellow) with Milli-Q water to a final GO concentration of 0.1 mg/mL⁻¹. L-ascorbic acid (99%, Merck) was added as a reducing agent in the amount of 4 g/L⁻¹. Solution containing the immersed samples was then heated at 80 °C under continuous stirring (≈600 rpm) for 2 h. During the process, the solution colour changed from grey to brownish and a rGO film is deposited on the solid surfaces in owe to the reduced solubility of rGO respect to the GO. As side by-products some colloidal graphene agglomerates appeared. Following the treatment, the samples were retrieved from the solution, gently rinsed with Milli-Q water, air-dried, and then subjected to subsequent testing and characterization. Visual investigation of the samples so produced was obtained by means of digital magnifier (OCULUX Macro Zoom, Microconsult).

Figure 1 - Sketch of the ball-on-disk principle. The test was performed with a 10 mm diameter ball applying a normal load of 4 N.

Electrochemical tests The potential effect of rGO as an anticorrosive coating was assessed by electrochemical techniques. A computer controlled potentiostat (Autolab, Metrohm) controlled via Intello electrochemical software (vers. 2.1) and a three-electrode corrosion cell (EG&G Parr Flat cell) constituted the electrochemical set-up. 1

Tribological tests

cm2 is the exposed area of the working electrode while a platinum

The coefficient of friction (COF) was determined using a ball-on-disk tribometer

grid and a saturated calomel electrode (SCE) constituted counter

(POD 4.0, Ducom Instruments, India), in which a stationary spherical ball (10

and reference electrodes, respectively. Electrochemical tests were

mm diameter, in our case) was brought into sliding contact with a rotating

carried out in aerated 5 % NaCl solution at room temperature.

disk specimen under controlled conditions applying a constant normal load

Prior to each measurement, open-circuit potential (OCP) was

throughout the test. During testing, that was carried at room temperature, the

recorded until a stable potential was reached (about 1 hour),

friction force generated at the ball–disk interface was continuously measured,

then EIS and potentiodynamic polarization (PDP) measurements

and the COF was calculated as the ratio of the measured friction force to the

were performed. EIS measurements were carried out with an AC

applied normal load (4 N) as function of the sliding distance. Figure 1 depicts a

amplitude of 10 mV at open circuit potential in the frequency range

scheme of test. Three replicate tests were carried out for each specimen, and

100 kHz to 1000 mHz while, successively to the EIS measurement

at the end of the test, the worn samples were observed by SEM microscopy

PDP curves were registered at scanning rate of 0.1667mV/s

(Hitachi, SU3800, filament electron source) operating at 15keV and 16.3mm

from -0.9V to -0.2V vs SCE in the anodic direction. The inhibition

working distance.

efficiency (IE) of the rGO coating was calculated accordingly to the following equation (1)

Results

Sample preparation The detailed physical characterization of the rGO layer obtained via GO IE% = 100 x

(1)

reduction with L-ascorbic acid is reported in literature [23-25], in our case the successfully formation of rGO film was cheked by FTIR measurements (not reported here) and visual investigation. Representative images of the sample surface before and after the deposition of rGO are depicted in Figure

Where:

2 (AA5754 alloy) and Figure 3 (AA6068 alloy). For both aluminium alloys, no

IE = inhibition efficiency; icorr, ref= corrosion current of the untreated

detectable changes in surface morphology were observed after the treatment;

sample.

colour towards a more brownish hue.

aluminium sample; icorr, rGO = corrosion current of the rGO treated

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however, the treated samples exhibited a slight, but clearly visible, shift in

SPECIAL ISSUE ON ARCHITECTURE & DESIGN

RESEARCH BREAKTHROUGH

Figure 2 - Digital macro images of the sample AA5754 before (a) and after (b) the deposition of rGO coating (field of view 3mm x2mm).

Figure 3 - Digital macro images of the sample AA6068 before (a) and after (b) the treatment with rGO (field of view 3mm x2mm).

Electrochemical corrosion tests PDP curves are shown in Figure 4, and values of Ecorr and icorr obtained

resistance (Rs), the charge transfer resistance (Rct), and a constant phase element (CPE). The Nyquist plots of both coated and uncoated samples

by the tangent extrapolation method are displayed in Table 2. Despite

exhibit a typical depressed semicircular shape in the high-frequency

the Ecorr values remain almost unaffected by the rGO treatment the icorr

region. Notably, the diameter of the semicircle for the rGO-coated samples

values showed a clear decrease pointing out a corrosion reduction with

is significantly larger than that of the uncoated sample. This increase

inhibition efficiency (IE %) values respectively of 82% for AA6068 and 84 % for AA5754.

indicates a higher charge transfer resistance (Rct), which is associated with

enhanced corrosion resistance of the coated aluminium samples.

The corrosion protection performance of the rGO coating on Al alloys was investigated by electrochemical impedance spectroscopy (EIS).

Wear tests

The Nyquist plots, and the corresponding equivalent electrical circuit,

The coefficient of friction of rGO against a steel sphere was evaluated

are presented in Figure 5. The equivalent circuit consists of the solution

to better elucidate its role, together with the wear behaviour of treated

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Alloy

Ecorr

icorr

(V vs SCE)

(µA/cm ) 2

Ecorr

icorr

(V vs SCE)

(µA/m )

untreated

inhibition efficiency (IE, %)

and untreated samples. Figure 6 depicts the coefficient of friction (COF) as a function of sliding distance (m). The red curves correspond the untreated samples, whereas the blue curves represent the rGO-treated samples. After rGO

+ rGO

treatment, both alloys exhibit a significant

AA5754

-0.73± 0.01

1.1 ± 0.1

-0.72± 0.01

0.2 ± 0.1

reduction of COF values. Figures 7 and 8

AA6068

-0.72 ± 0.01

5.7 ± 0.1

-0.71 ± 0.01

0.61 ± 0.1

for the treated and untreated samples. The

Table 2: Electrochemical corrosion values obtained from PDP curves.

display the SEM images of the wear surfaces wear scars on both the untreated alloys are characterized by their extensive width and high roughness, accompanied by a plethora of debris. Moreover, wear debris (not displayed here) was observed on the sphere used with the untreated sample, showing the presence of severe adhesion wear and justifying the high variability of COF. Nevertheless, the samples treated with rGO exhibited much smaller wear track, consistent with reduced COF and almost none wear debris.

Discussions

It is well known that rGO obtained by partial reduction of GO via chemical reduction in aqueous environment, retains residual oxygen-containing functional groups that enhance adhesion capability towards the oxide Figure 4 - PDP curves of uncoated (dashed curves) and rGO-coated (solid curves) Al samples recorded in aerated 5% NaCl. rGO-coated samples show a clear decrease in icorr values, compatible with an inhibition of the corrosion process.

layer present on the surface of air-exposed aluminium items. [26]. After deposition of rGO layer the colour of the samples turns towards a more brownish hue but, from the electrochemical point of view no significative change in the OCP and Ecorr, respect to the untreated samples were observed (Figure 4). Such electrochemical data asses that the rGO layer is not in direct contact with metallic surfaces, avoiding the potential galvanic coupling which could increase the corrosion rate. [27,28]. That is probably due to the partial surface coverage by rGO layer and the absence of direct contact of the rGO layer with metal parts. Nevertheless, the presence of such film effectively reduces the corrosion rate in mild NaCl bearing environments, limiting the

Figure 5 - Nyquist plots for uncoated and coated Al samples. The inset displays the proposed circuit equivalent.

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icorr of about 1 order of magnitude (Table 2) with respect to the untreated samples. The inhibition effect player by rGO layer is

SPECIAL ISSUE ON ARCHITECTURE & DESIGN

RESEARCH BREAKTHROUGH

Figure 6 - The coefficient of friction (COF) as a function of sliding distance (m) for untreated (a) and rGO – treated (b) samples.

reasonably attributable to the increased charge transfer resistance (Rct) as highlighted by EIS measurements (Figure 5). That is

consistent with a reducing permeation of water, oxygen, and chloride ions as proposed in previous works [29, 30] and is attributed to the near-impermeability to gases and liquids of graphene-like materials. Furthermore, the increased hydrophobicity and the lubricating effect played by the rGO layer, as demonstrated by the wear tests (Figure 6), may further inhibit the retention of aqueous solution at the surface or within the pores of the oxide layer, effectively

Figure 7 - SEM micrographs of wear traces on AA5754: (a) Untreated sample, (b) rGO treated sample. Same magnification for the two samples, scale bar in the picture.

enhancing the barrier effect, which is widely recognized as the predominant corrosion protection mechanism of rGO-based coatings.

