Single-layer powder coating systems on steel substrates in the context of GSB International e.V.
India
Syensqo gains certification for digital product carbon footprint tool 23 ROAD TO 2050
Teknos and UP Catalyst join forces to develop sustainable carbon materials for paints and coatings
ArtiCoating: compact, flexible and intuitive robot for industrial coating applications from ITS
Paint stripping of steel and metal substrates before recycling: process, efficiency and environmental aspects
Production
Optimised enamelling thanks to new application equipment: ELBA Italy’s breakthrough
ON
A new cataphoresis + coating plant: insourcing as a strategic lever for MMC Metalmeccanica
Wood-effect decoration on aluminium: natural aesthetics, superior performance, and technical innovation
The finish of an architectural envelope as an interface that synthesises technology, research, culture, and storytelling in a project: the experience of Focchi Spa
HIGHLIGHT OF THE MONTH
GMR: innovation and sustainability with cutting-edge polymer solutions for the coil coating sector
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ON TECHNOLOGY
Super durable sublimation films: wood-like effects and extreme performance for aluminium
Interpon D Natural Metals: the quality and style of metal, encapsulated into a powder coating
CUSTOMIZED SOLUTIONS
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ECO-FRIENDLY CHEMICALS
CHEMTEC’S technologies are designed to have a very limited environmental impact, to reduce consumption of resources and for a greater operational simplicity.
CHEMTEC develops customized solutions that aim to maximize the customer’s satisfaction.
NANOTECHNOLOGICAL CONVERSION COATING
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DISCOVER MORE ON WWW.CHEMTEC.IT
110 FOCUS ON TECHNOLOGY
NIBAV Home Lifts: elegance meets innovation in the world of vertical transport
116 RESEARCH BREAKTHROUGH
Engineers develop breakthrough method for aluminium surfaces, enabling advancements in cooling, self-cleaning and anti-icing technologies
118 ADVANCEMENTS
The most versatile paint stripper on the market: suitable for every surface, system, and coating
120 HIGHLIGHT OF THE MONTH
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122 FOCUS ON TECHNOLOGY
DEA Italian Worklab expands its coating expertise through a partnership with its pre-treatment chemical supplier
130 FOCUS ON TECHNOLOGY
Compact and smart industrial handling solutions: the case of coating contractor Air.ver.
138 ANALYSIS
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142 COLOUR STUDY
AkzoNobel unveils the 2026 Colour of the Year: Rhythm of Blues™
144 ROAD TO 2050
Siemens’ all-electric paint line sets new standard for decarbonisation in manufacturing
145 ROAD TO 2050
GARDCO announces global transition to PFAS-free products 146 SUCCESS STORIES
Dürr building a CO2-efficient paint shop as a turnkey project for Volkswagen
Improved electrophoresis performance with ultrafiltration membrane technology
UCIF INFORMS
The future of finishing among AI, new talent, and sustainability: building tomorrow’s supply chain today 157 HIGHLIGHT OF THE MONTH
3D animation: the future of industrial presentations 158 SPECIALIZED TRAINING
Tailored training: customised in-company courses from ipcm® Academy
ENVISION THE F UT URE OF POWDER COATINGS FOR
ARCHITECTURAL PROJECTS
Scan to learn more about our Architectural coatings
EDITOR’S LETTER
In recent years, companies have had to deal with a series of events that have completely (both positively and negatively) disrupted long-established industrial paradigms.
The fourth industrial revolution, characterised by the extensive use of automation, data, and artificial intelligence, is now transitioning to Industry 5.0’s new collaborative model, which integrates the human dimension and environmental and social sustainability with the most advanced technologies.
The 2021–2023 global supply chain crisis, triggered by the pandemic but rooted in the very essence of globalisation, which had been creating a very fragile system, has led to a new type of globalisation that is less integrated and more regionally-focused and in which political stability and supply security are as important as production costs. The challenge for many industries will be to adapt to a shorter, more expensive, but also potentially safer supply chain.
Alessia Venturi
The shift in trade corridors, as demonstrated by data for 2021-2023, is leading to a gradual decoupling between the West and China, with an increase in trade between the EU and North America with India and other countries in the Global South1, as well as a gradual relocation of production to closer and politically stable countries (‘reshoring’, ‘friendshoring’, ‘nearshoring’)2. To make matters worse, tariffs introduced as instruments to protect national markets are adding further pressure.
In short, globalisation is becoming more expensive: what was once a competitive advantage is now an economic risk that must be carefully managed.
At the same time, sustainability is no longer an option but an imperative, especially in traditionally energyintensive sectors or those with complex processes, such as the surface treatment industry. The question then arises: is the market ready to pay the price?
Companies worldwide need to act on multiple fronts: increasing operational efficiency and flexibility, customising products, reducing costs and environmental impact, optimising the supply chain, improving workplace safety, creating quality job opportunities in line with the demands of the younger generation, and accelerating technological innovation.
The real challenge, however, is to transform these costs into opportunities, providing the market with tangible and perceivable value by turning them into profitable investments and weathering market fluctuations. While these are all complex issues that I have only been able to touch upon briefly due to space constraints, they are clearly and articulately explored in the following pages, where you will also find a detailed analysis of the geopolitical scenario and the redefinition of trade routes and supply chains by ChemQuest, a global consulting firm specialising in the specialty chemicals and materials sector.
This issue is also particularly rich in international content thanks to ipcm®’s numerous missions abroad, the latest of which were to India and the United States, for the Surface & Coatings Expo in Chennai and Fabtech in Chicago, respectively.
In India, we encountered a dynamic market, buzzing with excitement and thirsty for technical knowledge and industrial culture; amidst the myriad contradictions of this country, we visited advanced industrial facilities with products of the highest quality. In the States, we witnessed the emergence of increasingly close commercial relationships and partnerships between US and European companies, overcoming the barrier of tariffs through expertise, technology, and value propositions. thus means gaining insight into the workings of the surface treatment industry at a global level, understanding its synergies, opportunities, threats, and critical issues. And above all, it means being present where it matters most.
Mexico, Brazil, Thailand, Vietnam, Nigeria, and Egypt.
These terms refer to the relocation of production to one’s own country or to neighbouring, allied, or friendly countries that share the same value system and geopolitical alignment.
Single-layer powder coating systems on steel substrates in the context of GSB International e.V.
Guido Rohloff
GSB International e.V. – Düsseldorf, Germany guido.rohloff@gsb-international.de
In the field of liquid paints for steel and galvanised steel components used in outdoor architecture, direct-to-metal (DTM) systems are becoming increasingly important. Powder coating manufacturers are now also offering comparable solutions that save both material and application effort. These advanced powder coating systems are not covered by technical standards but already included in the quality guidelines of GSB International e.V..
The history of GSB International e.V. began in 1977 with singlelayer coating systems for aluminium, at that time pretreated with chromium VI. Later, quality guidelines for coatings on steel and galvanised steel substrates were added. This article focuses on GSB-approvals for these steel-based systems. Traditionally, double-layer systems have been the industry standard. However, interest in single-layer alternatives is growing. The main reason is that in the liquid paint sector, DTM systems are gaining market share. This efficiency in terms of material and processing has now been adopted by powder manufacturers as well. Although single-layer powder systems are relatively new to the market, they are already covered by GSB guidelines.
Before providing an overview of single- and double-layer systems and their normative framework, it is important to clarify certain terminology. Double-layer systems refer to so-called dual systems, in which a primer and a topcoat are applied. This approach offers two key advantages. The primer smoothes the surface slightly and improves corrosion protection as well as substrate adhesion. It is very important to distinguish between double-layer systems and
duplex systems. Duplex systems combine a zinc coating with an organic layer on top. However, even in the case of galvanised steel, double-layer systems can be used (zinc layer + primer + topcoat). For this reason, a clear distinction must be made between blank steel and galvanised steel. Ultimately, the choice between a single- or double-layer system depends largely on the corrosivity category for which the coating is intended. Additionally, surface treatment and preparation play an essential role and need to be considered.
Blank steel
Steel is highly susceptible to corrosion, which makes thorough surface preparation and pretreatment essential prior to coating. According to GSB quality regulations, the following pretreatment methods are permitted: iron phosphating, zinc phosphating, and chromium- or chromium VI-free pretreatments (GSB, 2024; see GSB ST 663-6). In the latter case, the chemicals used must be GSB-approved as well.
For mechanical surface preparation, blasting is a commonly applied method. If blasting is the chosen method, the resulting surface roughness of aprox. Rz 40µm is crucial and should correspond to Sa 2½ in accordance with ISO 12944-1. However, for thin-walled components with a material thickness of 3 mm or less, as well as for certain component geometries, the high energy input from blasting can cause mechanical deformation of the workpieces. In such cases, chromium or chromium VI-free pretreatment offers a suitable alternative to blasting.
Galvanised steel
It is a different situation for galvanised steel, regardless of material thickness or component geometry. If surface preparation is required, a soft blasting process known as sweeping is applied. This ensures that the zinc layer is not damaged or removed. Prior degreasing is always recommended, since surface contaminants such as grease or oil can otherwise be pressed into the zinc surface by the blasting media, which would negatively affect paint adhesion.
For surface pretreatment of galvanised steel, the following processes are permitted under GSB quality regulations: chromating, zinc phosphating, as well as chromium- or chromium VI-free pretreatments. In this case also, the chemicals used require GSB approval (GSB, 2024; see GSB ST 663-6).
GSB International e.V. has already included single-layer powder systems with approval for aluminium for use on steel and galvanized steel substrates in it´s quality guidelines, where only double-layer systems by using a primer or steel approved systems were permitted until now.
These examples illustrate that various surface preparation and pretreatment methods are available. The selected method plays a crucial role in achieving the intended corrosivity category. The same applies to the choice of coating materials.
Corrosivity categories
The quality regulation GSB ST 663-1 defines specific requirements for coating systems in relation to corrosivity categories and protection periods (Tables 1 and 2 in the following pages). It is important to note that these classifications cannot be used to directly compare pretreatment methods with the corrosivity categories they are intended to achieve, as the type and structure of the coating contributes significantly to corrosion protection. The tables are structured in accordance with the following standards: ISO 12944-1, DIN 55633, DIN 55634.
With the publication of the revised standards DIN 55633-1 and DIN 55634-1 for the coating of thin- and thick-walled components made of steel and galvanised steel, the tables for coating systems on these substrates have been updated. Please note, the tables currently included in the GSB quality regulations, however, still reflect the state prior to the revision of DIN 55633-1 and DIN 55634-1. Thanks to significant technical advancements in coating materials, today’s individual systems are considered far more effective than in the past. As a result, single-coat systems are increasingly moving into focus. They can now achieve corrosivity categories and protection periods that were previously attainable only with double-layer structures. In addition, the sustainable, effective use of resources is becoming increasingly important. Profitability considerations are no longer limited to material costs alone, but also take into account the entire lifecycle of components or projects considering factors such as service life, personnel and energy requirements, material consumption, and machine utilization.
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Table 1: Examples of powder coating systems on galvanised steel.
S = sweep, AP =alternative pretreatment, ZP = zinc phosphate, Cr = chromating, EP = epoxy resin, SP = polyester resin, EP/SP = epoxy-polyester resin
EP and EP/SP do not meet the requirements for UV resistance of outdoor weathering
L, M, H, VH indicate the protection time to be achieved by the coating in the respective corrosivity category:
L (Low) up to 7 years,
M (medium) 7-15 years
H (High) 15-25 years
VH (very high) over 25 years
The corrosivity categories C 2 - C 5 refer to the corrosion protection effect of the coating on the zinc coating: C 2 = low, C 3 = medium, C 4 = high, C 5 = very high
Table 2: Examples of powder coating systems on steel.
SA = blasting, AP = alternative pretreatment ZP = zinc phosphate, EP = epoxy resin, SP = polyester resin, EP/SP = epoxy-polyester resin
EP and EP/SP do not meet the requirements for UV resistance of outdoor weathering
L, M, H, VH indicate the protection time to be achieved by the coating in the respective corrosivity category:
L (Low) up to 7 years,
M (medium) 7-15 years
H (High) 15-25 years
VH (very high) over 25 years
The corrosivity categories C 2 - C 5 refer to the corrosion protection effect of the coating on the zinc coating:
C 2 = low, C 3 = medium, C 4 = high, C 5 = very high
New developments in single layer systems according to GSB ST 663
According to the GSB quality regulations, powder coatings may be used as singlelayer systems on steel and galvanised steel substrates provided that the coating system has obtained GSB-approval for single-layer application on these substrates, or is applied as part of a double-layer structure with a primer (GSB, 2024; see GSB ST 663-4 and GSB ST 663-6). When a GSB-certified primer is used as an additional corrosion protection layer and adhesion promoter, topcoats that are otherwise approved only as single-layer systems for aluminium substrates may also be applied, provided that intermediate adhesion is verified by the system manufacturer or the coater. Demand for single-layer systems is steadily increasing. One of the main reasons is the previously mentioned revision of DIN 55633-1 and DIN 55634-1. Particularly for thin-walled components, as defined in DIN 55634-1, protection periods in the corrosivity categories C4H and C4VH can now be achieved using epoxy-polyester single-layer systems in combination with zinc phosphating
or chromating pretreatments—previously attainable only with double-layer systems including a primer. GSB International e.V. is responding dynamically to these advances. The revised quality regulations, which will come into force in January 2026, will place greater emphasis on single-layer systems for steel and galvanised steel. From this point on, singlelayer systems that currently hold GSB approval exclusively for aluminium substrates will also be permitted for use on steel. To ensure sufficient reliability for both coaters and end users, single-layer systems must meet one of the following scenarios:
1. The coating material is approved as single layer system for steel or galvanised steel
2. The coating material must be approved as a single-layer system for aluminium and the manufacturer must explicitly approve their use as a single-layer system on steel and/or galvanised steel, e.g. on technical or product data sheets.
Conclusion
GSB International e.V. is well-prepared to address the challenges of the future. In the field
of single-layer systems, coating companies can save significant resources. Fewer process steps are required, less coating material is consumed, meaning overall CO2 emissions are reduced and sustainability increases.
At the same time, the independent third-party certification provided by GSB ensures reliability and trust. Only material manufacturers that have successfully passed the required tests receive approval, which is a prerequisite for use by GSB-certified coating companies. This guarantees reliability for manufacturers, coaters, and end users alike.
References
GSB International e.V. (2024). International Quality Regulations for the Coating of Building Components. GSB AL 631 / GSB ST 663. Retrieved from: https:// gsb-international.de/en/quality-regulations/ - valid from January 1st, 2026.
Norms and Standards
- DIN EN ISO 12944 Paints and varnishes - Corrosion protection of steel structures by protective paint systems – Part 1 to 9 in their currently valid version
- DIN 55633-1:2021-03 Paints and varnishesCorrosion protection of steel structures by powder coating systems - Part 1: Assessment of powder coating systems and execution of coating
- DIN 55634-1:2025-08 Paints, varnishes and coatings - Corrosion protection of supporting thinwalled building components made of steel.
Tests carried out by independent accredited testing institutes and approved by GSB ensure reliability and trust for manufacturers, coaters, and end users alike, to cover the whole process chain.
KANSAI HELIOS strengthens future U.S. operations with new powder coatings plant
This investment represents the group’s boldest move yet in its long-term growth strategy and is its largest North American expansion to date, reinforcing KANSAI HELIOS’s position as a leading global coatings manufacturer and international employer in the chemical industry.
KANSAI HELIOS has acquired a state-ofthe-art manufacturing facility in Johnstown (Ohio, USA), marking a significant expansion in its North American presence.
The impressive 135,000 m2 site will serve as the central hub for the production of innovative powder coatings, supporting key markets across the automotive and general industry sectors in the United States.
Located on a 28-acre site at 231 Commerce Boulevard, the Johnstown facility features advanced infrastructure including airconditioned production areas, cleanrooms, cutting-edge security systems, and sustainable design elements. Situated in a naturally scenic part of the city, the facility offers an ideal environment for modern coatings production and a compelling workplace within the global KANSAI HELIOS group. The region’s strong infrastructure and business-friendly climate provide a solid foundation for continued success.
“By opening this new production facility, we are not simply expanding - we are taking a giant leap forward. This site will quadruple our production capacity and become the cornerstone of our future operations in North America, enabling us to better serve our customers with greater flexibility and efficiency,” has stated Bastian Krauss, President and Executive Director of KANSAI HELIOS Group. Equipped initially with state-of-the-art production machinery supplied by the group’s powder coating specialists in Germany, the site will manufacture KANSAI HELIOS powder coatings to the highest standards of durability, aesthetics, and environmental responsibility. KANSAI HELIOS plans to create approximately 50 new jobs in the Columbus region by 2030, encompassing technical, production, and administrative roles. The site will benefit from shared R&D capabilities, technical know-how, and best practices from across the group, enabling faster innovation cycles and agile
responses to shifting market demands.
“This growth not only brings high-quality jobs to our city but confirms Johnstown as an excellent location for global manufacturers seeking longterm success. We are honoured to welcome KANSAI HELIOS and look forward to the positive impact they will have on our economy,” has added Johnstown Mayor Donald Barnard. Future employees will benefit from world-class training programmes developed in partnership with KANSAI HELIOS’s European production sites in Germany and Austria, ensuring the local workforce is highly skilled and ready to thrive in a safety- and quality-focused environment. This acquisition further integrates KANSAI HELIOS with its parent company, KANSAI PAINT, strengthening a global network that spans Asia, Europe, and North America. The Johnstown facility marks a significant milestone in KANSAI HELIOS’s strategic journey to explore new markets, enhance supply chain resilience, deepen customer relationships, and deliver cutting-edge coating solutions across the continent.
“We’re launching more than just a production facility. Our goal is to build a highly skilled local workforce that reflects the values and excellence of our global organisation. We are eager to find dedicated and motivated employees in the promising Columbus region,” has concluded Bastian Krauss.
Matt finishes have been dominating the design market for some years now, at the expense of glossy finishes that are now a legacy of the past.
Europolveri, with a vision to keep offering its customers new products, has launched a new range of deep matt pastel-coloured products specifically developed for the world of design.
These colours are aligned with the latest market trends, which increasingly seeks soft shades and finishes that can warm up the design elements. The products developed are polyesterbased in an ultra matt version, available in Qualicoat class 1 and class 2, to serve not only the world of furnishing, but also the architecture sector. These products have been subjected to strict scratch resistance and durability tests to guarantee the highest possible performance.
For further information www.europolveri.it
LIGHTWEIGHT, SUSTAINABLE
Specialized in international plant engineering for sustainable paint shops, we have developed an energy-e cient gripper system for gently handling all common wheel sizes.
Thanks to its modular design, the new drive technology can be implemented using either a pneumatic or a purely electrical servo drive, o ering maximum flexibility in modern production facilities. It‘s simply smart and smooth.
Brainflash introduces Cube in Cube filter solution for dusty overspray
The Cube in Cube filter has been specially designed for overspray with high drying speeds and dust formation and can be used in the first separation stage like a Vario paint mist separator within the edrizzi® system.
Brainflash Patententwicklungs GmbH has expanded its modular paint mist filter system, edrizzi®, with a new “Cube in Cube” module designed for demanding painting conditions. The latest addition targets dry and dusty overspray, closing a gap in applications with low initial pressure differences and dry dusts.
“With the newly developed Cube in Cube module, Brainflash Patententwicklungs GmbH is expanding its modular paint mist filter system edrizzi® with another solution for demanding painting conditions. The filter has been specially designed for overspray with high drying speeds and dust formation and can be used in the first separation stage like a Vario paint mist separator within the edrizzi® system. The module can also be placed behind an edrizzi® Vario as a CUBE02 secondary filtration variant to guarantee maximum separation performance and service life,” has stated the company.
Technical features of Cube in Cube
Very low initial pressure difference of only 10 Pa, making it particularly energy-efficient.
Filter area of 0.85 m² made of bonded naffi® filter fleece, stabilised by an outer cardboard casing.
Space-saving delivery in flat condition, user-friendly handling.
Modular design: compatible with the edrizzi® modular system.
Can be used as a paint mist filter in the first filter stage or as a CUBE02 post-filter variant - modular and flexible.
The naffi® filter medium, used in the Cube in Cube, was developed exclusively for industrial painting in the edrizzi® system. It consists of 100% recycled polyester, is glass fibre-free, and can be used without personal protective equipment. The module therefore contributes to improving workplace conditions in the painting industry.
The Cube in Cube has been successfully tested in a variety of industrial applications, including plants in the furniture and automotive industries. In several cases, no additional post-filter stage was required, highlighting the module’s high efficiency and separation performance.
About the edrizzi® system
Since 2003, the edrizzi® system has been used in international paint shops. With eight different paint mist separators, multiple pre- and post-filters, and a modular sheet steel construction, it provides a flexible solution for a wide range of surface treatment requirements. Separation efficiency reaches up to 97% of overspray, offering cost-effectiveness, low maintenance, and improved occupational safety.
Thanks to its clear system architecture, the edrizzi® dry separation system can be seamlessly integrated into new or existing plants. The system can be installed horizontally, vertically, or in combination, with size and design scalable to suit individual requirements. All components are delivered flat and disassembled to simplify handling and logistics, with assembly being quick and intuitive.
For further information: www.edrizzi.com
Covestro acquired two stand-alone production sites of Vencorex
With this acquisition, Covestro strategically expands and enhances its aliphatics production portfolio in the US and Asia-Pacific, reinforcing its presence in profitable and innovative business areas such as Coatings and Adhesives.
Covestro has signed an agreement with Vencorex Holding SAS, a subsidiary of Thai chemical company PTT Global Chemical Public Company Limited, to acquire two stand-alone production sites for HDI (Hexamethylene Diisocyanate) derivatives in Freeport (USA), and Rayong (Thailand). These entities were formerly part of French aliphatics specialist Vencorex.
“The acquisition of these two former Vencorex sites fits perfectly to our portfolio and our strategic goals. While we maintain cost discipline to secure our short-term performance, we strengthen our long-term competitiveness through targeted investments like this one,” has stated Christian Baier, Chief Financial Officer of Covestro. Covestro is a supplier of HDI derivatives, a key component in polyurethane coatings, adhesives, and sealants. These products are widely used in applications ranging from automotive and bridge coatings to shipbuilding, and electronics. The new sites will complement Covestro’s existing capacities in the US, Germany, China, and India.
“These new capacities in Thailand and the US will augment our existing comprehensive production capabilities across all major regions. They will enable us to produce and deliver according to our customer’s demands even better, especially during current market challenges. After the acquisition of the Resins & Functional Materials (RFM) business from DSM and investments in organic growth this is yet another sign of confidence the company has in the coatings and adhesives business. I look forward to welcoming the new colleagues into our organisation,” has added Thomas Roemer, Head of the Business Entity Coatings and Adhesives at Covestro.
In industrial settings, the graphene-silver coating has strong potential to improve hygiene, reduce contamination, and extend the lifespan of materials and equipment.
Researchers at the National Graphene Institute (NGI) at The University of Manchester (United Kingdom) have developed a novel antimicrobial coating that could revolutionise hygiene standards across healthcare, consumer, and industrial applications.
Silver has long been valued in wound care for its potent antibacterial properties, owing to its ability to release ions that disrupt bacterial cells. However, traditional silver-based treatments often suffer from rapid or uneven ion release, which can damage surrounding healthy tissue and limit their long-term effectiveness.
To address these challenges, the Manchester team, led by Professor Rahul R. Nair, has engineered a graphene oxide-based membrane capable of releasing silver ions in a controlled and sustained manner. The membrane’s structure features nanoscale channels that act as precision filters, regulating the ion release and thereby offering more consistent and longer-lasting antibacterial protection.
“By harnessing the potential of graphene oxide membranes, we’ve unlocked a method for controlled silver ion release, paving the way for sustained antimicrobial efficacy in various applications. Our research represents a paradigm shift in antimicrobial coating technology. By harnessing the potential of graphene oxide membranes, we’ve unlocked
a method for controlled silver ion release, paving the way for sustained antimicrobial efficacy in various applications,” has stated the lead author Rahul Nair.
In a bid to better simulate real biological conditions, the researchers developed a new testing model using foetal bovine serum. This allowed them to closely replicate the physiological environment the coating would face within the human body, providing more accurate insights into its long-term performance.
Looking ahead, the team plans to explore how this innovative coating can be incorporated into a wide range of medical and everyday products— helping to make bacterial resistance a more manageable challenge rather than a persistent hidden threat.
“This approach allows us to deliver just the right amount of silver for extended protection. It has potential in many areas, including wound care dressings and antimicrobial coatings for implants, and could bring longterm benefits for both patients and healthcare providers,” has added first author Swathi Suran.
For further information: www.manchester.ac.uk
Graco to acquire Color Service
This acquisition will enable Graco to expand and reinforce its global presence in the paints and coatings market.
Graco has completed the acquisition of Color Service S.r.l., an Italian company headquartered in Dueville (Vicenza, Italy) recognised as a global leader in the production of automated dosing systems for powder and liquid applications. With a strong presence across a variety of markets - including textiles, rubber, tyres, cosmetics, plastics, and food - Color Service exports its products worldwide, serving customers who demand precision, traceability, and automation in the microdosing of materials for high-value processes.
“We have found in Graco the right partner to broaden our global presence and accelerate growth. The affinities between our two corporate cultures were clear from the very first meetings; we are confident that Color Service will integrate seamlessly into such a solid organisation, and together we will offer even greater value to our customers worldwide,” commented Stefania Toschi, President of Color Service.
“The addition of Color Service strengthens our powder handling portfolio and opens new growth opportunities with complementary technologies for new applications. This acquisition supports our global expansion strategy and aligns with Graco’s commitment to delivering innovative, high-quality solutions that solve complex customer challenges,” stated Mark Sheahan, President and CEO of Graco. The transaction was successfully completed at the end of July 2025. Color Service, which employs around 140 people globally, will continue to operate from its headquarters in Dueville, maintaining its current management team.
For further information: www.graco.com and www.colorservice.eu
For over 50 years, Galstaff Multiresine has been a trusted partner in the development of high-performance polyester resins for Coil Coating, supporting the Food Packaging, General Industry, and Building & Construction sectors.
OUR EXPERTISE IN COIL COATING RESINS FOCUSES ON :
Oil-free saturated polyesters (ITALESTER)
Designed for sustainable and food-contact compliant coatings.
Bio-circular innovations (e.g. Italester H 27-BB)
New water soluble, eco-balanced resins.
Durable coil resins
Ensuring adhesion on metals, high chemical & mechanical resistance, UV stability, and consistent finish.
Complementary systems (ITAMIN & URONAL) Hardeners and partners like Itamin (amino resins) and Uronal (isocyanates) for integrated oven-cured solutions.
BENEFITS OF COIL COATING VS OTHER TECHNOLOGIES :
High efficiency: continuous process, controlled thickness, reduced waste.
Uniform quality: repeatability on large surfaces.
Excellent durability: corrosion, UV, scratch & chemical resistance.
Sustainability: low VOC, energy savings, reduced emissions.
Versatility: wide range of colors, finishes, and formability.
Grounded in ESG values and certified by ISO 9001 and 14001, GMR invests in tailor-made, sustainable solutions for the Coil Coating industry of tomorrow!
HIGHLIGHT OF THE MONTH
India drives growth: Dürr bets on flexibility and green efficiency
With more than 70 painting lines and 500 robots installed, Dürr India has established itself as a key player in a booming automotive market, fuelled by the rise of electric vehicles and an increasing demand for sustainable solutions. In this interview, Prashanth Alevoor explains how the company is adapting its global technologies to local needs, focusing on modularity, digitalization, and emission reduction. With innovations such as EcoProBooth, EcoDry X, and EcoPaintJet Pro, Dürr India looks ahead to the future: a flexible, clean, and efficient “Paint Shop of the Future,” ready to support the country’s green and digital transformation.
Overview of the company and market insights
Can you briefly introduce Dürr India and its role within the global Dürr Group?
“Dürr has been present in India since 1997. Since then, we have consistently taken the lead in delivering paint shops with exceptional automation capabilities across painting processes, application technology, exhaust air purification, and energy efficiency. In addition, we also support OEMs with their requirements for vehicle assembly systems as well as Li-ion battery manufacturing line setups. The establishment of the Global Engineering Center in Chennai has allowed us to leverage local engineering talent alongside international expertise, catering to Dürr’s global entities. Dürr India is also recognized as the Center of Excellence for Two-Wheeler Painting Technology within the Dürr Group.”