Conclusions

A reduced graphene oxide (rGO) layer was successfully deposited onto commercial grade aluminium alloys by the simple reduction of GO aqueous solutions using L-ascorbic acid. The capability of the film, so generated, to improve the anticorrosion characteristics of two different aluminium alloys (namely AA5754 and AA6068) widely used for structural applications was successfully tested in aerated NaCl aqueous solution via electrochemical test. Potentiodynamic polarization measurements

Figure 8 - SEM micrographs of wear traces on AA6068: (a) Untreated sample, (b) rGO treated sample. Same magnification for the two samples, scale bar in the picture.

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demonstrate that rGO coatings does not significatively affects the

improving the corrosion and wear resistance of bare aluminium alloys for

corrosion potential (Ecorr) but indeed reduce the corrosion rate of about

practical applications in mild ambient environments, while preserving their

84% and 82% for AA5754 and AA6068, respectively. EIS measurement

aesthetic appearance. Although the enhancement in corrosion resistance

confirms this behaviour indicating a strong increment of the polarization

is lower than that provided by conventional chromate-based conversion

resistance respect to the untreated samples. On the other hand, wear

coating or anodizing treatments, the simplicity of the process and the low

tests conducted using ball-on-disk measurements highlighted that the rGO

cost and low toxicity of the reagents make this environmentally benign

layer plays a beneficial role in reducing the coefficient of friction. In treated

method well suited for large-scale industrial implementation.

samples the scar traces resulted much smaller and a reduced presence of debris was observed. These effects are reasonably attributable to the formation of an almost continuous layer of graphene-like material, strongly

Acknowledgements

adhering to the substrate, which impair the direct contact between the

The authors acknowledge financial support from the Italian Ministry

tribometer's ball and the surface of the sample thereby reducing wear. The

for enterprise and made in Italy (MIMIT) for partially supporting this

observed corrosion inhibition effect can be also due to the capability of

research through the project: “Studio di applicazioni industriali innovative

rGO layer to impair the penetration of aggressive agent (mainly water and

del graphene” (Acronim: GRAFENEX) funded within the call:“Accordi per

chloride ions) inside the pores and cracks naturally present on the surface.

l’Innovazione” (D.M. MiSE 31/12/2021).

This study presents a relatively simple and cost-effective approach to

References [1] W.A. Badawy, F.M. Al-Kharafi, A.S. El-Azab, “Electrochemical behaviour and corrosion inhibition of Al, Al-6061 and Al-Cu in neutral aqueous solutions”, Corros. Sci. vol 41, pp. 709–727, 1999 [2] R. G. Kelly, et al., “Passivity and localized corrosion”, in “Electrochemical techniques in corrosion science and engineering”. Marcel Dekker inc., 2002, 55-123. [3] R. C. Newman, “Local chemistry considerations in the tunnelling corrosion of aluminium” Corros Sci. vol 37, 3, pp. 527-533, 1995 [4] S.J. Richard Prabakar, Y.-H. Hwang, E.G. Bae, D.K. Lee, M. Pyo, “Graphene oxideas a corrosion inhibitor for the aluminum current collector in lithium ionbatteries”, Carbon vol 52, pp 128–136, 2013 [5] S. Chen, L. Brown, M. Levendorf, W. Cai, S.-Y. Ju, J. Edgeworth, X. Li, C.W.Magnuson, A. Velamakanni, R.D. Piner, J. Kang, J. Park, R.S. Ruoff, “OxidationResistance of Graphene-Coated Cu and Cu/Ni Alloy”, ACS Nano 5, pp 1321–1327, 2011 [6] A.S. Kousalya, A. Kumar, R. Paul, D. Zemlyanov, T.S. Fisher, “Graphene: an effective oxidation barrier coating for liquid and two-phase cooling systems”, Corros. Sci. 69, 5–10, 2013 [7] Y. Liu, J. Zhang, S. Li, Y. Wang, Z. Han, L. Ren, “Fabrication of a superhydrophobic graphene surface with excellent mechanical abrasion and corrosion resistance on an aluminum alloy substrate”, RSC Adv. 4, pp 45389–45396, 2014 [8] C.K. Chua, M. Pumera, “Chemical reduction of graphene oxide: A synthetic chemistry viewpoint. Chem. Soc. Rev. 43, pp 291–312, 2014 [9] C.K. Chua, M. Pumera, “The reduction of graphene oxide with hydrazine: Elucidating its reductive capability based on a reaction-model approach” Chem. Commun. 52, pp 72–75, 2016 [10] R. Jakhar, J.E. Yap, R. Joshib, “Microwave reduction of graphene oxide”. Carbon 170, pp 277–293, 2020 [11] V.V. Chaban, O.V. Prezhdo, “Microwave reduction of graphene oxide rationalized by reactive molecular dynamics”. Nanoscale, 9, pp 4024–4033, 2017 [12] O.M. Slobodian, P.M. Lytvyn, A.S. Nikolenko, V.M. Naseka, O.Y. Khyzhun, A.V. Vasin,S.V. Sevostianov, A.N. Nazarov, “Low-Temperature Reduction of Graphene Oxide: Electrical Conductance and Scanning Kelvin Probe Force Microscopy”. Nanoscale Res. Lett. 13, 139, 2018 [13] W. Gao, N. Singh, L. Song, Z. Liu,A.L. Reddy, L. Ci, R. Vajtai, Q. Zhang, B. Wei, P.M. Ajayan, “Direct laser writing of micro-supercapacitors on hydrated graphite oxide films” Nat. Nanotechnol. 6, pp 496–500, 2011 [14] A. Longo, R. Verrucchi, L. Aversa, R. Tatti, A. Ambrosio, E. Orabona, U. Coscia, G. Carotenuto, P. Maddalena, “Graphene oxide prepared by graphene nanoplatelets and reduced by laser treatment” Nanotecnology, 28, pp 224002–224008, 2017 [15] G. Utkan, T. Öztürk, Ö. Duygulu, E. Tahtasakal, A.A. Denizci, “Microbial Reduction of Graphene Oxide by Lactobacillus Plantarum” Int. J. Nanosci. Nanotechnol. 15, pp 127–136, 2019. [16] M.J. Fernández-Merino, L. Guardia, J.L. Paredes, S. Villar-Rodil, P. Solís-Fernández, A. Martínez-Alonso, J.M.D. Tascón, “Vitamin C is an ideal substitute for hydrazine in the reduction of graphene oxide suspensions.” J. Phys. Chem. C, 214, pp 6426–6432, 2010 [17] A.T. Habte,D.W. Ayele, “Synthesis and Characterization of Reduced Graphene Oxide (rGO) Started from Graphene Oxide (GO) Using the Tour Method with Different Parameters” Adv. Mater. Sci. Eng. 15, 5058163, 2019