From an interview with Prashanth Alevoor Managing Director of Dürr India Private Ltd.
EcoProBooth, the new Dürr spray booth that combines all painting tasks in an integrated plant and application technology system.
How important is the Indian automotive market for Dürr in terms of strategy and growth potential?
“The automotive industry is a key driver of the Indian economy. The market in India has been growing tremendously in the past few decades, and as of 2025, ranks as the third largest automotive market in the world by sales volume. The country produces a wide range of vehicles, including two-wheelers, three-wheelers, passenger cars, light commercial vehicles, trucks, buses, tractors, and heavy commercial vehicles. Recently, India surpassed China to become the world’s largest two-wheeler market in terms of sales, with production exceeding 21 million units in late 2024. We anticipate that India will continue to maintain its growth momentum. According to forecasts, car sales may reach around 5.5 million units and two-wheeler sales could rise to 23 million units by 2030 in India, which is a very positive sign for the industry.”
How has Dürr India evolved in the last decade in response to the growth of the domestic automotive industry?
“Dürr India started providing technologies to global OEMs who were putting up their factories
Prashanth Alevoor, Managing Director of Dürr India Private Ltd.
in India. Parallelly, we started supplying Indian OEMs. Today Dürr is the leading provider of paint shops for the automotive and twowheeler industries in India. We also specialise in offering paint shop solutions for the threewheeler sector and various other industrial sectors, such as construction equipment, agricultural machinery, wind energy, and a range of manufacturing industries. Our revenue distribution is divided into 60% automotive and 40% general industry. Our clientele includes nearly all major automotive OEMs who benefit from our paint shop solutions. Dürr India has successfully delivered over 70 painting lines and 500 painting application robots.”
Indian automotive market dynamics
What are the key characteristics and challenges of the Indian automotive sector today?
“The key characteristics of the Indian automotive market include a large and growing market size, a developing EV ecosystem, costcompetitive manufacturing, rapid technology adoption, emergence as an export hub, with active support from the government. However, the industry also faces several challenges such as fluctuating consumer sentiment, affordability concerns, and supply chain disruptions. What is unique of India is the lower automation level of the factories, since labour costs are far lower compared to the global average. This implies that the market requires hybrid solutions combining automation with manual technologies. At the same time, India is a price sensitive market: one of Dürr India’s biggest challenges is to bring global technologies to the Indian price levels.”
Are EV vehicles popular here in India?
“Electric vehicles are revolutionizing India’s automotive landscape, emerging as the most exciting and fastest-growing segment in both passenger vehicles and two-wheelers. A significant portion of the total two-wheeler market now consists of electric vehicles.”
How has the rise of electric vehicles in India influenced the demand for painting and coating solutions?
“The increasing popularity of electric vehicles (EVs) in India has brought about a changing demand for painting and coating solutions, influencing both quantity and technological needs. Although the main body painting procedures have stayed consistent, the specific needs for underbody sealing, painting, and baking with thicker materials have necessitated the use of new technologies such as EcoInCure ovens from Dürr.”
How are Indian OEMs’ needs different from those in more mature markets like Europe or North America when it comes to painting technology?
“The Indian market differs significantly from markets such as Europe or North America, primarily due to variations in market maturity, multiple model mix, cost sensitivity, climate, and regulatory environments. Despite being 1.4 million people, in India the car density is much lower compared to Europe because two-and three-wheelers are predominant on the streets. In several years the government has laid emphasis on the infrastructure so now we have better road connectivity and people are purchasing more cars. It will still take a decade to catch up with European car density.
The Indian market predominantly caters to compact and medium-sized cars as well as two-wheelers. There is a high availability of skilled and semi-skilled labour, which leads to lesser penetration of automation. Technology adoption tends to be more gradual in comparison to mature markets.
I would add that Indian OEMs look for a high flexibility of the Paintshop in order to paint multiple models of cars sold on a single line. While in mature markets you may have only a couple of models painted on a single line, in India the hatchback, the sedan and SUV or the pick-ups are painted all on a single line. Therefore, the adaptation of the technology is complex.”
Technology and Paint Shop Solutions
How does Dürr address the increasing need for flexibility in new Indian production lines?
“Dürr’s R&D is strongly focused on advancing energy-efficient and sustainable solutions. As a result, we have developed the “Paint Shop of the Future” concept, which is designed to be modular, flexible, scalable, and highly energy efficient. Through innovative solutions such as EcoProBooth, EcoInCure, EcoProWet PT, and others, we are effectively addressing the evolving needs of the market. Let us have a closer look at the EcoProBooth: the size of the booth allows all types of cars to be painted, from compact models to SUVs, but it can easily be expanded to take pickups and vans. Instead of being used in a linear layout with unchanging cycle times, the painting box can be repurposed for a parallel production layout. It’s flexibility allows the painting process to be tailored to the current vehicle models and scaled and upgraded as needed.”
What kind of painting and surface treatment technologies are most in demand among Indian car manufacturers today?
“In India, there is a high need for environmentally-friendly and energyefficient surface treatment technologies. The demand for automation is also growing rapidly, in line with advancements in Industry 4.0 and digitalisation.”
Is there a growing interest in low-bake or energy-efficient paint shop solutions in India?
“Low-bake solution is one among several. High transfer efficiency
applications and EcoDry X are also in great demand both in greenfield and brownfield projects.”
Sustainability and Efficiency
How is Dürr India helping its customers reduce CO2 emissions and energy consumption in their paint shops?
“With its “Paint Shop of the Future,” Dürr has developed a concept that leads the way in terms of sustainability and efficiency. Dürr India has already implemented a range of advanced technologies in the Indian market which play an essential role in this concept such as EcoReflect, EcoDry X, EcoInCure, and new-generation robots equipped with EcoBell4. Notably, the demand for these solutions is rising not only in automotive but across the industry segments in India.”
Are Indian OEMs actively investing in sustainable solutions like dry separation or EcoProBooth?
“We are proud to highlight that the beta site for our EcoDry X technology was established in India, in collaboration with an Indian OEM. EcoDry X is a multi-stage dry paint overspray separation system based on disposable cardboard filters. With lower CO2 emissions and minimised energy consumption, the EcoDry X perfectly represents sustainable systems. This technology serves as a clear testament to the growing demand for sustainable solutions among Indian OEMs. Their increasing focus on sustainability is evident, with many now actively seeking and implementing such technologies.”
EcoInCure, the new-generation car body curing oven, heats and cools from the inside for greater efficiency. Demand for solutions like this is growing across India’s automotive and industrial sectors.
Precious Finishes. Bright Futures
When there is no compromise to be made on a powder coating finish, architects need look no further than AkzoNobel’s Interpon D2525 Anodic powder coatings range. It delivers the stunning look of anodized aluminum and unbeatable resistance to weathering, all within a solution that reduces energy consumption, increases productivity and reduces carbon footprint.
Available in a striking selection of matt and metallic-effect finishes, from shiny golds and soft silvers to steely blues and earthy bronzes, matching every mood and style. The ideal alternative to anodized aluminum for windows and facades, the finish delivers excellent color and gloss retention. Formulated with Interpon D Low-E technology to support sustainability goals by curing at a lower temperature or faster speed, the range is pushing the boundaries of sustainable solutions in powder coatings.
Your imagination starts with our finish.
interpon.com
High-energy thinking, low-energy curing
Dream big, build sustainably. With Interpon D2525 Low-E powder coatings, you get the perfect combination of performance and sustainability-conscious design. Available in a stunning range of colors, textures, and special effects, they ensure façades, windows, and doors stand out, while superdurability protects surfaces for generations. These innovative coatings cure faster or at lower temperatures, reducing energy use and cutting carbon emissions—without compromising on style or durability. A revolutionary finish for visionary architecture.
What about the implementation of Dürr’s digital solutions?
“Digital solutions are an integral part of Dürr India’s success on the market: Indian customers are very quick in embracing digital technologies. Most of our new projects, both greenfield and brownfield, already include DXQ solutions, which is Dürr’s digital product suite.”
How does Dürr adapt its global innovations to meet local cost sensitivities and infrastructure constraints?
“Great question. Dürr India has placed a strong emphasis on localization, collaborating closely with our supply partners and qualifying many of them throughout the region to be near our customers. We have a welldeveloped supply chain in India. Nearly 75–80% of our solutions are manufactured locally.
While we obtain key technologies from our global network, we prioritise localisation whenever it is viable, ensuring that our solutions are customised to meet the unique requirements of the Indian market.
Dürr India is also very close to its customers: we have four locations across India from the north to the south, and they are all located closely to the industrial areas where our customers are located. Within an hour we can reach them and we can quickly help them with their issues.”
Outlook
How do you foresee the future of the paint shop business in India over the next 5–10 years?
“The Indian paint shop industry has evolved beyond simply painting vehicles; it is now focused on engineering smart, clean, flexible, and sustainable surface treatment solutions that support India’s digital, green, and electric future.”
What upcoming technologies or solutions is Dürr India excited to bring to the market?
“EcoProBooth, that is a spray booth that combines all painting tasks – interior painting, exterior painting, base coat or clear coat – in an integrated plant and application technology system.
EcoProWet, a flexible, sustainable, and scalable pre-treatment system in the painting process. Car bodies of all types are cleaned in modular chambers.
EcoPaintJet Pro, that is Dürr’s overspray-free paint application. These are just a few of the many technological innovations we plan to implement soon here in India.”
EcoDry X is a multi-stage dry paint overspray separation system based on disposable cardboard filters.
The pilot site for this technology was established in India in collaboration with an Indian OEM.
ROAD TO 2050
Syensqo gains certification for digital product carbon footprint tool
Syensqo has committed to reaching carbon neutrality for Scope 1 and 2 emissions by 2040. This certification marks a significant step forward in that journey.
Syensqo has secured third-party certification for the methodology behind its digital Product Carbon Footprint (PCF) tool, which is currently deployed across its Novecare business line. The certification confirms the robustness and reliability of the tool in calculating the carbon footprint of products used in Coatings and various industrial sectors.
Conducted by TÜV Rheinland, the certification process involved rigorous audits and
verification of the tool’s functionality. It ensures full compliance with internationally recognised standards, including ISO 14067 and the Together for Sustainability (TfS) guidelines tailored for the chemical industry. This milestone reinforces Syensqo’s commitment to supporting customers on their sustainability journeys. By providing credible, high-quality carbon data, the company aims to help partners reduce emissions and build more sustainable value chains.
“This certification reinforces our ability to support our customers in achieving their sustainability goals by guaranteeing the validity of our calculations. By certifying our digital PCF tool, we’re demonstrating our commitment to delivering trusted data, fostering a virtuous value chain and enabling the development of sustainable products,” said Michael Radossich, President of Syensqo’s Performance & Care Division.
PCF is emerging as a key indicator of a product’s environmental impact, and Syensqo is scaling up its efforts accordingly. In 2024, customer demand for PCF data across the Novecare portfolio increased tenfold compared to 2023, highlighting both growing market focus and the enhanced capabilities of Syensqo’s digital tool.
The tool is also central to two major supplier-focused initiatives. The first involves integrating verified PCF data from suppliers into Syensqo’s digital calculations. This enabled the company to align PCF values with its suppliers for 38% of its raw materials Scope 3 emissions in 2024. The second, launched in 2025, sees Syensqo working with its Top 70 suppliers to establish Climate Pledges— commitments to support decarbonisation efforts aimed at lowering PCF. As of April 2025, this initiative covered 35% of Scope 3 emissions from raw materials.
Teknos and UP Catalyst join forces to develop sustainable carbon materials for paints and coatings
The partnership will focus on key areas including material testing, development, production and supply, with the goal of creating alternatives to conventional fossil-based carbon black for powder coatings and wet paints.
Teknos and UP Catalyst have signed a Memorandum of Understanding (MoU) to collaborate on advancing sustainable carbon materials for use in paints and coatings.
By converting industrial CO2 emissions into high-value carbon materials, the collaboration supports a circular economy approach and helps reduce reliance on fossil resources. The initiative is expected to strengthen sustainability across the supply chain while contributing to both companies’ climate objectives.
“We are excited to join forces with Teknos to bring sustainable carbon materials into mainstream industrial use. This cooperation not only advances our shared environmental goals but also showcases the scalability and versatility of CO2-based carbon materials,” has commented Rait Maasikas, CFO of UP Catalyst.
“Our collaboration with UP Catalyst, will accelerate the development and scale-up processes to commercial volumes of sustainable raw material alternatives. We constantly search for, and test, new sustainable raw material alternatives. By using sustainable materials, we help both Teknos and our customers reduce emissions,” has added Pasi Virtanen, Head of Innovation at Teknos.
ArtiCoating: compact, flexible and intuitive robot for industrial coating applications from ITS
Rostislav Dvořák
IDEAL-Trade Service, spol. s r.o. – Brno, Czech Republic dvorak@itsbrno.cz
ITS presents ArtiCoating, a compact 7-axis robotic coating solution designed to enhance efficiency, flexibility, and adaptability in small-batch, highmix production environments, while simplifying programming and deployment.
With ArtiCoating, the Czech company ITS introduces a proprietary robotic solution developed to meet current demands in the coating industry. This compact robot application enhances both efficiency and flexibility in painting processes and is suitable for smallbatch, high-mix production environments.
System overview
ArtiCoating is a robot-controlled coating system designed for both manual and automated operations. Compatible with spray booths from all manufacturers, the system requires no modification of existing control units, ensuring full retention of warranty and minimizing implementation time. It can be installed and commissioned - including operator trainingwithin one week.
The system is ideal for operations of all sizes, from small workshops to high-volume plants, and supports a quick switch between manual and robotic spraying. This flexibility allows production lines to easily adapt to different product types, sizes, or surface geometries.
Flexibility through the seventh axis
One of the standout features of ArtiCoating is its seventh axis, which is included in the standard version. This significantly expands the robot’s range of motion and enables:
Coating of deep curves and undercuts
Reaching low positions close to the floor
Application of paint on overhead surfaces, often inaccessible to human operators.
With a movement path of 3000 mm including the spray gun, the robot can cover most passthrough profiles of standard coating booths.
Key technical advantages
7-axis kinematics for full reach and optimal spray angles
ATEX Certification (Zones 22/21 and 2/1) for use in explosive atmospheres
Compact all-metal construction, suitable for continuous industrial use
Fast applicator mounting for quick switch between modes
No need for coordinate systems – realproduct teaching simplifies learning
Intuitive interface with full-text searchable program database
Optional barcode integration for automated program selection.
Intuitive programming and user experience
The system was specifically developed for operators without previous robotics experience. Programming and path planning are highly intuitive, based on manual movement of the
spray gun over a real product. There’s no need to understand coordinate systems or robot configuration - the operator simply moves the applicator into position. Spraying sequences consist of clearly defined steps, where the operator assigns whether the motion is for painting or repositioning. These steps can be inserted, modified, or deleted. Program storage is unlimited, and full-text search enables easy access even with large numbers of jobs.
MORE THAN 30 YEARS OF EXPERIENCE IN INDUSTRIAL AND
Fast training and easy deployment
Operator training typically requires only one day, and can be conducted directly at the customer’s facility or at the ITS development centre.
For more complex coating applications, extended training programs are available. The robot’s control logic eliminates traditional programming risks - no data loss occurs even if the robot is physically damaged, as learned trajectories are stored safely and independently.
Consulting for the professional and productive world.
Germedia addresses both the professional and productive sectors. Thanks to its cross-disciplinary expertise, it collaborates not only with professionals such as architects, engineers, and law firms, but also with builders, paint manufacturers, and craftsmen.
The ArtiCoating application enhances both efficiency and flexibility in painting processes and is suitable for small-batch, high-mix production environments.
Sustainable and energy-efficient design
Environmental responsibility was a key factor in the system’s development. The robot’s lightweight motion system ensures low energy consumption, while its aluminium alloy housing is both durable and fully recyclable.
Artificial intelligence and future potential
ITS is actively developing new features for ArtiCoating, including the integration of artificial intelligence. Future enhancements will include the ability to:
Automatically learn manual motions for robotic replication
Make real-time path corrections with minimal input
Implement voice-command-based control for improved ergonomics.
Addressing labour shortages and low-volume production
ArtiCoating is designed to support a flexible and scalable production strategy, helping companies to:
Reduce repetitive and physically demanding tasks
Maintain production quality even with fewer skilled workers
Achieve economic feasibility for small batch sizes.
As labour shortages in manufacturing persist, ArtiCoating offers a reliable and autonomous solution to ensure process stability and long-term competitiveness.
Live demonstration available
The system can be seen in operation at the ITS development centre in Brno, Czech Republic. ITS also offers customers the opportunity to test ArtiCoating with their own products and coating systems, allowing them to evaluate process quality and performance firsthand.
The system was specifically developed for operators without previous robotics experience.
The flexibility of ArtiCoating allows it to easily adapt to different product types, sizes, or surface geometries.
PAINTING
Advanced Robotic Painting Technology
Engineered for maximum flexibility, our system adapts to diverse automotive and industrial needs with unparalleled efficiency
SOLUTIONS
▪ State-of-the-Art Industrial Painting Line
▪ Built in 2020 and fully operational since 2021
▪ Utilizes 4 cabins equipped with Fanuc 6+1 axis painting robots, designed for handling complex 3D geometries and 2 transfer robots, providing unmatched operational flexibility
▪ Features WAGNER paint feeding system with gear pumps, ensuring high efficiency, versatility, and rapid color changes across 3 primers, 7 basecoats, and 2 clear coat circulations
▪ Designed with a large painting window and double-sided jigs to optimize maximum production output
▪ Employs RFID tracking for complete and reliable process traceability
Our robotic painting solutions deliver unmatched precision, reduced waste, and increased throughput for automotive and industrial applications
Discover our advanced solutions at motor-classic-solutions.com or we gladly invite you to visit our plant in H-2800 Tatabánya, Vigadó u. 6, HUNGARY
Paint stripping of steel and metal substrates before recycling: process, efficiency and environmental aspects
Edited by Sinto AGTOS GmbH
Emsdetten - Germany info@agtos.de
Paint stripping is a decisive step in steel and metal recycling, with a strong impact on material quality and process efficiency. This article compares mechanical, thermal, and chemical methods, highlighting the advantages of shot-blast machines in terms of productivity, environmental performance, and cost-effectiveness.
The paint stripping of steel and other metal substrates is a critical step in the recycling process that has a decisive influence on the quality of the recycled material and the efficiency of the subsequent processing steps. Various processes are used that differ in terms of their efficiency, energy consumption, CO2 emissions and the generation of hazardous waste.
Shot-blast machines
Shot-blast machines play a central role in mechanical paint stripping. These systems use covering caps to propel abrasive particles onto the metal surface at high speed. Due to their kinetic energy and geometric shape, these particles remove paint, rust and other contaminants. Such machines are particularly widespread in the automotive and steel processing industries. In Germany, shot-blast machines are used in around 60 - 70% of large steel recycling plants. Shot-blast machines are also widely used worldwide, particularly in industrialised countries with advanced recycling infrastructures such as the USA, Japan and South Korea. They are used in around 50 to 60% of all large recycling machines worldwide.
The use of shot-blast machines offers several advantages. They can clean large areas in a short time, which makes them particularly suitable for industrial applications. In addition, shot blast machines can be easily scaled and adapted to the required surface throughput thanks to the number of turbines and their output. In contrast to manual blasting, shot blasting processes are fully automated, meaning that the need for or commitment of labour is correspondingly low.
At the same time, health risks can be minimised. Compared to chemical processes, shot-blast machines produce less hazardous waste and have a lower impact on the environment.
Recycled material in an Sinto AGTOS drum blast machine.
Sinto AGTOS GmbH
Another advantage is that shot-blast machines allow the company more flexibility. The material of the abrasive can be adapted to the material of which the parts intended for reuse are made. This means that no contamination occurs during subsequent melting if blasting abrasive is carried in. The purity and quality of the materials are therefore not affected. They can be processed directly in the subsequent process. However, the operation of these machines requires considerable amounts of energy, a fact that surprisingly even operators sometimes neglect in their rough calculations for the hourly machine rates.
Thermal paint stripping process
Thermal processes utilise high temperatures to burn off paints and coatings. This method is often used for large-area and thickly coated metals. Thermal processes are very effective and fast, but generate significant amounts of CO2 emissions and have the highest energy consumption of all paint stripping processes. This method is therefore used less frequently in Germany and other countries with strict environmental regulations.
Chemical paint stripping processes
Chemical paint stripping processes involve immersing the metal parts in
chemicals that dissolve the layers of paint. This method is particularly effective at removing stubborn coatings and is gentle on sensitive parts, as there is no mechanical stress on the material. In Germany, chemical processes are used in around 30% of recycling plants, particularly in industries with high quality requirements such as aviation and electronics. Worldwide, chemical processes are used in around 20 to 30% of recycling processes. It should be noted that chemical processes entail significant environmental and health risks, the proper control of which requires considerable effort and is the responsibility of the operators. In Central Europe, these areas are comprehensively regulated by law, but this is not the case everywhere in the world.
The responsible use of chemicals requires special disposal procedures for the resulting hazardous waste and trained personnel, which increases the personnel costs.
It should also not be forgotten that the production and disposal of chemicals must be taken into account in the carbon footprint.
Energy comparison and CO2 emissions
The energy comparison of the processes shows that thermal paint stripping processes have the highest energy consumption, followed by wheel blasting systems and finally chemical processes.
ENERGY CONSUMPTION
CO₂ EMISSIONS
PERSONNEL COSTS
HAZARDOUS WASTE
WHEEL BLAST MACHINES
High, but moderate compared to thermal processes.
Relatively low, mainly due to energy consumption.
Low, as it is automated.
Minimal, mainly abrasive material.
CHEMICAL PROCESSES
High costs, mainly for the production and disposal of chemicals.
Significant due to production and disposal of chemicals.
High, requires trained personnel.
High, requires special disposal.
THERMAL PROCESSES
Highest, as high temperatures have to be generated.
Highest through combustion and high energy consumption.
Medium, automated but control-intensive.
Low, mainly ash and burnt residues.
Thermal processes also perform worst in terms of CO2 emissions, while wheel blast cleaning systems and chemical processes perform better in relative terms, despite their specific challenges (Table 1).
Application perspectives and opportunities for improvement
The increased use of wheel blasting systems offers numerous advantages and can significantly improve the efficiency and environmental friendliness of recycling. Efficiency can be further increased by using state-of-the-art control technology and optimised covering caps. In addition, CO2 emissions can be further reduced by using green energy and more energy-efficient drives. Integrating these systems into existing automation systems helps to further reduce labour costs and increase overall production efficiency. This can help to counteract the shortage of skilled labour.
The recycling of the blasted paint material or its thermal utilisation could be interesting and promising.
Conclusion
To summarise, shot-blast machines are an efficient, environmentally friendly and costeffective solution for paint stripping steel prior to recycling. They offer numerous advantages compared to chemical and thermal processes.
The targeted use and optimisation of such systems make a significant contribution to increasing the quality of the recycled material while minimising the environmental impact of the process.
Recycled material before and after the blasting process.
Due both to the environment and to introduction from different processes, bacterial growth in EC systems is inevitable. As a result of the use of increasingly environmentally friendly systems and low-emission preservatives in particular, only partial protection of pipelines, rinsing zones and coating basins is possible. This increases the importance and significance of good, diligent hygiene throughout the entire coating process - from pretreatment to the coating process itself to waste water treatment and system maintenance.
Incrustations, adhesions and other residue on the walls of rinsing zones or in the E-Coat basin, for example, make ideal habitats for a host of microbes. The microbes multiply in these habitats and work together to form their own habitat: biofilm. Within this biofilm, microbes can grow unchecked and even protect themselves from external influences. This is one of the most common sources of infection, as biofilms which are not removed cannot be successfully combated with chemicals like biocides alone, leading to even more growth.
Basic production hygiene is necessary to ensure that all this doesn’t interrupt coating processes or even lead to production downtime. The following have been proven effective here:
Basic cleaning
Interim cleaning
Continual measures.
Basic cleaning
FreiLacke recommends cleaning systems in their entirety at least once a year. Here, the EC basin is pumped into the counter container and the basin is cleaned of sludge, residue and other soiling. The rinsing zones are also drained and intensively cleaned of any incrustations and residue using a suitable method, such as high-pressure cleaning. The collecting containers under the rinsing tunnels also need to be taken into account here, as deposits (i.e. incubators for bacteria) can form here due to fluctuating fill levels in particular. Pipelines like the cascades of the ultrafiltrate rinsing zones should also be checked and, if necessary, cleaned when a system is cleaned.
Subsequent preservation using suitable biocides is also enormously important, as this is the only way to achieve optimal effectiveness through a combination of mechanical and chemical treatment. The corresponding specifications regarding the quantities to be used and treatment time absolutely must be followed here.
Interim cleaning
Over the course of the year, and independent of basic cleaning, it is recommended to already take preventive measures for system hygiene at an early stage. That’s why FreiLacke recommends draining the ultrafiltrate rinsing zones and cleaning them at regular intervals. When doing so, intensively clean the rinsing tunnel and the collecting trays of the rinsing zones - first mechanically, then chemically. The interval is based on the level of production utilisation, the age of the system and the general level of soiling. For many customers, a one- to three-month rhythm has proven effective. Despite taking all these measures, bacterial contamination can and will occur over the course of the year. When this happens, biocide treatment must be carried out at an early stage to prevent excessive growth, the formation of biofilm and difficulties in coating.
Continual measures
Continual measures include both daily and weekly measures. The first of these measures is daily determination of the bath values. Indications of possible bacterial contamination may already be
exhibited and identifiable here. Increasing conductivity in the coating bath in particular, especially in the ultrafiltrate, is an indicator and distinguishing feature of rising microbial contamination.
The weekly routine also includes monitoring the bacterial situation using suitable immersion and dish-type nutrient media. Thanks to their ease of use and broad range of bacterial detection, dip slides have proven to be very effective and can be used by anyone after brief instruction. At a minimum, sampling should be carried out in the coating bath, the ultrafiltrate and the final rinse before the EC and can be expanded to include other areas as needed.
New modern and more environmentally friendly coating systems contain considerably less solvent, making them more susceptible to potential bacterial growth. Experience from the past few years has shown that the ultrafiltrate rinsing zones and demineralised rinsing zones upstream of the EC were frequently the origin or starting point of many cases of bacterial contamination. Weekly preservation of the ultrafiltrate rinsing zones can lead to a considerably longer EC basin service life and prevent rapid contamination here.
As mentioned above, general cleanliness and order round the system are indispensable in the battle against continual microbial contamination. This starts directly in the system with the avoidance/regular removal of residue and continues in the rinsing zones, in which stagnant water and incrustations etc. should also be avoided/removed on a regular basis.
Areas round the system such as the filters, ultrafiltrate containers and coating replenishment equipment also contribute to good overall results, however. Soiling, for example, should be removed immediately and old filters disposed of so bacteria can’t incubate there. In sum, the following continual measures contribute to the prevention/early detection of bacterial growth and make it possible to respond accordingly:
Daily determination of the bath values
Monitoring via sampling with dip slides
Regular preservation of ultrafiltrate rinsing zones
Demineralised water monitoring/preservation
Cleanliness round the systems
Final rinse pretreatment, monitoring and prevention of spreading.
Biocide kit
As mentioned above, microbial contamination can never be fully prevented, even with outstanding system hygiene. The frequency and - most importantly - consequences can be massively influenced by system hygiene and maintenance, however.
Should preservation still be necessary, we have effective and efficient remedies available to us in the form of the biocide kit. All biocides have been correspondingly tested and approved for use with EC equipment at the FreiLacke laboratory. Through a potential combination of different agents, a broad range of different bacteria, yeasts and other fungi can be combated and possible adaptation prevented.
It’s crucial to note that the treatment time (at least 48 hours) must be complied with. This applies to all biocides. During this time, production must not be carried out, as the application of voltage and the coating process will render the biocides ineffective and unusable.
Essentially, a quantity of 0.2 percent based on the basin volume has proven effective. In special cases, larger or smaller amounts may also make sense. This should always be coordinated with FreiLacke AE.