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[18] J. Liu, L. Liu, X. Wu, X. Zhang, T. Li, “Environmentally friendly synthesis of graphene–silver composites with surface-enhanced Raman scattering and antibacterial activity via reduction with l-ascorbic acid/water vapor” New J. Chem. 39, pp 5272–5281, 2015 [19] A.O.E. Abdelhalim, V.V. Sharoyko, A.A. Meshcheriakov, S.D. Martynova, S.V. Ageev, G.O. Iurev, H.A. Mulla, A.V. Petrov, I.L. Solovstova, L.V. Vasina, “Reduction and functionalisation of graphene oxide with L-cysteine: Synthesis, characterization and biocompatibility” Nanomed. Nanotechnol. Biol. Med. 29, 102284, 2020 [20] Y. Wang, Z. Shi, J.Yin, “Facile Synthesis of Soluble Graphene via a Green Reduction of Graphene Oxide in Tea Solution and Its Biocomposites.” ACS Appl. Mater. Interfaces 3, pp 1127–1133, 2011 [21] E. Vatandosta, S. Azade Ghorbani-Hasan, F. Chekin, S.N. Raeisi, S.-A. Shahidi “Green tea extract assisted green synthesis of reduced graphene oxide: Application for highly sensitive electrochemical detection of sunset yellow in food products” Food Chem. X 6, 100085, 2020 [22] B.Z. Kurt, Z. Durmus, E. Sevgi, “In situ reduction of graphene oxide by different plant extracts as a green catalyst for selective hydrogenation of nitroarenes.” Int. J. Hydrog. Energy 44, pp 26322–26337, 2019 [23] M. Palomba, G. Carotenuto, A. Longo, “A Brief Review: The Use of L-Ascorbic Acid as a Green Reducing Agent of Graphene Oxide”. Materials 15, 6456, 2022 [24] A. Kreta, I. Jerman, M. Bele, A.K. Surca, M. Gaberšˇcek, I. Muševiˇc, “Nanoscopic Characterization of Reduced Graphene Oxide for Anticorrosion Coating of AA2024”. Eng. Proc. 87, 82, 2025 [25] K.-O. Hülya, “Evaluation of morphological, structural, thermal, electrical, and chemical composition properties of graphene oxide, and reduced graphene oxide obtained by sequential reduction methods”, Carbon Trends, Vol 17, 100429, 2024 [26] S. Pei, H.-M. Cheng, “The reduction of graphene oxide”. Carbon 50, pp 3210–3228, 2012 [27] M. Schriver, W. Regan, W.J. Gannett, A.M. Zaniewski, M.F. Crommie, A. Zettl, “Graphene as a long-term metal oxidation barrier”. ACS Nano 7, pp 5763–5768, 2013 [28] C. Healy, F. Yu, J.G. Lozano, M.P. Ryan, P.E. McHugh, T. McNally, “Graphene and graphene oxide for corrosion protection of metals”. Corros. Mater. Degrad. 1, pp 127–150, 2020 [29] J.S. Bunch, S.S. Verbridge, J.S. Alden, A.M. van der Zande, J.M. Parpia, H.G. Craighead, P.L. McEuen, “Impermeable atomic membranes from graphene sheets”. Nano Lett. 8, pp 2458–2462, 2008 [30] B.P. Singh, S. Nayak, K.K. Nanda, S. Bhattacharjee, L. Besra, “Graphene-based materials and their composites: A review on production, characterization and applications”. Prog. Mater. Sci. 56, pp 1178–1271, 2013

SUCCESS STORIES

Trasmetal expands in India with a new vertical coating line for steel profiles Trasmetal has renewed its partnership with a leading Indian industrial group by installing a new vertical line to coat steel profiles up to 4 metres in length, designed to complement a previously installed horizontal system for products up to 12 metres long.

A renewed partnership

Overview of the new coating line

s one of the most dynamic emerging markets on the international

The project marked a further stage in the collaboration between Trasmetal and its Indian client. The Italian company had, in fact, already supplied the same group with a horizontal coating plant for particularly heavy parts and steel profiles. The new plant has been designed to treat and coat steel profiles up to 4 metres long.

The production cycle begins in the loading area, where the profiles are

stage, India is experiencing strong industrial development, driven

attached to the load bars and, via a monorail conveyor travelling at 1.8

by growth in the automotive, manufacturing, and infrastructure

m/min, are conveyed to the continuous-flow pre-treatment tunnel, which

sectors. The expansion of production capacity and the gradual

performs three stages: phosphodegreasing, rinsing with mains water, and

modernisation of factories are also fuelling demand for increasingly

rinsing with water from the reverse-osmosis microfiltration line.

advanced technologies.

“The profiles then reach the two-chamber oven, a key feature of the new

It is precisely in India that Trasmetal (Milan, Italy), a company specialising

line. Typically used in vertical systems, this configuration must take

in the design and installation of industrial coating systems, has recently

into account the thermal power required, determined by the weight and

completed one of its latest projects: a new vertical coating line for steel

material being treated. Its two sections perform different functions: one

profiles up to 4 metres in length, supplied to a major industrial group active

dries the components at the end of the pre-treatment stage, and the other

in the production of components and systems for industrial shelving and

cures the powder coating at a later stage in the cycle,” explains Carlo

racking.

Zucchetti, an engineer at Trasmetal. “This configuration enables the two

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SPECIAL ISSUE ON ARCHITECTURE & DESIGN

required thermal stages to be combined within a single

bar using osmosis water, and a two-chamber oven

system, albeit physically separated into two dedicated

for drying and curing. Its coating booth was supplied

chambers.”

by Gema.

Once dry, the profiles are transferred to the powder

The two systems demonstrate Trasmetal’s ability to

application booth. The parts then return to the oven’s

develop tailored solutions for specific components

curing section and finally proceed to the unloading area.

and production requirements: on the one hand, a

“Particular attention has also been paid to the manual

horizontal line for large and heavy parts, and on

operations at both ends of the line. Both the loading

the other, the new vertical plant for coating steel

and unloading stations are equipped with a 1-metre

profiles up to 4 metres in length, with high production

workbench to assist operators in handling the profiles,”

capacity. With this latest line, Trasmetal has further

says the engineer.

consolidated its presence in the Indian market and

Two configurations for two different production requirements

strengthened its existing partnership with the local industrial group.

The new vertical line complements the horizontal plant previously built by Trasmetal for the same client, which was designed to coat steel profiles and particularly heavy components intended for applications where the required dimensions of the parts were a key consideration. “One of its distinctive features is the high transfer speed required for the hanging bars between the various stages, which is a key factor in managing the line’s productivity,” Zucchetti continues. The horizontal line is also equipped with a three-stage, continuous-flow pre-treatment tunnel that performs a phosphodegreasing stage and two rinses, a final spray

From left to right: The profile loading stage. Overview of the application area. The vertical coating system designed by Trasmetal is equipped with a monorail conveyor that operates at a speed of 1.8 m/min.

HIGHLIGHT OF THE MONTH

Mirodur reorganises its factory to meet new market demand From an interview with Riccardo Vitelli, Mirodur (Aprilia, Latina, Italy)

riccardo.vitelli@mirodur.com

Through a major project to reorganise its manufacturing and logistics facilities, Mirodur aims to further improve customer service, increase the availability of its coating products, and lay the foundations for future investments in automation. This strategic decision responds to changing market demands, in which rapid turnaround times and reliable supply have become as important competitive advantages as product quality.

n recent years, procurement dynamics within production companies have changed profoundly. Whereas in the past many customers would place orders well in advance, today both manufacturers and coating

contractors operate on a shorter planning horizon and inevitably demand ever-faster supply times, even for smaller batches. This development has altered the role of logistics for coating manufacturers, as ensuring product availability has become a key factor in guaranteeing operational continuity for customers, reducing waiting times, and strengthening trust. The reorganisation project undertaken by Mirodur, a long-established producer of industrial paints, stemmed from this awareness, aiming to triple the space devoted to storing coating products and enhance the company’s ability to respond promptly to an increasingly unpredictable market.

Mirodur’s new warehouse increases storage capacity and improves the management of finished products.

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HIGHLIGHT OF THE MONTH

A new layout to improve efficiency

organised, mapped-out layout is an essential prerequisite for introducing

The space reorganisation project covers a section of the factory,

future automation systems for storage and handling processes. “To drive

approximately 2,000 m², built in 2004 and used for various operational

this transition, we have recently strengthened our in-house expertise by

purposes over the years. This area is now being fully converted and

bringing in a team of engineers and partnering with consultants who

allocated to a new warehouse for liquid paints. “In recent years, we have

specialise in industrial process optimisation,” adds the sales manager. The

seen a radical shift in purchasing habits. Customers are demanding

aim is to build an increasingly efficient organisation capable of supporting

immediate availability and maximum flexibility in order management. That

future growth while maintaining high standards of quality and service.

is why we have decided to invest heavily in our logistics infrastructure,” explains Riccardo Vitelli, sales manager at Mirodur. Thanks to the new layout, storage capacity has increased by

Investing today for tomorrow’s market

Although paint formulation quality remains key, factors such as order

approximately 1,500 pallet spaces. The reorganisation also enables more

fulfilment speed and service levels are now equally important competitive

efficient use of the available height and floor space within the facility:

advantages. “With this project, we have not simply expanded a warehouse,”

because this area is designated for the storage of finished and packaged

concludes Riccardo Vitelli. “We have structured our company to meet

products, it is not classified as an ATEX environment, allowing the use

the challenges of the coming years. We want to provide our partners

of more compact and flexible material-handling equipment and a more

with prompt support, laying the foundations for sustainable, flexible, and

efficient shelf layout, which further optimises the existing space and

strongly service-oriented growth.”

increases the volume of material that can be handled here.

The first step towards automation

The reorganisation of the company’s spaces is not a one-off measure but the starting point for a broader development plan. Creating a well-

The warehouse reorganization covers an area of approximately 2,000 m² and is also designed to prepare for the future introduction of automated storage and handling systems.

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HIGHLIGHT OF THE MONTH

The future of powder coatings: Rapid Coat’s private label offering Interview with Anuj Gupta Director of Rapid Coat Powder Coatings, Noida (Uttar Pradesh) - India

rivate-label manufacturing is a form of third party contract

In 1995, we began manufacturing epoxy polyester powders and by 2000 we

manufacturing in which a specialised manufacturer produces

began exporting our products. In 2009, the Government of India awarded

products that are marketed under the customer’s own brand.

us with the recognition of “One Star Export House”, and in 2017, we earned

This model allows companies to expand their offering or access new

Qualicoat approval from Switzerland — one of the most demanding quality

technologies without having to develop in-house production facilities,

certifications in our industry.

expertise and R&D capabilities. In the surface treatment industry, this can

Today, we are a team of over 500 people, serving more than 2,000 clients

be particularly attractive for companies looking to add powder coatings

with exports to 40-plus countries. Our people have always been part of

to their existing range of liquid coatings. This is the direction taken by

that growth, and we take real care of them in return alongside the CSR

Rapid Coat Powder Coatings, which combines more than 50 years of

(Corporate Social Responsibility) activities we carry out in the communities

experience in the manufacture of powder coatings with a solid production

around us. What hasn’t changed since 1974 is what we stand for: Quality,

infrastructure and extensive know-how gained across different markets

Durability, Trust.”

and applications. As Anuj Gupta, Director of Rapid Coat Powder Coatings, explains, this expertise provides the foundation for Rapid Coat to position

What are Rapid Coat Powder Coatings’ strategic objectives for the

itself not simply as a supplier, but as a full partner for companies looking

coming years, particularly in the European and North American

to enter or expand in the powder coating market.

markets? Which industrial sectors and market opportunities do you consider the most promising?

Could you tell us about the company’s history, the key milestones in

“Our objective is to become a private label supplier in the European and

its growth, and the values that have guided its development since its

the American market. With five decades of experience in manufacturing

foundation?

powders, we are confident in being able to offer products with adequate

“Rapid Coat Powder Coatings was founded by my father, Ajit Gupta, in

quality at a very competitive price.

1974. He faced enormous challenges such as shortage of funds, not

We bring real strengths to that role. We operate world-class infrastructure,

having a team or technology and only a handful of customers. Every step

with 16 production lines and a combined capacity of over 20,000 tons

forward had to be earned.

a year. We are not new to this — we already export to 40-plus countries,

In 1985, we began manufacturing thermoplastic powders — the

so international trade is something we understand deeply. In India we

foundation of what would become our powder coatings business. The

are approved suppliers to ABB, Samsung, LG, Daikin and other globally

early years were difficult but my parents never gave up on what they had

recognized companies.

set out to build.

What sets us apart as a partner:  Dependable: consistent quality and reliable delivery, every time; © Rapid Coat Powder Coatings

 Cost-effective: a low-cost, high-efficiency manufacturing model; Scalable: capacity to grow alongside our partners as their demand increases;  Certified: approved under WRAS, Qualicoat, and UL, giving our partners confidence in international markets. We are also one of the few companies in the world that manufacture both thermosetting and thermoplastic powders, which allows us to offer our customers the complete spectrum of powder coatings. The market opportunity we see most clearly is liquid coating manufacturers who want to offer powder coatings but do not want to

Anuj Gupta, Director of Rapid Coat Powder Coatings.

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invest in plant and machinery, manufacturing, product development, or

HIGHLIGHT OF THE MONTH

hiring new people. For them, partnering with us means entering the

powder coatings market immediately, without incurring any CAPEX costs or complexity.” In recent years, private label manufacturing of powder coatings has become a rapidly growing business segment. When did you decide to invest in this business model, and what market needs did you identify? “Private label manufacturing is part of a larger vision for the business. Look at how the world’s biggest brands operate: Apple depends on third party manufacturing. Similarly, Nike also follows a similar business model. Likewise, there are other global brands such as Levi’s, Dyson and IKEA who are partially or wholly dependent on third party manufacturing. In doing so, a company can focus its resources on branding and distribution while a trusted partner takes care of manufacturing. That’s how we want to support paint companies in Europe and America. We also see a real shift in our industry — segments traditionally using liquid paints are being converted to powder coatings. They are more durable, environmentally friendly, and recyclable. In addition, there is no requirement for any additional chemicals and solvents to apply the

Rapid Coat Powder Coatings headquarters in Noida (Uttar Pradesh), India.

HIGHLIGHT OF THE MONTH

Anuj with his father, Ajit Gupta, Founder, Chairman & Managing Director of the company.

Rapid Coat Powder Coatings’ team: over 500 employees serving more than 2,000 clients in over 40 countries.

Participation in international events reflects Rapid Coat’s commitment to expanding its presence in international markets.

powder. If I were an industrial liquid coatings manufacturer I would view

In an increasingly competitive market, what sets Rapid Coat Powder

this trend towards powder coatings as a threat.

Coatings apart as a private label manufacturing partner? Which

However, it’s not easy for an industrial liquid coatings manufacturer to

capabilities, certifications, and production strengths do you consider

start producing powder coatings. This is because the raw materials,

your key competitive advantages?

manufacturing process, machines, skills required are entirely different.

“The main thing that sets us apart is where we come from. We have

It will take millions of Euros of investment and years of learning for a

successfully competed for fifty years in India — which is, one of the most

company to produce powder coatings with a world class quality.

price-sensitive and quality-conscious markets in the world. A market like

A private label (third party manufacturing) business model is the fastest

that does not forgive weak quality or a high price; it demands both price

way for a liquid coatings manufacturer to offer powder coatings to their

and performance. That is the standard we were built on, and it is the

customers. And do so without investments in plant, machinery, R&D,

standard we now bring to every partner we serve internationally.

production and workforce.”

Everything else we offer builds on that foundation:  Credibility: our Qualicoat Class I and Class II, ISO 9001, UL 94 V-0, and

What advantages does Rapid Coat Powder Coatings offer customers

WRAS certifications.

who wish to develop their own powder coating brand? How do you

 Scale and precision: 16 production lines, over 20,000 tons of annual

support customers throughout the entire process, from formulation and

capacity.

manufacturing to certifications and international logistics?

 Cryogenic grinding capability: specialised applications.

“We see ourselves as a full partner, not just a supplier. We serve customers

Above all, we are a family business in its second generation, with fifty

in the automotive, home appliances, architectural, electrical, furniture,

years behind us. Private label means a partner trusts us with their brand —

fencing, and several other industries, giving us valuable insight into their

that’s why they choose to grow with us, not just order from us.”

specific requirements. This broad exposure gives us immense competitive advantage. Other key advantages we offer include:  R&D: 6 laboratory scale lines dedicated for product development 10+ Engineers. World class testing equipment such as DSC, TGA, FTIR, XRF, Spectrophotometer, Laser Particle Size Analyzer etc.  Product range covering both thermoplastic and thermosetting powder.  Dedicated team to handle customer queries quickly. Our partners don’t need to wait to enter new markets; that groundwork is already done. We have existing private label manufacturing partners in Canada, South Africa, Sri Lanka, and Ecuador so, this is not a capability we are building — it is one we are already running. In short, a customer gets a complete manufacturing partner, without having to build that capability on their own.”