The hygiene audit: a system’s health check-up
You can’t target and solve problems unless you understand where the causes lie and are able to identify them. FreiLacke stands by its customers with comprehensive service here as well. This is why it supports them with system cleaning, concepts for preventive maintenance and cause analysis by way of a hygiene audit. This hygiene audit is like a “health check-up for your system”, where the entire process is put to the test with regard to microbiological contamination. A hygiene audit entails a systematic examination of the various zones - from pretreatment to the final rinse after EC coating. During an audit, the process liquids are sampled and swabs of walls, undercuts, cover plates and deposits are taken. All these samples are then spread onto nutrient media and examined for aerobic/anaerobic bacteria, yeasts and other fungi.
This “health check-up for your system” gives users a clear overview and deeper understanding of the potential trouble spots and starting points for recurring germ infestations. A systematically conducted hygiene audit also makes it possible to identify areas of action and take targeted measures to prevent continual germ infestation and to ensure a stable and high-quality coating process.
Insufficiently and only partially flowed-over cascade line of an ultrafiltrate rinsing zone with clearly visible biofilm.
Dip slide evaluation bacteria drawn from a contaminated demineralised water rinsing zone.
Dip slide evaluation yeast and other fungi drawn from a contaminated demineralised water rinsing zone.
TITAN-Catalytic unveils two innovations at FABTECH Chicago 2025
Visitors discovered the new technologies in the Finishing Pavilion, where TITAN-Catalytic presented live demonstrations in collaboration with NIKO Conveyors.
At this year’s FABTECH, held from 8–11 September at McCormick Place Convention Centre in Chicago, TITAN-Catalytic unveiled two major product innovations.
The first, TITAN Air, introduces catalytic hybrid oven technology designed to transform curing processes. By combining advanced infrared with hot-air recirculation, the system delivers faster, smarter, and more efficient performance. Key features include:
3× faster curing: significantly reduced cycle times without compromising quality.
Consistent, high-quality finishes: uniform heating across all surfaces.
Flexible integration: can be used as either a booster or a standalone cure/dry-off solution.
Looking ahead to 2026, TITAN XP is a catalytic heater designed for Class I, Division II areas. Built for durability in demanding environments, the heater is FM- and CSA-certified. Additional features include:
Versatile fuel options: compatible with natural gas or propane.
12VDC startup: select models available for low-voltage applications.
Robust design: stainless steel construction ensures long service life.
Safety certified: approved for use in hazardous heating zones.
For further information: titan-catalytic.com
TITAN-Catalytic
KYZEN showcases METALNOX cleaning chemistries at FABTECH 2025
The KYZEN Clean Team presented both aqueous and vacuum degreasing solutions, offering live in-booth demonstrations for visitors.
KYZEN, supplying a comprehensive range of chemistry solutions designed to tackle the cleaning challenges faced by today’s metal industry manufacturers, exhibited at FABTECH 2025 (8–11 September, McCormick Place, Chicago, USA). Key products showcased included METALNOX M6324CP and METALNOX M6386, which highlight KYZEN’s approach to both corrosion protection and process efficiency. METALNOX M6324CP is a heavy-duty, alkaline cleaner/inhibitor that incorporates effective steel corrosion inhibitors. It is suitable for removing chlorinated and paraffinic oils used in machining, stamping, and deep draw operations. The product also features oil-splitting properties and is capable of removing difficult soils such as carbon smut, all while maintaining low foam and very low VOC levels. Meanwhile, METALNOX M6386 is a modified alcohol-based solvent blend formulated for automated vacuum degreasing systems. It effectively removes both non-polar oils and water-based polar contaminants, drying without leaving residues. The solution is designed for cleaning metal hardware, fasteners, and components, and is compatible with a wide variety of seal materials.
About KYZEN
KYZEN supplies environmentally responsible, RoHS-compliant precision cleaning chemistries for industries ranging from electronics and advanced packaging to metal finishing and aerospace. Founded in 1990, the company’s cleaning technologies, scientific expertise and customer support have consistently been recognised with some of the industry’s most prestigious awards.
For further information: www.kyzen.com
www.sinto.com
A TAILOR-MADE SOLUTION FOR PERFECT SURFACES
INDIVIDUALLY TAILORED TO YOUR NEEDS
As a full-service provider, we offer customized wheel blasting solutions – from the machine concept to after-sales service. With many years of experience, we develop tailor-made wheel blasting systems to support the long-term success of your company.
www.agtos.com
Optimised enamelling thanks to new application equipment: ELBA Italy’s breakthrough
Monica Fumagalli, ipcm®
Enamelling versus powder coating: two different worlds, two approaches to metal protection and finishing. Recently, cooking appliance manufacturer ELBA Italy has optimised its electrostatic powder enamelling process thanks to new application equipment supplied by Wagner S.p.A., capable of ensuring uniformity, precision, and superior aesthetic quality. Characterised by higher baking temperatures and greater film thicknesses than traditional coating, this is more controllable and efficient, with a significant reduction in rework and defects.
Powder enamels, also known as porcelain or vitreous enamels, are a widely used solution for protecting and enhancing metal surfaces. They are obtained from inorganic materials, such as silica, metal oxides, and vitreous compounds, which are melted at temperatures between 810 and 850 °C to form a hard, glassy layer that not only acts as a surface deposit but also gives structure to the treated metal by becoming an integral part of it. Silica forms the basis of these coatings, whereas metal oxides determine their colour, mechanical strength, and chemical resistance properties. Their formulation can be enriched with pigments, matting agents, and surfactants, mixed and ground with precision to obtain specific finishes, from matte to glossy or semi-glossy and from durable to waterproof.
The process results in an aesthetically pleasing coating that is resistant to corrosion and high temperatures, but it presents some critical issues:
the need for high temperatures for melting, the necessity to handle fragile materials, and the challenge of controlling the layer’s thickness and uniformity. Precisely these characteristics distinguish enamelling from traditional powder coating, which is based on organic polymers and requires lower curing temperatures. Although the physics of electrostatic deposition are similar, powder enamel behaves very differently: transfer efficiency is lower (around 40%), resulting in increased overspray and the need for specific filtration systems; the application thickness is greater,
between 150 and 200 microns; and the process is much more sensitive to environmental conditions.
At the same time, the advantages of electrostatic powder enamelling remain in line with those of powder coating and primarily derive from the benefits guaranteed by the automation of modern application systems: recovery of excess powder, precise control of film thicknesses, coating uniformity, better edge coverage, and smooth and shiny finishes after baking.
Top left: oven cavities entering the pre-treatment tunnel.
Top right: oven cavities waiting to be enamelled.
Opening photo: in the ovens and cookers manufactured by ELBA Italy, refined design and high performance are enhanced by high-quality finishes obtained through enamelling (mainly in black) and powder coating.
Left: an overview of the powder coating plant.
For the most part, electrostatic dry powder enamelling is employed in the large domestic appliance sector. In recent years, the increasing automation of processes has improved result repeatability and production efficiency, also contributing to cost containment, and R&D on chemical formulations and powder grinding technologies is continuing to optimise application parameters and reduce defects. To better understand the characteristics of this technology applied to the field of household appliances and see how the use of advanced application equipment, such as that of Wagner S.p.A., can streamline operations, we visited the premises of ELBA Italy in Borso del Grappa (Treviso). This long-established company, now a part of the Haier Group and employing over 400 people, is celebrating seventy-five years in business this year: starting out in 1950 by offering enamelling services, it is now one of the most recognised brands in the smart cooking sector, thanks to its attention to detail and a fully integrated production cycle.
ELBA: when “Made in Italy” refers to more than just good food
“ELBA originated from one man’s initiative, the founder Elio Baggio, who year upon year interpreted the demands and tastes of family life, surrounding himself with partners who shared his values and were able to bring projects to fruition,” the corporate profile reads. “Attention to detail, passion for technology and talent led the company to become an integral part of the ‘Italian economic miracle’ of the post-war period, now called Italian Style.” The ability to translate customer desires into attractive, functional, and easy-to-use appliances soon took the fame of the ELBA brand beyond Italian borders, from the Middle East to Africa and into the Far East. Its products can now be found in the homes of millions of consumers worldwide.
If ‘Made in Italy’ has become a truly global label, it is thanks to two key factors: superior quality and distinctive design. To meet both these requirements, ELBA has chosen to keep its entire production of built-in
The inside of the Wagner enamelling booth for cavities. In the foreground, the 6-axis robot coating the ‘ceiling’ of an oven cavity.
The evolution of ELBA: Italian excellence since 1950
The history of ELBA began in 1950, when Elio Baggio founded a small factory in Marostica, in the province of Vicenza (Italy), focusing on enamelling and the production of wood and coal stoves. Over time, the company specialised in the enamelling of components for stoves and cookers, as well as bathtubs, sinks, and other bathroom furnishings at the request of leading manufacturers in Northern Italy, such as Zanussi, Zoppas, and Fargas. By the end of the 1950s, the post-World War II reconstruction had been completed, and the following years were characterised by enormous demand for basic household appliances such as cookers and refrigerators.
Ten years later, the company moved to Bassano del Grappa and officially launched the ELBA brand (an acronym of the founder’s name), which quickly established itself on the national market for its freestanding kitchens. By the mid-1960s, ELBA’s products had already crossed Italian borders. In the following years, production grew rapidly, with exports accounting for the majority of sales. The end of the 1970s marked a further step forward with the introduction of built-in appliances, which opened the doors to major European markets such as France, the United Kingdom, and Germany.
In 1987, ELBA joined the De’Longhi Group, strengthening its industrial capabilities. A few years later, it moved to its current site in Borso del Grappa, where it was able to expand its production area (50,000 m²), install an additional enamelling plant and two coating lines, and redesign its factory layout, thus significantly increasing its production capacity.
Another milestone was the acquisition by Fisher & Paykel in 2006, which boosted its technological development and international expansion through innovative synergies in research and design. In 2010, as the company’s presence expanded further into the Middle East, its position was consolidated with the introduction of new built-in products with gas technology. In the same year, the tagline ‘Talent for cooking’ was launched, which has been a part of ELBA’s identity ever since.
Finally, in 2021, the company became part of the Haier Europe Group, expanding its range of household appliances to include refrigerators, dishwashers, coffee machines, and microwave ovens. Today, with a presence in over seventy countries, ELBA continues to be a symbol of Italian creativity, quality, and innovation, a brand that has transformed tradition into global recognition.
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ovens and freestanding domestic cookers in its own factory, managing all stages from the receipt of sheet metal coils to the assembly of finished products in-house. Thousands of parts leave this plant every day, thanks to nine lines dedicated to ovens and freestanding cookers, and five to classic and induction cookers. The enamelling department alone coats an average of 700 oven cavities per day in a single shift – a figure that immediately gives an idea of the strategic role of this process within the production chain.
At the heart of production: ELBA’s enamelling department
The factory’s area devoted to surface treatments houses two different application technologies: a traditional line supplied by Euroimpianti (Valeggio sul Mincio, Verona, Italy) with a Wagner powder application booth, which is used for oven casings, front panels, and rear components, and an enamelling system for treating cavities, sheet metal parts, drip pans, and side panels.
“Cavities are undoubtedly the components that are the most difficult to enamel,” explains Luca Ferello, the Enamelling Process Manager. “We use DC04 steel or titanium sheets that we form, bend, and assemble by spot welding; assembly with the other oven components only takes place after enamelling. Sheet metal parts, on the other hand, require a single riveting operation.”
Before enamelling, all workpieces undergo a surface preparation
cycle in three stages: cleaning with cold mains water, degreasing with demineralised water at 60 °C, and drying.
Enamel application takes place in two dedicated Wagner booths, designed respectively for oven cavities and sheet metal parts. Installed in 2023 to replace the previous powder coating system, these have made the process faster, more efficient, and more economical, also thanks to the simultaneous upgrading of the conveyor, cleaning tunnel, and baking oven. Once enamelled, the workpieces are manually transferred to the conveyor that takes them to the oven, where they are baked at approximately 850 °C. At this temperature, the vitreous enamel chemically bonds with the metal, forming a hard and resistant coating that is ready for the following production stages.
The challenge of electrostatic enamelling: Wagner’s solution
“During enamelling, the main critical issue with the electrostatic application process stems from its chemical nature, because the electrostatic charge is difficult to apply with an inorganic element, and from the product’s weight, which is greater than that of traditional powder,” explains Marco Ghirimoldi, Business Development Domestic Appliances at Wagner. “The specific weight of enamel is almost double that of regular powder paint. This results in lower transfer efficiency, the need to use more guns to ensure coverage of complex-shaped parts with recessed and hollow areas, and a greater amount of overspray.”
From top left, clockwise:
The loading area for sheet metal parts.
The enamelling booth for sheet metal parts.
The guns installed in the booth devoted to sheet metal parts are equipped with a double head and a dedicated electrode, as well as blowers above the nozzles to prevent powder accumulation.
The baking oven.
From top left, clockwise:
Reworking a cavity.
Enamel applied on metal is not just a layer covering its surfaces but actually integrates into it, giving it structure and robustness.
ELBA Italy is now one of the most recognised brands in the smart cooking sector, thanks to its attention to detail and fully integrated production cycle.
The enamelling booths installed at ELBA are equipped with PEA C4 series guns, featuring a charging voltage of up to 100 kV and automatic pressure control (AFC) to optimise powder adhesion. To limit the build-up of vitreous enamel on the nozzles’ edges, these guns are designed with simplified circuits and ceramic nozzles that are highly resistant to wear. They are also combined Venturi pumps in hardened steel and ceramic inserts (as in the case of ELBA), chosen specifically to withstand the high abrasiveness of the enamelling products, which is why the filtration system also includes special filters.
Configurations vary depending on the type of treated workpieces. “For sheet metal parts, we use double-head guns to split the enamel flow. Each of them has a dedicated electrode and a blower above the nozzle to prevent powder accumulation. In the booth devoted to cavities, on the other hand, a 6-axis Kuka robot applies the enamel on the upper interior, the most critical area, and 3-axis robots complete the coating of the side surfaces. Overall, the booth for enamelling sheet metal parts has 30 guns, 8 of which are fixed, whereas the one devoted to cavities is equipped with 22 guns,” continues Ghirimoldi. Finally, the system allows for total recovery of the powder, which is mixed with fresh product and reintroduced into the application cycle. The installation of the two booths, which took just ten days thanks to the work of two teams, was preceded by tests at the Wagner centre in Valmadrera (Lecco, Italy), which specialises precisely in developing enamelling technologies. “These tests also led us to implement a compressed air treatment system, which regulates temperature and humidity according to atmospheric conditions, one of the variables that most influence the enamel application process. This stabilises the fluid beds, keeping the properties of the air in contact with the enamel constant throughout the process,” Ghirimoldi emphasises. The booths have been customised according to ELBA’s productivity, space, and operational requirements. Their reciprocators can be activated or deactivated depending on the shape of the workpiece or the type of operation (first application or reworking), and the spraying distance can be adjusted to avoid the Faraday cage effect. Thanks to this technological upgrade, ELBA has improved its workflow, application process, and coating quality while reducing the critical issues typical of electrostatic enamelling, which is inherently more challenging than traditional powder coating.