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BRAND-NEW

Shedding light on 85 years of Helios Quartz history The discovery of a historic Helios Quartz ultraviolet generator offers an opportunity to retrace the origins of the company and the evolution of UV technology. Today, after more than 85 years of activity, Helios Quartz is an international reference point in the production of UV and IR lamps, quartz glass processing, and the development of solutions for industrial, scientific and medical applications, continuing to carry forward its tradition of innovation.

ometimes the past resurfaces in the most unexpected places. That is

Today, many of the principles described in those early manuals are still

exactly what happened when the grandson of one of our customers,

reflected in modern applications of phototherapy and heliotherapy. For this

while carrying out work at the company, came across an old device whose

reason, a device such as this is not only a valuable historical artefact, but

purpose was unknown to him. Intrigued by the Helios Quartz logo on the

also a symbol of a therapeutic principle that remains relevant today.

lamp, he contacted us to restore it and uncover its history.

For us, this discovery carries an even deeper meaning.

The rediscovered object is a mercury vapour quartz ultraviolet generator,

For more than 85 years, we have been manufacturing ultraviolet lamps

also equipped with an infrared radiator, allowing the ultraviolet and infrared

and developing technological solutions for a wide range of applications.

emissions to be used either separately or in combination. Powered by

Rediscovering a device bearing our name has allowed us to reconnect with

a 220-volt supply and mounted on an adjustable stand, the device is a

our origins and reflect on the journey of innovation that has brought us to

remarkable example of the electro-medical technology developed during

where we are today.

the first half of the twentieth century.

This is far more than a historical piece of equipment. It is a symbol of the

At the time, devices such as this were used for so-called actinic therapy, a

passion, research and expertise that have guided our work for generations.

treatment widely practised before the advent of modern pharmaceutical

Looking back at our past allows us to appreciate how far we have come,

medicine. Ultraviolet radiation was primarily used for the treatment and

recognise the evolution of technology, and look to the future with the same

prevention of rickets, as well as to promote general wellbeing, support

spirit of innovation that has always defined Helios Quartz.

children’s growth and aid recovery in certain forms of anaemia. For further information: www.heliosquartz.com

Helios Quartz manuals from the period provided detailed instructions for using the equipment, recommending treatment sessions lasting only a few minutes, carried out at a controlled distance and with gradually increasing exposure times. According to the scientific understanding of the time, exposure to ultraviolet radiation stimulated the production of vitamin D, promoting proper bone mineralisation and helping to reduce the risk of deficiency-related conditions, particularly during the winter months when

Scan the QR Code to learn more about the restored generator

exposure to natural sunlight was limited.

From left to right:

The restored Helios Quartz ultraviolet and infrared radiation generator. The SILVYRED model in the Helios Rays catalogue: the generator combined a mercury vapour quartz ultraviolet generator with an infrared radiator. The cover of the historic Helios Rays catalogue.

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BRAND-NEW

Interpon unveils Soulful Sage™ as its 2027 Color of the Year AkzoNobel has named Soulful Sage™ as Interpon’s 2027 Color of the Year, reflecting the growing influence of softer, nature-inspired colour palettes and natural materials in contemporary architecture.

vailable in the Interpon D2525 range of superdurable powder coatings, Soulful Sage™ is a refined soft green with subtle grey

undertones that brings warmth and understated character to facades, windows, doors, furniture and a wide range of powder-coated products. Balancing contemporary expression with enduring appeal, it offers architects, designers and specifiers a versatile colour that complements today’s architectural language while remaining relevant for years to come. More than a single colour, Soulful Sage™ is the centrepiece of a carefully curated palette of nine complementary creams, greys and blues. Together, they open up new possibilities for bringing colour, material and form together - whether creating quiet harmony or bold architectural contrast. Designed to work effortlessly across powder-coated applications, the palette enables architects and designers to create distinctive visual identities while complementing materials such as aluminium, steel, timber, stone and concrete. Developed by AkzoNobel’s Global Aesthetics Center, the 2027 Color of the Year draws on more than 30 years of colour research, global trend analysis and collaboration with colour experts, architects and designers. The result is a forward-looking colour palette that helps architects and specifiers make confident colour decisions for projects designed to endure. Jorrit van Rijn, Global Marketing Manager, AkzoNobel Powder Coatings, said: “When architects specify colour, they’re making a decision that can define the character of a building for decades. Soulful Sage™ captures a colour direction that feels contemporary today and relevant for decades to come, while the proven durability, colour retention and sustainability credentials of Interpon D2525 give specifiers confidence that their original design intent will endure.” As part of the Interpon D2525 portfolio, Soulful Sage™ combines contemporary aesthetics with outstanding weatherability, colour retention and superdurability, helping preserve the original design intent while reducing maintenance requirements throughout the life of the building or product. All colours in the 2027 palette are available with warranties of up to 25 years when applied by an Interpon D Approved Applicator. The Interpon D range is supported by an independently verified Environmental

Product Declaration (EPD) and meets Qualicoat Class 2 and GSB Master certifications, as well as the performance requirements of AAMA 2604, giving specifiers confidence in both sustainability credentials and longterm performance. For further information: www.interpon.com/insights/coty27

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ADVANCEMENTS

The Kenosistec KSA line expands: decorative PVD reaches new levels of productivity Simone Colombo Kenosistec (Casarile, Milan, Italy)

simone.colombo@kenosistec.it

Kenosistec presents the KSA 1500, its new batch PVD system for decorative applications, designed to process large components while ensuring high colour uniformity and increased productivity. Developed in response to the evolving needs of the market, the new solution combines aesthetic quality, process repeatability, and optimised production volumes.

hen people think of PVD, functional applications usually come to mind first: cutting tools, mechanical components, wear-resistant coatings. But there’s another world — just

as technically demanding, and even more exacting when it comes to aesthetics. This is where Kenosistec has built specific, recognised expertise over the years. Taps and fittings, cutlery, door and furniture hardware, decorative objects and furnishing components: sectors where the coating has to do more than protect — it has to communicate quality, value, and colour consistency across production batches that are often large and geometrically diverse.

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ADVANCEMENTS

Decorative PVD raises challenges that purely functional PVD never faces. A dense, durable film isn’t enough: what’s needed is colour uniformity across complex geometries, batch-to-batch repeatability, and the ability to work polished, satin, or brushed surfaces without compromising the finish. It’s a field where process know-how has to meet a real sensitivity to the aesthetics of the finished product. The KSA line was created to give manufacturers of taps and fittings, cutlery, and furnishing components — and the designers who work with them — a batch system built specifically for industrial-scale decorative PVD: one that combines serious production volumes with the ability to coat larger parts, suited to architectural or furnishing applications, all while holding the quality and uniformity these markets demand. Not a general-purpose system adapted for decorative work, but a platform designed around how these companies actually operate: variable geometries, frequent colour changes, high repeatability, and cycle times that fit industrial production.

The KSA line was developed to provide manufacturers of taps and fittings, cutlery, furnishing components, and designers with a batch system specifically designed for industrial-scale decorative PVD.

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ADVANCEMENTS

The KSA 1500 is the new decorative PVD batch system designed to process large components.

Introducing the KSA 1500

Strong demand for this kind of system

larger parts and even higher productivity.

reflects real demand Kenosistec has seen from players across the taps/

The KSA 1500 responds to a need that’s become increasingly common

fittings and furnishing sectors, all looking for systems that can support

across the sector — the need to process larger-format components, from

production growth without sacrificing coating quality. As part sizes trend

fittings to large-scale hardware and furnishing pieces, without losing

upward and required volumes grow alongside them, a chamber built for

the colour uniformity and quality that have always defined Kenosistec

exactly this need answers a long-standing request.

The line now welcomes a new addition: the KSA 1500, a chamber built for

systems. It was customer demand that shaped it: manufacturers asked for systems capable of handling larger loads and bigger parts, and the KSA 1500 is the

Interest in a solution like the KSA 1500 didn’t come out of nowhere — it

Looking ahead

The KSA 1500 is a natural step in the evolution of the KS line — not an

answer.

endpoint. Kenosistec continues to invest in materials research, colouring

The key advantages of the KSA 1500:

processes, and system engineering, with the goal of giving manufacturers

 Larger chamber, able to accommodate bigger parts or higher part

of taps and fittings, cutlery, and hardware systems that combine beauty,

counts in a single cycle.

durability, and industrial productivity, always balancing the finished

 Higher productivity, with a significant increase in throughput at the

product with production cost optimisation.

same cycle time.