Defects in enamelling
Unlike in traditional powder coating, every defect in enamelling is unique, which means that every day presents a new challenge. “We chose Wagner equipment both for its superior technical performance and because our coating department was already familiar with it. Indeed, it has enabled us to increase production efficiency and manage rework more effectively.”
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On sheet metal parts, defects can be removed with a grinding wheel. Then, the workpiece is reloaded onto the conveyor for a new cycle, and the operator selects the most suitable configuration so that the Wagner spray guns apply the enamel exclusively on the affected area, thus preserving the surfaces that are already compliant.
For oven cavities, however, the procedure is more complex. After removing the non-compliant coating, the entire surface is wet-coated by spraying a powder enamel specially formulated for reworking and mixed with water. In this case, it is not possible to limit the application to the defective area alone, as the subsequent baking stage at high temperatures would risk compromising the coating’s uniformity.
Another challenge for the enamelling department’s operators is posed by the innovative solutions in terms of aesthetics and design brought by ELBA’s R&D team. One example is an oven without a front panel and with an extremely thin rim.
“This configuration poses some difficulties in the application phase, especially with a complex and invasive process like enamelling, but we have overcome them thanks to the contribution of Wagner’s technology,” the company points out.
Quality in kitchens around the world
Today, two years after the launch of the new enamelling plant, ELBA has achieved excellent results in terms of coating quality, also thanks to its greater attention to raw materials, whose samples are tested through enamelling trials before processing. This is a complex, difficult-to-manage process. In addition, ELBA’s production is very diverse: in a single day, the enamelling department handles up to five batches of completely different components, making it impossible to set stable application parameters for long processing cycles (except for daily adjustments based on weather conditions).
Before starting an application cycle, a trial is always carried out on samples already subjected to adhesion tests to check their conformity. Then, before entering the oven, a preliminary visual inspection is also carried out, which precedes the actual quality control phase. “Reworking is one of the main bottlenecks in our factory,” the company concludes. “However, thanks to our partnership with Wagner, we have significantly reduced its frequency and made the process following defect elimination more effective. It is precisely such a high degree of attention to detail that has made our products famous in kitchens worldwide.”
From left to right: Kevin Busatta, Domenico Cimino, and Luca Ferello from ELBA Italy.
Geopolitics and the Global Supply Chain: what’s next?
George R. Pilcher, Vice President, The ChemQuest Group, Inc. The ChemQuest Group, Inc. – Cincinnati (OH), United States
The coatings industry has experienced a variety of supply chain issues over the past 50+ years, but none as severe and broadbased as what is now being referred to as “The Great Supply Chain Crisis” of 2021-2023. While it was catalysed by an event—the onset of the global pandemic in 2020—the seeds of such a crisis were borne in the global supply chain for many years prior to COVID-19. All that the pandemic did was to knock down the first domino in a complex configuration of dominoes that had been lining up for years prior—the rest of them fell as a result of the way in which they had been positioned for at least a decade or more prior to the crisis. Bottom Line: The Great Supply Chain Crisis may appear to have been triggered by the global pandemic, but if the pandemic had not occurred, something else would have eventually caused it to happen. A house of cards is always destined to collapse—the only unknowns are “how long before it falls” and “who or
what will cause it to fall.” Fall it will, however… this is not speculation, but rather a fact of nature, physics, and common sense.
As we sit here three years later, the real questions should not be “Will such a supply chain disaster ever occur again in the future,” but rather, “When will the next supply chain crisis hit the global manufacturing network?”
Following The Great Supply Chain Crisis, a lot of action was taken to prevent such an event in the future—action by businesses, both small and large; local and state governments; governments of countries around the globe; cooperative organizations, such as the World Bank; and global non-profit organizations, such as the Red Cross. A lot was learned, and a lot of the learning that was applied to the various areas of business, government, and global cooperative organizations was of a very positive and proactive nature and would certainly help to stabilize the global supply chain in the event of another unexpected event, such as COVID or
similar event destined to affect the entire global community and wreak havoc with the complicated arteries of commerce that carry the lifeblood of the global economy in them. What if, however, the next situation that negatively affects the global supply chain is neither sudden nor expected? What if, instead, it is a predictable set of circumstances that we know will cause such a problem, but which we cannot predict with regard to when it will have an impact?
To address that potential scenario, let’s take a look at some of the effects on the global trade corridors that took place during the years 2021-2023 (Table 1 and Fig. 1).
There is no doubt that trade among the U.S., Canada, and Mexico increased, although exports from China to the U.S. declined, as did exports from China to Hong Kong. Exports from the U.S. to China remained approximately the same, however—with only a 1% drop over the threeyear period.
The forces that will shape the future flow of trade are already in play. The real question is not “Will future global trade look different from today,” but rather, “How will future global trade look different from today?”
Geopolitics and economic outcomes: yesterday, today, and tomorrow
Whether ongoing tariff issues, the War in Ukraine, or cybersecurity controls, all companies are affected in some way, and to some degree, by those issues that affect global trade and which have already created a
variety of negative situations for global industry participants. This is news everywhere. What is not typically discussed in the news, however, is that negative situations very often lead to opportunities for positive change, as long as one is open to change. McKinsey, for example, has identified 10 “key value drivers” that should be evaluated by business leaders for potential opportunities arising from geopolitical issues of one sort or another [3]:
Trade agreements
Import and export controls
Domestic environmental, labour, and immigration policies
Tariffs and other trade barriers (e.g., steel, aluminium)
Conflict (e.g., Ukraine, Red Sea, Taiwan, Ecuador, Gaza, et al.)
Technology, intellectual property, and cybersecurity controls.
On the largest scale possible—global trade—we are seeing the early stages of what are likely to become major shifts in the years ahead, with regard to “who trades with whom” and how this will affect global regional trading patterns. For example, it is highly likely that there will be decreased trade between both North America and EU with China, but increasing trade between North America and the Association of Southeast Asian Nations
Table 1: Shifts in Global Trade Corridors, 2021-2023 [1].
Fig. 1 - International trade to grow 30% by 2033 (2.9% CAGR [2]).
1 South = 133 nations of the UN G77, excluding China
2 West=U.S., EU27, UK, Canada, South Korea, Japan, Australia, and New Zealand
Table 2 - Estimated change in trade, 2023-2033.
ChemQuest
(ASEAN)—and both the EU and North America will be increasing trade with India and selected other countries in the “Global South,” such as Mexico, Brazil, Thailand, Vietnam, Nigeria, and Egypt (Table 2 and Figure 2, [4]).
Looming challenges for traditional approaches to stable supply chains
What became clear following The Great Supply Chain Crisis remains true today: just-in-time (JIT) inventory is dying. It works well for a single, powerful producer at the end of the value chain, but it comes to grief when more than one link in the production chain also demands JIT. Similarly, reshoring (or nearshoring, friendshoring, ally-shoring) for critical products and the reduction of shipping costs is being embraced by many companies worldwide. We are already seeing various steps being taken to reduce dependence on Chinese specialty chemicals.
Geopolitical considerations are increasingly becoming a part of the thought process in industry participants’ plans for the future, whether tactical plans for the near future or strategic plans for the longer-term. It is imperative that we be taking into consideration “what if” scenarios involving, but certainly not limited to:
Resolution—or indefinite continuance — of the Russo-Ukrainian War
Suez Canal disruptions
Potential conflict between the U.S. and Panama over ownership of the Panama Canal
Tariffs/potential tariffs/threat of tariffs
Potential invasion of Taiwan by China
The “Greenland Question”—the U.S. is not alone in coveting its potential military importance and strategic mineral supply
Changes in the balance of power in the Middle East—fallout from the Israeli/U.S. bombing in Iran
Syria breaking away from Iran and seeking backing by Saudia Arabia
Gaza Strip—major differences in viewpoint among Arab nations and U.S.; possible U.S. designs on Gaza Strip.
Additional challenges include:
Materials substitution
- Replacement of materials requiring paints and coatings by non-paint-reliant materials
- Industrial and specialty: Clear and colour wrap films, larger windows in vehicles
Market consolidation
- Consolidation of paint and coatings formulators and raw material providers
Figure 2 - Anticipated world trade trends.
- Paints and coatings formulators continuing to consolidate globally, with major players such as Sherwin-Williams, PPG, AkzoNobel, and Nippon driving M&A activity
Labour shortages
- Labour shortage leading to higher automation and increased use of robotics and…
- Fewer immigrants to take jobs that workers already in the country do not wish to perform, leading to lower productivity and forcing the use of greater automation—with consequent discontent among unions.
Trade outlook
China is the 800-pound gorilla in the Global South, but its total trade growth will be limited to an estimated 2.7% annually over the next decade, well below the current average real annual GDP growth estimate of 3.8%.
There are a number of reasons for this, both economic and geopolitical (Figure 3). China’s trade within BRICS+ (Brazil, Russia, India, China, South Africa, Egypt, Ethiopia, Indonesia, Iran, and the United Arab Emirates) is projected to account for 44% of China’s total forecast trade growth over
the next decades, and its trade relationship with Russia is projected to increase significantly. Bilateral trade will grow by $269 billion by 2033 (6.3% CAGR).
As China’s trade with the U.S. and EU slows, it is growing strongly with much of the rest of the world. We project that annual two-way trade with the West will contract by $221 billion by 2033—representing an average annual decline of 1.2%. (NB: The cost of imported Chinese goods would increase, however, by more than $200 billion if no alternative sources were available and if import volumes were to remain constant).
We project that China’s trade with the Global South, by contrast, will surge by $1.25 trillion by 2033, representing a CAGR of 5.9%. This shift will support China’s geopolitical agenda of reducing its economic reliance on the West while deepening ties with major emerging markets.
India is emerging as the other big Global South trade story, as it pursues favourable relations with most of the world’s major economies. Boston Consulting Group predicts growth of 6.4% CAGR in India’s total trade through 2033, to $1.8 trillion; its trade with the U.S. is expected to more than double over the next decade, to $116 billion in 2033 [5].
The effects of geopolitics are escalating—we are even now witnessing seismic shifts in global trade. The U.S. has already violated the United
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States-Mexico-Canada Agreement (USMCA; former NAFTA) by imposing new tariffs. Depending upon the results of the renegotiation of the trade agreement between the U.S., Mexico, and Canada in 2026, it is likely that annual trade between the U.S. and Mexico will increase by $315 billion by 2033, representing a CAGR of 4%, and U.S.-Canada trade will grow by $147 billion as companies serving North American markets shift more of their supply chains.
Washington is concerned that Chinese firms’ intent to circumvent high U.S. protectionist barriers against low-cost Chinese electric vehicles (EVs) and other goods by assembling them in, and exporting them from, Mexico, thereby taking advantage of its “duty-free” access under the current USMCA. One issue to watch is whether the U.S. will leverage the USMCA renegotiation to seek to have Mexico screen Chinese foreign direct investment in its North American manufacturing value chain. At the moment, this would be anyone’s guess… Currently, this is essentially how China is slipping things into the U.S. via Vietnam. And so it goes… “Friendshoring” is a new term (along with “ally-shoring” and “nearshoring” and a few other similar terms) redefining North American trade relationships, where trade relations are bolstered with U.S. allies. U.S. trade with the EU, for instance, is projected to grow by $303 billion, a CAGR of 3.1%, by 2033.
Companies must consider the risks and opportunities created by geopolitical shifts that will alter their supply chains and business strategies and develop game plans for adapting to disruption. As trade
lanes evolve, consider shifting your supply chains to make them more robust, cost effective, and resilient.
Tariffs: a genuinely complex issue
Multiple studies of the long-term effects of tariffs in the 20th and into the 21st centuries indicate that, with only a few exceptions, tariffs do more harm than good. Though they may provide short-term relief and often give the public a psychological “high,” tariffs typically act as painkillers—and like painkillers, they just give temporary relief.
The Great Depression was fuelled, in the view of Franklin Delano Roosevelt and many others, by sky-high tariffs that had placed the U.S. on “the road to ruin” by inviting retaliation and discouraging investment. While there are many differing opinions on the value of tariffs, history clearly shows that, while short-term tariffs may be used to bring about strategic changes in relationships among nations, long-term tariffs are always damaging to the nation that imposes them. In the U.S., for example:
Tariffs reduce the demand for foreign goods, which has historically led to the strengthening of the dollar, resulting in less global demand for American goods.
The 2002 tariff increases on selected steel products backfired—U.S. Senator Lamar Alexander (R-Tennessee) observed that since “there were 10 times as many people in steel-using industries as there were in steelproducing industries… [steel using industries] lost more jobs than exist in the steel industry.”
Figure 3 - Geopolitical events catalyse shifts in global trading patterns.
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A group of supply chain and operations management experts from Georgia State University, Colorado State University, Arizona State University, and Kuwait University found that the U.S. tariffs enacted in 2018 had a ripple effect of unintended consequences that negatively affected global supply chains. The group concluded that these tariffs had “an overall negative impact” on firm value that led to a decrease in the value of domestic producers within the protected industries.
The 2018 U.S. tariffs increased costs by $51 billion/year—a burden shouldered principally by U.S. companies and consumers. (NB: Per the Federal Reserve, while 1,000 jobs were added to the steel industry, 75,000 jobs were lost among industries using steel.)
Tariffs of the permanent (rather than tactical/semi-strategic) type tend to run afoul of the “Law of Unintended Consequences.”
Trade wars and tariffs
Supply managers have been warned for years that it is difficult to manage supply chain risk when buying products from (1) manufacturers a long distance away and (2) potential adversaries, says Timothy R. Fiore, CPSM, C.P.M., chair of the Institute for Supply Management® (ISM®) Manufacturing Business Survey Committee. “Supply managers should be prepared for this,” he says. “In actuality, we likely are not.”
According to The Economist, China claims its exports to America rose by $30 billion between 2020 and 2023, whereas the U.S. claims Chinese imports fell by $100 billion [6]. Sometimes, words simply fail…
According to the non-partisan Congressional Budget Office, President Trump’s campaign pledges1 would add an estimated $7.75 trillion to the projected debt through FY 2035, part of which is expected to be offset by revenue estimated at $2.7 trillion to $4.5 trillion generated by increased custom duties2. Per the National Retail Federation, currently proposed tariffs could cost U.S. consumers as much as $78 billion a year in annual spending power.
No matter which side of the political aisle one feels most comfortable occupying, tariffs always hurt the country imposing them (Table 3, [7]).
The role of politics, both domestic and global, on global trade and supply chains
Politics—domestic
To take only a single aspect of the current “deportation of illegal aliens” dialogue as an example, deporting children of illegal immigrants born on U.S. soil (“Dreamers”) would deplete the U.S. workforce of ~300,000 future U.S. workers at a time when the U.S. is at full employment (i.e., at 4.2% as of the end of May). Losing this many workers would create a future disaster.
Table 3 - Economic impact of two potential tariff levels 60% tariffs on China and 10% tariffs on all other nations*.
1 The Fiscal Impact of the Harris and Trump Campaign Plans-Mon, 10/28/2024 - 12:00
* These figures quantify the impact of tariffs on various prices and sectors. They isolate the impact of tariffs from other macroeconomic and industry trends. The figures are based on econometric modelling by the Hartford’s Global Insight Center and findings from other researchers.
Where, exactly, will the workers come from to fill the void? The U.S. birth rate is below replacement rate, so future workers essential to maintain GDP will not come from within the borders of the United States. Period. Deporting 7MM? 9MM? 11MM? (pick a number) of illegal immigrants will affect the following areas in what ways and to what degree?
Seasonal harvesting—the U.S. is currently experiencing a significant shortage of career and seasonal farm workers
Seasonal farmworkers aging out—resulting in higher prices to consumers and putting some farms out of business
Migrant workers are not illegal immigrants and nor are they deadbeats—they are mandatory for maintaining a healthy economy, both now and into the future.
Illegal immigrants are not automatically criminals, other than for committing the crime of crossing the border without permission—the clear majority of “illegal immigrants” have no criminal records.
In fact, according to U.S. Customs and Border Security, of the 11 million undocumented immigrants in the U.S., only 3% are convicted felons, and an additional 4% have non-felony convictions [8].
Per the University of Georgia, however, of the 341 million U.S. citizens, 8% are convicted felons and 20% have non-felony convictions [9].
We are coming precipitously close to doing what the Germans call “Das Kind mit dem Bade ausschütten”—“throwing the baby out with the bathwater”.
Tariffs only enrich the U.S. Federal Government’s General Fund—U.S. consumers are not given a portion of the tariff to help offset higher prices… And prices will be higher. If the U.S. hits China with a 10% tariff on Tupperware®, the U.S. Government will collect 10% on all Chinese
Tupperware® sold to U.S. consumers. But, before you can say “consumer savings,” the retailers will raise the price of Tupperware® by 10%, so it is the consumer who actually pays the cost of the tariff, not the Chinese manufacturers, AND increasing consumer prices automatically causes inflation that cannot easily be checked by FED fund controls.
Politics—selected geopolitical concerns
Changes in supply
- China used to produce copper phthalocyanine pigments for finishing in India
- China is now able to manage the entire Cu/phthalo supply chain internally, from basic reactions, to drying and finishing
- This is affecting one chemical after another
Concerns about trade route security/stability
- Houthis in the Red Sea
- Potential blockading of the Strait of Hormuz by Iran
- Possible American interference in Panama
- Importance of GIUK (Greenland, Iceland, United Kingdom) Gap? Real?
Perceived? Military only? Maritime only? Both military and maritime?
Implications of Russia/Ukraine War
- Negotiated settlement
- Enforced settlement
- Continued warfare—including the role of North Korean miliary personnel and Chinese munitions?
Increasing dissatisfaction with China by both the U.S. and EU
- Tariff issues
- Concerns over Taiwan
- Support, albeit minimal, for the Russians in the War Against Ukraine
- Belt and Road Initiative (BRI): Silk Road Economic Belt; 21st Century Maritime Silk Road; Polar Silk Road; Other components of BRI; Degenerating diplomatic relationships—we are in a “Geopolitical Recession,” which is characterized by Borge Brende, president of The World Economic Forum, by global fragmentation and polarization, leading to less cooperation and more competition than in the past; Supply concerns (China produces: 42% of all epoxy resin, 44% of all chemicals, 50% of the world’s steel, 70% of all rare earth ore, 90% of all refined rare earth metals).
The Great Supply Chain Crisis of 2021-2023
The major disruption in global supply chains initiated by the COVID-19 pandemic, and intensified by the “Big Freeze” in the Permian Basin (principally Texas) in February 2021, was characterized by:
Major bottlenecks at ports
Labour shortages
Increased demand for certain goods, leading to:
- Delays in deliveries
- Product shortages
- Price increases for consumers across various industries
- Panic ordering by both desperate producers and customers
The pandemic triggered lockdowns, which caused sudden changes in consumer demand, factory closures, labour shortages at ports and production facilities, and major disruptions in the flow of goods. As a result, consumers experienced longer delivery times, empty shelves, and higher prices. In addition, the availability of common household necessities (e.g., paper goods, disinfectants, and many food items) was critically curtailed, and there was significant R/M reduction/destocking following the end of the crisis. A basket of coatings R/Ms, indexed to 2019 vs. selected coatings R/M component prices, increased 40-50% from the first quarter of 2020 to the fourth quarter of 2022. Industries such as electronics, automotive, and consumer goods were particularly impacted, and recent events like the Russia-Ukraine conflict further exacerbated supply chain issues, particularly in energy and commodity markets.
Timeless lessons learned from The Great Supply Chain Crisis
The lessons the world learned following The Great Supply Chain Crisis will continue to be of use as geopolitical, economic, and other challenges impact the supply chain. Specialty chemicals companies should particularly remain cognizant of issues related to raw material supply, logistics, customers, and research and development.
Raw Material Supply
Every raw material used to make paint and coatings in the U.S. should have at least one reliable vendor in the U.S. that either makes the material in the U.S. or has significant stocking capability in the U.S. to keep the regional supply chain filled with material the next time the global supply chain is thrown off kilter.
From top to bottom:
Figure 4 - Cost history to ship by truck.
Figure 5 - Cost history to ship by rail.
Having a single source of any raw material is a bad idea. Instead, whenever possible, have alternate raw materials (and alternate suppliers) approved for every raw material that is used in routine production. Every producer should have multiple suppliers whenever possible (at least 2-3), so that it has a purchasing record with companies other than its primary supplier. Violation of this rule should be tolerated only due to the absence of a second source. In addition, certain high-profile manufacturing operations should be repatriated to the U.S., as should the ancillary suppliers to those industries.
Logistics
One of the most devastating aspects of The Great Supply Crisis was the inability to ship and receive goods, even when there was supply and orders could be filled. Containers were often in ports where they could not be easily retrieved, and panic orders were so high that there would have been insufficient containers to carry the goods, even if they had been in more convenient locations. Ships were stacked up at ports where there was insufficient manpower to unload them and too few trucks to provide intermodal transportation from the docks to the final destination. Cost-to-ship rose dramatically, and the entire global trading community had to sit helplessly by because so little could be done to rectify the situation in anything approaching real time (Figs. 4, 5 and 6). The message here is both easy to visualize and difficult to achieve: availability of raw materials is of little value if they cannot be transported to the facility that will turn them into saleable products. Manufacturers absolutely must be building reliable logistics capability now, and pressure testing their processes and procedures in real time to make sure that when the next supply chain crisis hits, they will have the maximum ability to transport materials from the source to their production facilities.
Customers
Both raw material suppliers and their customers, whether they are producing paints and coatings, adhesives, lubricants, household cleaners, or anything else in the specialty chemicals value chain, rate their customers and suppliers (officially or unofficially) on an “A,” “B,” “C” scale:
“A” suppliers/customers—Partnerships; purchases
made on overall value, not lowest price; loyalty; fair payment terms; on-time delivery; overall quality; quality of technical service; quality of sales service—are they merging these days?; significant history of working together, and clear establishment of trust; etc.
“B” suppliers/customers—Mixtures of “A” and “C” characteristics. . . What does it take to turn a B customer into an A customer? How about turning a B customer into a C customer? When are these changes most likely to happen?
“C” suppliers/customers—Chase every penny down the rabbit hole; consolidate purchases with minimum number of products to obtain pricing; indulge in hoarding behaviour; treat R/M suppliers as if they were bankers; are guilty of poor forecasting; have excessive “RUSH” orders; refuse to pay small-batch upcharges; etc.
During good times, it is possible to have an “A-B-C” classification without the need to take specific action on it. Business is good, orders are heavy, time is limited—so little thought is given to the overall effect that different raw material suppliers and customers are having on your bottom line, much less on your supply chain. During hard times, however, it is important to make sure that those suppliers and customers that enable you to realize the highest value for your business absolutely must be the focus of your attention. If you are a resin producer with only a single tank wagon of a resin that six of your customers are begging for, and one of them is a small but growing “A” customer and another is a very large but excessively demanding “C” customer, give some serious thought to rewarding the small “A” customer. You are likely to find that your action is rewarded many times over.
Research & Development
The development of new and significantly improved products is the lifeblood of any producer’s efforts to enhance its market share in the specialty chemical industries, such as paints and coatings; sealants and adhesives; HI&I; lubricants; personal care; and many others. Absolutely nothing should prevent at least a minimum amount of true R&D from taking place, even during the darkest hours when all hands are on deck trying to put out fires. Coatings is a technology-based, global industry—those with a strategy focused on the continual development of new and improved products will be the winners.
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Closing thoughts
More than anything else, we need to learn from the past, including from the recent, post-COVID past. Developing resilient and transparent supply chains is at the top of the list, when it comes to being prepared for geopolitical shifts that might affect global supply chains. This is closely followed by building a geopolitical view from the perspective of your own company. It doesn’t require additional computation power or fancy systems, but it does require that everyone within the specialty chemical value chain, whether producers of raw materials or final products, such as coatings and adhesives, become more familiar with what’s going on in the world and how it might affect them. This is the only way to be prepared for eventualities that may or may not occur, but being prepared is the only way in which anyone can be protected from those that DO occur. Become informed about your supply chain—those who purchase a mixed metal oxide pigment containing cobalt should at the very least know what is happening in the cobalt mines in The Democratic Republic of Congo. This is not an unreasonable step to take—if you need a cobalt-based colored inorganic calcined pigment (CICP) in your paint products, you will need this knowledge to protect your supply. Enhance your organization’s ability to sense and respond to changing geopolitical landscapes—encourage the appropriate parties in your organizations to read The Economist; Financial Times; and The Wall Street Journal. Never view the time spent studying these publications as “wasted” or “down” time—we live in a new age, and it requires that we be knowledgeable about different issues that may have been of significantly less importance in the past.
Along with these actions, provide whatever in-house or outside training is necessary to strengthen decision-making processes to remain agile and
to enable your company to embed geopolitical scenarios and analysis into capital allocation and strategic planning. Make a concerted effort to expand your presence in growth markets—what was once a “hope for the future” should now be considered to be “what is need right now.” Above all, embrace smart nearshoring, friendshoring, and reshoring. These are not merely slogans designed to get industry participants excited about changing the future—they are the means by which industry participants will be able to change the future. Finally, it is understandable that not every company can invest in regional differentiation, but there are many raw material and finished product producers who could, if they tried. In our current geopolitical climate, it is better to try and fail, than not to try at all. Most companies are capable of doing far more than they give themselves credit for, so challenge those items that the organization is sure that it cannot do—and, when in doubt, give the author a call at The ChemQuest Group. We’ve spent the past 49 years helping members in the specialty chemical chain do things that they never dreamed were possible.
Bottom line
As global trade fragments and regionalization accelerates, organizations will need to adopt differentiated structures and technology stacks—a onesize-fits-all approach will no longer suffice. Neither does it make sense to do everything on your own, when help is available. Try not to think in terms of “inside help” and “outside help.” This is a misleading differentiation that has prevented many, many organizations within the specialty chemicals value chain from realizing their full potential. Now is not the time to “do it all on your own.”
References
1. “Smarter growth, lower risk: Rethinking how new factories are built,” McKinsey & Co., February 24, 2025, https://www.mckinsey.com/capabilities/operations/ourinsights/smarter-growth-lower-risk-rethinking-how-new-factories-are-built.
2. “Great Powers, Geopolitics, and the Future of Trade,” BCG, January 13, 2025, https://www.bcg.com/publications/2025/great-powers-geopolitics-global-trade.
3. “How business leaders can proactively navigate geopolitics,” McKinsey & Co., https://www.mckinsey.com/featured-insights/mckinsey-live/webinars/how-businessleaders-can-proactively-navigate-geopolitics
4. Ibid.
5. “Great Powers, Geopolitics, and the Future of Trade,” BCG, January 13, 2025, https://www.bcg.com/publications/2025/great-powers-geopolitics-global-trade.
6. “Trump and Biden have Failed to Cut Ties with China,” The Economist, February 27, 2024, https://www.economist.com/finance-and-economics/2024/02/27/howtrump-and-biden-have-failed-to-cut-ties-with-china.
7. “Tariffs: The Crossroads of Geopolitics and Economics,” The Hartford, May 19, 2025, https://www.thehartford.com/insights/economic-trends/tariffs-geopoliticaleconomic-consequences
8. Criminal Alien Statistics, U.S. Customs and Border Protection, https://www.cbp.gov/newsroom/stats/cbp-enforcement-statistics/criminal-noncitizen-statistics
9. “Criminal Repercussions,” University of Georgia, https://research.uga.edu/news/study-estimates-total-u-s-population-with-felony-convictions/#:~:text=People%20 with%20felony%20convictions%E2%80%94including,the%20African%2DAmerican%20male%20population.