The path of the KSA line — and the KSA 1500 in particular — confirms

 Consistent colour uniformity, maintained even on more demanding

a principle that has always guided Kenosistec’s work: decorative PVD

geometries and formats, drawing on the experience built across the KSA

shouldn’t have to choose between aesthetics and performance. It can, and

line.

should, deliver both.

 Production scalability, built for manufacturers who need to grow their volumes without compromising coating quality.

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HIGHLIGHT OF THE MONTH

From the cataphoresis membrane to zero discharge: MEGA’s technologies for the coating industry Federica Alberti SG Projects Srl – Voghera (Pavia, Italia)

federica.alberti@sgprojects.it

n paint shops, water is not an ancillary utility but a process raw material: it is needed for pre-treatment, for cataphoresis ultrafiltrates, for topping up the baths, and for washing products and equipment. At the end of

MEGA: from the membrane to the complete plant

MEGA a.s. is headquartered in Stráž pod Ralskem, in the Czech Republic, and specialises in electrodialysis ED(R), electrodeionisation (EDI) and

the cycle, it leaves the plant loaded with metals, surfactants, resins and

electrodialysis with bipolar membranes (EDBM). The company has over

dissolved salts. For years, the answer was to treat it just enough to meet

thirty years of experience, with applications ranging from water treatment

discharge limits.

to cataphoretic coating, and from the dairy to the pharmaceutical sector.

Today, the cost of industrial water and of concentrate disposal is rising,

Technologies for cataphoretic coating are handled by MEGA-TEC, a group

permits are becoming stricter, and in many areas, water availability itself

company that designs and supplies coating plants and cataphoresis cells.

has become a significant production factor.

What sets MEGA apart from most suppliers is its supply chain: the

The question coming from the market is therefore no longer simply how to

company does not buy membranes from third parties, but develops

stay within legal limits, but what environmental cost the water used in the

and manufactures RALEX® membranes in-house, uses them to build

process carries and how much wastewater can be kept out of consortium

stacks and cells, and assembles complete units from these stacks,

networks and sewers. This is the logic behind Zero Liquid Discharge (ZLD):

ranging from small pilot systems to large industrial plants. Controlling

closing the water loop until liquid discharge is eliminated — or reduced to

the entire production process allows MEGA to customise geometries

a minimum. A single treatment plant is not enough — a global assessment

and processes, ensure continuity in spare parts supply, and provide pre-

of the entire production process is required, and electrodialysis processes

and after-sales support. In Italy, SG Projects is the commercial partner

often prove to be a key part of optimising production.

providing technical assistance and managing customer relations.

Outline of a ZLD system in a paint shop: membrane technologies are used both in the cataphoresis bath and along the water recovery chain.

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Cells and membranes for cataphoresis

In the cataphoresis bath, the cell regulates the chemical composition of the coating bath and keeps it stable throughout the industrial process, ensuring the required pH and conductivity. Film quality

performance partner

and process repeatability depend on this stability. MEGA-TEC is the only manufacturer worldwide able to supply every type of EFC cell: welded tubular cells with a RALEX® AMH6E-HD membrane (Ø 81 mm), produced using in-house-designed automatic welding equipment and covered by a four-year warranty; extruded tubular cells with an AM-XT membrane (Ø 65 mm), whose seamless surface hinders paint deposition and simplifies cleaning; and flat and semicircular cells with an AMH5E-HD membrane, the typical solution for retrofits. As a manufacturer, MEGA can customise dimensions to suit any tank on the market. Then there is the anolyte: the acid stream extracted from the cells can be regarded, to all intents and purposes, as a process effluent to be sent to the wastewater treatment system. Managing it properly upstream, with efficient cells and highly permselective membranes, reduces the salt load to be concentrated downstream.

Electrodialysis and EDR: concentrating instead of evaporating

Electrodialysis separates dissolved salts by means of an electric field: ions migrate through anionic and cationic membranes alternating within the stack, producing a desalinated diluate that can be reused and a concentrate that becomes increasingly rich in salts. Electrodialysis reversal (EDR) periodically reverses the polarity and switches the channels: any deposits that start to form are detached during each cycle thanks to the polarity reversal, which extends membrane life. Compared with reverse osmosis, which stops at around 75 g/l of salinity, electrodialysis does not push water through the membrane but moves the ions. Hence its advantages in ZLD, namely higher recovery rates; brine concentrations of up to 200 g/l; higher feed limits for COD, suspended solids, and turbidity, which reduce the pre-treatment required; tolerance to free chlorine; and a recovery rate that is not penalised by silica. ED(R)-30 stacks handle up to 60 m³/h each, in modular sizes from 100 to 700 cell pairs, while the EDR-IF generation has been developed specifically as a membrane concentrator for highsalinity water in ZLD and MLD processes.

ADVANCED TINTING SYSTEMS SPECIALIZED TECHNICAL CONSULTANCY PRODUCTION FLEXIBILITY TAILOR-MADE FORMULATIONS

EDI: ultrapure water without regeneration chemicals Electrodeionisation combines ion exchange membranes and resins in

Not only performance. But a true partner by your side.

a module supplied with direct current, which continuously regenerates the resins. MPure™ modules treat between 0.83 and 15 m³/h each, can be interconnected into systems of up to 180 m³/h, and produce water with a resistivity of up to 18.2 MΩ·cm (0.055 µS/cm at 25 °C), with recovery rates of up to 97.5%, without regeneration acids or caustic soda and therefore without eluates to be neutralised. In coating plants, demineralised water is used for the final rinses of the

INDUSTRIAL COATINGS

ANTICORROSION

AUTOMOTIVE

TINTING SYSTEMS

pre-treatment, for topping up the baths, and for ultrafiltrates: replacing ISO 9001 | ISO 14001 | ISO 45001

mirodur.com

HIGHLIGHT OF THE MONTH

a mixed-bed line with an EDI module eliminates an entire chemical

consumption item and reduces the backwash flow rate.

The architecture of a zero-discharge paint shop Process water first goes through physico-chemical and biological

treatment — increasingly with MBR membranes — which removes metals, suspended solids, COD and surfactants. The clarified water then feeds a reverse osmosis unit, which returns most of it as reusable permeate. This is where the classic ZLD problem arises: the osmosis concentrate is too dilute to be evaporated economically and too saline to be discharged. EDR acts precisely on this stream, bringing the RO + ED combination to water yields of around 98% and drastically reducing the volume reaching the evaporator, together with equipment size and energy consumption. In parallel, a fraction of the permeate is polished with EDI for critical rinses. There is also a non-thermal route: with EDBM, which uses bipolar membranes capable of splitting water into H⁺ and OH⁻ ions, the salts contained in the effluent are converted into acid and caustic soda that can be reused in the plant, for example for pH adjustment in water treatment.

EFC-V1 side cells and EFC-B4 bottom cells installed in a cataphoresis tank, and the two main geometries: tubular (welded and extruded), flat and semicircular.

Instead of buying chemicals and disposing of salts, the plant regenerates part of its own reagents on site.

The benefits for a paint shop

For a paint shop, these technologies offer several benefits, including a drastic reduction in water intake, with recovery rates of up to 95% with ED alone and around 98% when RO and ED are combined. Disposal costs are also reduced, as liquid effluent is replaced by a much smaller volume of solid residue. EDR pre-concentration allows the use of smaller, less energyintensive evaporators, while EDBM can eliminate the need for an evaporator altogether. EDI also produces demineralised water without the need for regeneration chemicals, while higher feed limits for COD, suspended solids and turbidity allow for simpler pre-treatment. Finally, a single point

The ED(R)-30 stack for low-salinity water, the EDR-IF concentrator developed for ZLD processes, and an electrodialysis unit in operation.

of contact for membranes, cells, modules and complete units ensures continuity in spare parts and simplifies system management.

Conclusions

ZLD is not a technology but a goal, achieved by correctly combining several processes. In paint shops, that combination starts with an advantage: ion exchange membranes are already on site, inside the cells of the cataphoresis bath, and the same technological family can be extended to water recovery. Every plant, however, has its own effluent composition and water balance: the choice between osmosis, EDR, EDI, and EDBM, where to integrate them, and the economically sustainable recovery level must be defined case by case, ideally starting with pilot trials on the actual water. SG Projects, an authorised distributor of MEGA technologies in Italy, supports customers in analysing their streams and designing the most suitable solution.

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MPure™ modules for electrodeionisation, which can be interconnected in parallel, and a module room in an ultrapure water production plant.

The most important industry events at your fingertips myFAIR is a free web app that can be accessed from both desktop and mobile devices, which allows you to stay up-to-date with the leading an ipcm app ®

events of the surface treatment sector.

HIGHLIGHT OF THE MONTH

Ceramic membranes for more flexible water treatment From an interview with Greg Newbloom CEO of Membrion - Seattle (Washington), USA

The increasing complexity of metal finishing processes is making wastewater treatment ever more challenging. Membrion has developed ECD technology, which uses ceramic membranes and electricity to remove ions, recover water and increase plant flexibility.

derived from the various, increasingly complex chemicals used in deposition processes. At the same time, the evolution of formulations and shifting regulatory limits require treatment systems to ensure consistent performance even as operating conditions change, without becoming a constraint on production. The goal is to do more than remove harsh contaminants, but to do so with a system that can evolve alongside the production process. Based on this principle, Membrion (Seattle, WA, USA) has developed its

n the metal finishing and surface treatment sector, wastewater

Electro-Ceramic Desalination (ECD) technology, which uses ceramic

management poses an increasingly complex challenge.

membranes and electricity to separate and concentrate metal ions

Rinse water may contain metals, additives and organic compounds

from wastewater.

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Membrion (Seattle, WA, USA) has developed its Electro-Ceramic Desalination (ECD) technology, which uses ceramic membranes and electricity to separate and concentrate metal ions from wastewater.

From university research to ECD membranes

The process uses ceramic membranes for desalination through a

“Membrion began as a spin-off company from the University of

technology known as Electro-Ceramic Desalination (ECD). Electrical

Washington in Seattle,” explains CEO Greg Newbloom. “Initially, we were

energy is applied to the wastewater flow, enabling the continuous

trying to solve a problem with membranes designed to separate and

removal of metals from water: the extracted elements are then

transfer very small particles, such as ions, metals, or salts, which tend to

transferred to a very low-volume concentrated stream, which is easier

be fragile and, as a result, can suffer from durability issues; this means

to manage and to subject to further treatment. Depending on the

that, in many complex environments, membrane technology cannot

quality achieved and the plant’s requirements, the treated water can

be utilised effectively, leading to a reliance on thermal or chemical

either be reused directly in production, e.g. in the initial finishing stage,

processes. We wanted to understand how to develop a more robust and

or disposed of. “We primarily apply this technology to the treatment

durable membrane. We therefore came up with the idea of using silica

of acidic rinse water, especially that generated in metal finishing

gel materials, similar to those commonly found in the sachets placed

processes and characterised by significant concentrations of these

inside shoe boxes to keep the contents dry and free from moisture.”

elements,” adds Newbloom. “The low-volume stream containing the

Indeed, these materials have very small pores, which are particularly

extracted materials is then sent to an evaporator for further treatment.

well suited to separating water from ions.

This makes it possible to achieve a Zero Liquid Discharge (ZLD)

“Over the last ten years, we have focused primarily on developing and

system, where liquid discharge is virtually eliminated.”

scaling this technology, with the aim of bringing it to an industrial scale and successfully launching it on the market. Today, we have reached a stage where we already have several operational plants, including in

Improved control to manage regulatory changes

In the treatment of metal finishing wastewater, metals are among the

the surface treatment and metal finishing sector. In these plants, we

main substances subject to regulation and concentrations must be

use membranes to treat particularly challenging wastewater, in some

closely managed to ensure environmental safety and compliance with

cases replacing more traditional methods based on chemical or thermal

discharge requirements. However, process water may also contain

technologies.”

other substances, often added to promote proper deposition and

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HIGHLIGHT OF THE MONTH

The warehouse reorganization covers an area of approximately 2,000 m² and is also designed to prepare for the future introduction of automated storage and handling systems.

process stability: these compounds, which are frequently organic, can

manage greater volumes of wastewater without treatment becoming

make it more difficult to remove metals to the limits set by legislation.

a constraint on production. In many processes, carrying out a rinse

“We are witnessing a continuous tightening of regulatory limits in the

between stages improves treatment quality and increases product yield;

United States and beyond. As a consequence, plants that previously

however, more rinses inevitably generate larger volumes of wastewater

achieved satisfactory results with chemical precipitation systems,

that must subsequently be treated. This can pose a challenge for

which produce sludge containing metals as a by-product, may now

treatment plants not designed to handle higher flow rates. “The solution

face greater difficulties: this sludge, generally classified as hazardous

we have developed provides companies with the flexibility to carry out a

waste, must normally be disposed of in a landfill,” explains Newbloom.

greater number of rinses, as needed. For us, it is not the volume of water

“Our technology, on the other hand, enables wastewater to be treated

treated that matters, but the quantity of ionic contaminants that need to

directly using a membrane-based process, offering greater control over

be removed. Even if ten times as many rinses are carried out, the total

the effluent’s quality and helping to ensure compliance with regulatory

quantity of ions to be removed remains the same: simply, the same ions

requirements. In addition, when process conditions change or new

are distributed across a volume of water ten times greater.”

chemical formulations are introduced, plants may struggle to adapt and maintain the required parameters: our system, on the other hand, is highly automated and adaptable, enabling management of these

A partner for North American businesses

A key part of Membrion’s work is helping businesses understand how

changes without having to redesign the entire treatment plant. In some

technological advances can open new opportunities and enable them

cases, simply increasing the amount of electricity applied is sufficient to

to continue to grow without being held back by the performance of their

remove a greater quantity of ions.”

wastewater treatment systems. “We would like finishing companies to

Such flexibility enables companies, especially large-scale factories, to

continue to evolve and adapt to market changes, so that they can remain

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HIGHLIGHT OF THE MONTH

competitive and seize new opportunities as they arise without being held

possibilities offered by this new approach and to turn water recovery and

back by a treatment plant that is unable to evolve alongside the rest of

reuse into a tangible opportunity for their production processes.

the production process,” states Newbloom.

“One of the approaches we often adopt when we start working with

This approach is particularly relevant in areas characterised by water

a company is to establish a genuine partnership, seeking first and

stress, where water availability may be limited or inconsistent in both

foremost to gain a thorough understanding of its business and

quantity and quality. “Through our solutions, we support companies

needs,” says Membrion’s CEO. The development of the ideal solution

facing situations where there may not be enough water available, or

stems precisely from this collaboration, offering not an oversized or

where its availability and quality are unpredictable. In such cases, we

standardised system, but technology tailored to the plant’s actual

help them to recycle and reuse water. We can reduce the volume of

needs. The aim, in other words, is to ensure that water treatment is not

water that needs to be fed to the evaporator by a factor of 10-20, making

a constraint on production but a tool for increasing flexibility, improving

it possible to use a much smaller evaporator to achieve Zero Liquid

resource recovery, and tackling future changes with greater freedom.

Discharge.” Water recovery is a common feature across many of the industries in which Membrion operates, including semiconductors, mining, food and drink, and consumer goods. “We deal with numerous and varied wastewater streams daily, but the common thread is that they tend to be complex and often variable. It is precisely these characteristics that make it difficult to treat them using traditional systems.” For these reasons, in addition to developing the technology, it is essential to educate and support businesses, helping them to understand the

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UCIF INFORMS

From a machine to a service: when finishing takes time Manuela Casali UCIF – Italian Surface Treatment Equipment Manufacturers’ Association, Milan, Italy ucif@anima.it

or decades, in the finishing sector, as in much of the mechanical

assuming responsibilities that would otherwise fall to the customer in

engineering industry, one moment has marked the end of every

conventional sales. For a company accustomed to being judged on the

relationship: the acceptance test. The plant would be designed,

quality of its product, learning to be judged on the quality of its customer

built, installed, and commissioned. The manufacturer would then leave

service is as much a cultural shift as a business one.

the factory, and the business relationship with the customer would

There is also an element of trust that deserves attention. A service

gradually dwindle to requests for spare parts, calls when something

contract means that the manufacturer can see what is happening at the

broke down, or a quotation for another investment, perhaps years later.

customer’s site: parameters, consumption figures, and faults. This level

Now, that model is changing, not for technological reasons: the

of openness is not granted to just anyone, and it is built up over time. It

technologies enabling this shift have been around for some time. What

is no coincidence that the most successful partnerships almost always

is shifting is something more profound: the very idea of what a plant

stem from established relationships, in which the supplier has already

manufacturer sells to its customers. Today, a customer does not simply

demonstrated an understanding of the customer’s production process, not

buy a machine. They buy the confidence that a machine will deliver the

just their own machinery.

expected result every day for the entire duration of the contract. It is a

For the finishing sector, all of this takes on particular significance. Surface

subtle difference in wording, but a substantial one in practice. If what is

treatments are delicate processes sensitive to even the slightest variables,

being sold is a result rather than an object, the relationship cannot end

where the difference between an excellent result and a barely acceptable

with the acceptance test: it must continue throughout the plant’s entire

one can hinge on a temperature reading or a drying time. In other words,

life cycle.

they depend on maintenance, fine-tuning, and expertise applied on a day-

This is where this change is taking shape. Remote support shortens

to-day basis. No other industry lends itself better to a model in which value

response times and reduces downtime. Predictive maintenance, once

does not end with delivery.

a technical activity, becomes a contractual service: no longer an invoice

Perhaps that is precisely the bottom line. A plant is no longer an object

issued after a breakdown, but a subscription fee that guarantees

that changes hands but the place where two sets of expertise, that of

the system’s availability. Operator training ceases to be a one-off

the manufacturer and that of the operator, come together on an ongoing

requirement and becomes an ongoing service, all the more valuable in a

basis. The manufacturer of a finishing system no longer simply delivers a

sector where staff turnover is rapid and process expertise is built in the

machine: it delivers, every day, the machine’s ability to do its job well.

field. Planned revamping extends a line’s service life rather than waiting for it to become obsolete. The economic consequences for the manufacturer are significant. Revenue from services differs from that generated by equipment sales: it is more consistent, less exposed to investment cycles, and capable of fostering a long-term relationship that cannot be achieved through the sale of a single plant. In a sector where orders can surge or dry up rapidly, such stability is not merely an accounting detail: it is a key factor in a company’s financial health. However, this transition also carries an organisational cost, and it would be disingenuous not to acknowledge it. Selling a service means setting up an organisation that did not previously exist: dedicated staff, guaranteed response times, spare parts logistics, and the management of process data and the rules governing access to it. It means drawing up different contracts with measurable performance indicators and

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Where new formulations take shape

The essential event for professionals in the paint, coatings, adhesives and sealants industry.

www.paint-coatings.it

28-29 OCTOBER 2026 NEW VENUE: ALLIANZ MICO, MILAN With the support of:

Media Partners:

MEETING THE INDUSTRY

Paint & Coatings Italy 2026: where coatings innovation meets industry change Paint & Coatings Italy 2026 will take place on 28–29 October 2026 at Allianz MiCo in Milan.

he coatings industry is entering a period of rapid technical change.

Sustainability is also becoming increasingly data-driven. Broad

Regulatory pressure is increasing, sustainability claims are coming

environmental claims are giving way to a requirement for measurable,

under greater scrutiny and formulators are being asked to replace

verifiable evidence at product level. Topics including Life Cycle

established chemistries without compromising performance.

Assessment, Product Carbon Footprint, Environmental Product

These challenges will sit at the heart of Paint & Coatings Italy 2026, taking

Declarations, the Ecodesign for Sustainable Products Regulation and

place on 28–29 October 2026 at Allianz MiCo in Milan. Bringing together

Digital Product Passports will therefore feature prominently in discussions

industry experts from across the sector, the event combines a focused

around the future of the sector.

exhibition with a rich conference programme designed around the issues

For coatings companies, this represents a significant shift. Environmental

currently shaping coatings development.

performance is becoming closely connected with product development,

One of the strongest themes running through this year’s programme is

regulatory compliance and commercial positioning. The ability to

regulation and its growing influence on formulation strategy. Restrictions

substantiate sustainability claims is increasingly as important as the

affecting substances such as PFAS and microplastics, together with

claims themselves.

evolving requirements around biocides, VOCs and REACH, are creating

Innovation will also extend beyond conventional formulation. Research

difficult decisions for manufacturers. The challenge is no longer simply

into smart and functional coatings will highlight how surface technologies

understanding what may change, but determining how products can be

are evolving to deliver entirely new capabilities. Among the programme

reformulated while preserving the functionality, durability and application

topics are mechanoluminochromic coatings, intelligent materials capable

properties customers expect.

of changing their luminescence in response to mechanical damage,

That makes performance a critical part of the conversation. Across the

opening new possibilities for monitoring stress, impact and wear.

programme, speakers will explore new materials, additives, resins and

The breadth of the programme reflects the increasingly interconnected

formulation approaches designed to help manufacturers respond to

nature of the industry. Alongside the main Conference, Paint & Coatings

regulatory and market pressures without lowering technical standards.

Italy 2026 will feature dedicated content through TechFocus, the

Sessions will move beyond theory to examine practical developments

Adhesives Forum, the Wood Industry programme, the new Sustainability

in both waterborne and solvent borne systems, advanced coatings

Academy and the new Inks Academy, bringing together expertise

technologies and new approaches to product performance.

from across coatings, inks, adhesives, materials science and surface technology. Visitors will also be able to explore the exhibition throughout both days, meeting suppliers of raw materials, formulation technologies, laboratory equipment, production solutions and specialist services. As regulation, sustainability and performance requirements continue to reshape the sector, Paint & Coatings Italy will provide a meeting point for the companies and specialists working on the industry’s next generation of solutions. For further information: www.paint-coatings.it/en/

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MEETING THE INDUSTRY

SFCHINA2026 - A show full of opportunities SFCHINA2026 will take place from 11 to 13 November in Guangzhou, P.R. China. The industry meets in Guangzhou

Industry momentum in surface finishing

China Import and Export Fair Complex in Guangzhou, P.R. China, bringing

industry. Demand from new energy vehicles is driving lightweight,

together professionals from across the surface finishing community.

corrosionresistant finishes; the semiconductor sector is advancing

Since 1983, SFCHINA has grown into Asia’s leading industry platform,

precision plating for nextgeneration chips; aerospace and electronics are

showcasing electroplating, coating applications, anodizing and surface

seeking higherperformance coatings; and sustainable construction is

treatment technologies and solutions. This year, the exhibition spans over

accelerating adoption of ecofriendly processes. With the Greater Bay Area

14,500 square metres, with more than 250 exhibitors from 13 countries

prioritizing advanced manufacturing and green materials under the China’s

and regions (as of August 2026) presenting their latest products and

15th FiveYear Plan, the exhibition offers visitors a timely opportunity to

technologies. SFCHINA2026 is set to provide industry professionals with

engage with our platform to explore solutions, align with regulations and

opportunities to explore innovations, exchange knowledge and expand

connect with peers.

SFCHINA2026 is scheduled to take place in Halls 4.1 and 5.1, Area A of the

networks in a dynamic marketplace.

SFCHINA2026 arrives at a pivotal moment for the surface finishing

Early registration – special privileges

Ideas that spark change

Technical programmes held concurrently with the exhibition will offer

SFChina). Visitors who complete registration before September 30, 2026

industry players valuable insights and opportunities for exchange. All

can enjoy early bird discount and will be eligible to enter the Lucky Draw,

programmes are free to attend.

a special event celebrating the 30th Anniversary of the concurrently‑held

 The Future Development of AI Coatings: Taking place across the first

CHINACOAT series of exhibitions. Overseas visitors, including those from

two exhibition days, this programme will feature 16 presentations from

Hong Kong SAR, Macau SAR and Taiwan region, will additionally receive a

leading experts. Sessions will run from 10:30 – 16:30 on November 11–12

complimentary digital Exhibition Directory and Welcome Gift (while stocks

at Hall 4.1, Booth 4.1E51, covering breakthroughs in AI‑driven coating

last), along with exclusive access to the onsite VIP Lounge.

technologies and their industrial applications.

Stay updated by following SFCHINA on Facebook, X, LinkedIn and

 Smart Plating, Chip‑Powered Future – Semiconductor and Electronic

YouTube, or contact the organizer for the latest event highlights.

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ipcm® - SEPTEMBER/OCTOBER 2026 - N. 101

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