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A new cataphoresis + coating plant: insourcing as a strategic lever for MMC Metalmeccanica
Ilaria Paolomelo, ipcm®
MMC Metalmeccanica has turned coating from a critical process to a strategic asset. By insourcing this phase and installing a new cataphoresis and powder coating plant designed by Finmat in collaboration with Futura, Infragas, and Nordson, it has achieved superior quality finishes, faster production times, and optimised logistics management.
Every company, regardless of the sector in which it operates, faces a complex challenge while growing: the need to meet high-quality standards while maintaining cost control and optimal use of resources. This is not an easy balance to strike, as excessive focus on cost containment risks compromising product quality, whereas focusing exclusively on excellence without careful process management can negatively affect competitiveness. That is why more and more companies are taking a serious look at how they organise their supply chain, with a focus on outsourcing or insourcing certain process phases to turn them into strategic assets. This decision goes far beyond simple operational management, as it affects the very structure of a business, the strength of its customer relationships, and its ability to adapt to market changes.
In the industrial world, one of the areas where this choice is most crucial is coating. Often perceived as a “final” or ancillary process, it is in fact a decisive step. It not only defines the aesthetics of products but also affects their durability, quality, and functionality, as well as their resistance to corrosion, atmospheric agents, and external stresses and even brand perception.
Choosing to insource this phase means making a significant but strategic investment that guarantees several advantages, including as follows:
having direct control over finishing quality;
reducing logistics times and costs by eliminating intermediate steps and transport;
ensuring greater flexibility in production management for a faster response to market demands;
building internal know-how that becomes a company asset and a further competitive advantage.
Of course, insourcing a new process also requires courage and long-term vision, as it involves significant investments in technology, training, and resources.
However, for many companies, this approach proves to be a genuine lever for success in terms of increasing finishing quality, strengthening market positioning, and building customer loyalty. This is precisely the direction taken by MMC Metalmeccanica (Melpignano, Lecce, Italy), which has turned coating from a weakness to a source of pride by investing in
innovative solutions capable of meeting the most complex needs of its customers. Indeed, it has established a new in-house coating department by installing a cataphoresis and powder coating system designed by Finmat (Pagani, Salerno, Italy). The new line integrates a variety of technologies, including a power&free conveyor supplied by Futura Srl (Robecco Pavese, Pavia, Italy), a Nordson coating application system, and RHT (Radiant High Temperature) infrared panels manufactured by Infragas (Mappano, Turin, Italy).
The history of MMC Metalmeccanica
Founded in 1976 by Luigi Mancarella, MMC Metalmeccanica began as a small family-run workshop specialising in ironwork, from railings and gates to small components. “Over time, we began to invest in innovative machinery, such as a sheet metal cutting system and a bending one. Back then, that was a real technological revolution for a workshop of our size,” says Consiglio Mancarella, who now runs the company together with his brother Marco.
The first significant step forward came with the acquisition of land adjacent to the original headquarters in Martano, in the province of Lecce. “Here, the first factories were being built in the 1980s, and we seized that opportunity to invest in a new building, thus expanding from a few hundred to around 4,000 square metres. In 1986, we began working with Fiat-Allis, producing small casings and plates. This experience marked our entry into the industrial vehicle sector. In the years that followed, we continued to invest in new technologies, including high-definition plasma cutting systems, which enabled us to produce increasingly complex components.”
With the new millennium, MMC Metalmeccanica took another step forward: in 2001, under the leadership of the founder’s sons, Marco and Consiglio, it became a limited liability company (Srl), consolidating its entrepreneurial identity and strengthening its innovation-oriented vision.
In 2008, as it had been steadily growing, it moved to its current 11,000 m²wide headquarters in the industrial area of Melpignano (Lecce). Finally, in 2016, MMC Metalmeccanica inaugurated its first coating department with the installation of a powder application line. In 2023, the previous plant was upgraded with a new automatic cataphoresis and powder coating line, a demonstration of the company’s ongoing commitment to innovation and growth. Today, MMC Metalmeccanica is a solid and dynamic business, a benchmark supplier in the ACE and earth-moving machinery sectors.
From a bottleneck to a breakthrough: in-house coating
Since its early days, coating management has been one of the main challenges for MMC Metalmeccanica. For years, it relied on external suppliers, which entailed numerous challenges in terms of time, costs, and logistics.
The loading area is equipped with control panels that allow operators to monitor all process parameters and select the most suitable recipe at the start of each cycle, based on the type of component to be handled, its intended use, and its required treatment.
The 13 tanks that make up the dip pre-treatment line.
“Coating has always been a critical phase. For a while, we tried to manage it in-house with a small liquid application booth, but we discontinued that after a few years. We sent our produced components to external coaters located dozens of kilometres from our headquarters, which then returned them to us for QC, packaging, and shipping. It was a long, complex, and above all, costly process.”
The need to find a solution to all these issues became even more pressing in 2008 when, following internal audits, some strategic customers pointed out the need to optimise logistics in order to continue their collaboration. That was the real turning point: MMC
Metalmeccanica decided to move to its current facility and, in 2016, to equip itself with its first powder coating plant. “With that first system, we solved most of our problems. By managing everything internally, we reduced lead times, streamlined production flows, and significantly improved product quality, since we could monitor every stage of the process.”
In the following years, the company continued to grow and expand its equipment fleet. In 2023, a new strategic investment further strengthened its production capacity: the installation of an advanced cataphoresis and powder coating plant designed and built by Finmat. “Cataphoresis was one of the treatments most requested by our customers from both the automotive and the earth-moving machinery industries,” explains Mancarella, “as it guarantees certified salt spray resistance of hundreds of hours, higher than that offered by a powder base coat. Thanks to this new line, we met not only our internal needs but also
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Components immersed in the cataphoresis tank.
those of many companies in our area, which until then had been forced to send their parts to northern and central Italy because there was no cataphoresis plant in the Salento region.”
An integrated production chain
“Today, we can define MMC Metalmeccanica as an all-round company with a large and technologically advanced equipment fleet. We have the expertise and specialised resources to manage and develop all processes related to a product’s lifecycle: from feasibility analysis and documentation, to design and production, including the necessary tooling, prototyping, industrialization, and the launch of mass production,” explains Luigi Mancarella, from the third generation at the helm of the company. The real productive strength of MMC Metalmeccanica lies precisely in its ability to manage every stage of its supply chain, from design to final
testing. “Our technical department produces the 3D drawings, prepares the prototypes and templates needed for assembly, and develops the tools required to manufacture each component.”
After the design phase, the raw material undergoes cutting on lastgeneration 4.0 machinery, including 3 laser cutting systems, 3 plasma machines, and 2 semi-automated cut-off machines, followed by bending on 3 CNC machining centres. The heart of the production department is the welding area, where innovation meets tradition: over 40 qualified welders, some of whom have been trained directly in-house, work side by side with 6 last-generation robotic systems. The production process continues on 2 machining centres and an automated lathe. Afterwards, the shot blasting phase prepares the parts for the finishing treatments: cataphoresis or cataphoresis + powder coating.
“Before packaging, each workpiece then undergoes thorough control:
An optical detection system detects the presence of the load bars and allows the overhead crane to unhook them and transfer them to the conveyor itself.
Components entering the bell oven.
the operators may perform simple checks (e.g. paint thickness and uniformity) or more complex tests (including salt spray testing and sampling) in our in-house laboratory,” notes Mancarella. The production cycle ends with dimensional tests carried out using 3D measuring arms, aimed at ensuring compliance with all the required tolerances, thus confirming MMC Metalmeccanica’s constant focus on quality.
The pre-treatment and cataphoresis cycle
The components can undergo either the complete cataphoresis + powder coating cycle or just the cataphoresis phase. In both cases, the process begins in the loading area, where the operators manually place the parts on load bars attached to an overhead crane, each with a maximum load of up to 2,000 kilograms. “The loading area is equipped with control panels that allow the operators to monitor all process parameters and select the most suitable recipe at the start of each cycle, based on the type of component to be handled, its intended use, and its required treatment,” explains Alfonso Sensale, technical sales manager at Finmat.
The pre-treatment process, whose chemistry was developed by Chemetall, takes place in 13 consecutive tanks and includes degreasing,
a series of cleaning stages, passivation, phosphating, and surface activation. “This line also performs a pickling phase, which is particularly useful for parts with delicate welds or finishes that require uniform coating even along the weld joints,” indicates Sensale.
After pre-treatment, the parts enter the cataphoresis tank, a fibreglass structure approximately 4 metres long, 1.6 metres wide, and 2.7 metres deep. The solution it contains is constantly agitated to keep it ready for use, while the current generator connected to the anodic cells enables the electrodeposition process. “The solutions in the other tanks of the pretreatment line are also constantly agitated and heated to ensure optimal operating conditions,” Sensale adds. At the end of the cataphoresis process, the components undergo two final cleaning stages with ultrafiltrated (UF) permeate, which removes any paint residues and allows the material to be recovered for efficient reuse.
“At that point, Futura’s power & free conveyor comes into play. Through an optical detection system, it detects the presence of the load bars and allows the overhead crane to unhook them and transfer them to the conveyor itself, which takes them into the curing oven. The components dwell at 180 °C for about 45-50 minutes inside the oven, designed with a
Automation and auxiliary systems of cataphoresis plant.
Detail of the power & free conveyor designed by Futura.
bell shape to ensure uniform baking even for thick parts,” says Sensale. It also has temperature probes and two gas-fired combustion chambers, which maintain a constant temperature. Finally, the load bars are conveyed by Futura's system to a storage buffer where they undergo a forced cooling step.
The paint application phase
At this stage of the process, the components follow different paths depending on customer requirements: if they only require cataphoresis, they are sent directly to the unloading area; otherwise, the conveyor designed by Futura takes them to the automatic coating Siver fast colour change booth with Nordson Encore HD spray systems. This scans the shape of each part before it enters and is also equipped with a manual pre-finishing and post-finishing area, intended respectively
for any initial touch-ups or to complete the finishing treatment in the most difficult-to-reach areas. Between these two steps, automatic application is performed using Nordson HDLV® high-density spray guns. In addition, this booth allows for quick colour changes in just 5-7 minutes.
After application, the parts enter the curing oven. 9 Infragas RHT panels have been installed at its entrance to accelerate the gelling of the paint applied to the metal parts, making them dust-dry quickly.
The infrared panels immediately raise their surface temperature to approximately 100-110 °C, instantly transforming the powder into a glassy layer. This not only accelerates subsequent curing but also reduces the risk of powder particle displacement due to the oven’s air curtains, designed by the manufacturer to maintain a stable temperature by preventing cold air from entering and hot air from escaping.
Manual pre-finishing.
Automatic paint application with Nordson HDLV® pumps.
Meeting production and sustainability requirements
“One of MMC Metalmeccanica’s main requirements was for a system capable of coating an extensive range of components – iron, galvanised steel, cast iron – because, as a contractor, it needs to treat hundreds of different products, each with its own specifications,” explains Alfonso Sensale. “We therefore designed a highly versatile plant that can handle up to twenty different coating recipes simultaneously and thus respond quickly to any customer requests.” The fully automatic system also has green certification. “Sustainability was another essential requirement,” states Consiglio Mancarella. “Infragas’ infrared panels were chosen precisely for this reason: they allow the components’ surfaces to be heated immediately and the paint to be cured in a few seconds, reducing the oven inlet temperature and ensuring significant energy savings.”
The coating booth’s cyclone.
“Finmat also installed a purification and demineralised water production unit,” adds Sensale, “as well as an ultrafiltration and recirculation system for the cataphoresis paint, which is a highly delicate product and must be kept in continuous circulation. For this reason, we have supplied membrane modules that separate pigments and solvents, ensuring that the solution is always ready for use and, therefore, reducing waste and costs.”
“The product used for the electrodeposition phase is water-based, unlike in the past,” Sensale also points out. “Previously, we almost exclusively employed solvent-based products for cataphoresis; today, the percentage of solvent is minimal. This reduces air emissions and protects the health of operators.”
Finally, safety was a top priority. “All pretreatment tanks and the cataphoresis one are enclosed to prevent operators from accessing them during operation. The cataphoresis tank, in particular, is equipped with traffic lights that visually indicate when access is permitted. The overhead crane is controlled remotely via Wi-Fi and has a manual control panel, side safety cushions, and buffers that regulate the movement of parts along the tunnel. Dedicated lasers constantly monitor the position of the load bars, ensuring precision and safety at every process stage,” illustrates Finmat’s technical sales manager.
Thanks to this system, MMC Metalmeccanica has not only raised its quality and production standards but also transformed coating into a real strategic asset by integrating innovation, sustainability, and safety.
9 Infragas RHT panels have been installed at the entrance to the curing oven to accelerate the gelling of the paint applied to the metal parts, making them dust-dry quickly.
The clean room and the laboratory.
The MMC Metalmeccanica team together with Alfonso Sensale, technical sales manager at Finmat, and Giuseppe di Bartolomeo, administrative manager at Finmat.
CURE
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A new palette for architectural innovation: AkzoNobel unveils the Interpon D Middle East Trends Collection for designers and architects
AkzoNobel, a global leader in high-performance powder coatings, has launched the Interpon D2525 Trends Collection, designed to offer designers and architects a striking selection of colours and finishes that complement the unique architectural style and natural beauty of the Middle East.
Building on the success of the Interpon D Futura powder coatings collection, a favourite of the architectural industry for more than 20 years, the Trends Collection includes three curated colour palettes: Desert Sands; Shimmering Mirage; and Arabian Nights. Inspired by the rich tones of the desert and the avant-garde architectural styles of the Middle East, the Trends collection blends effortlessly with both modern and traditional regional designs to bring fresh, lasting appeal to a building’s facade, windows and doors.
Desert Sands features a warm blend of reds, soft greys, earthy tones, and natural stone capturing the essence of the desert while honouring traditional craftsmanship. Shimmering Mirage is a serene mix of gentle greys and whites with a metallic sheen, adding a touch of magic and sophistication to any design. Arabian Nights evokes the rich colours of the desert at dusk, with earthy browns, deep coffee shades, and dusky blues that connect buildings to their natural surroundings.
AkzoNobel’s Trends Collection is backed by an Environmental Product Declaration (EPD), meaning the collection’s raw materials, manufacturing processes, and transportation have been thoroughly assessed for their sustainability. This provides important assurances to architects and designers that their choice of powder coating is environmentally
responsible and contributes to a building’s environmental rating. The Superdurable Interpon D2525 collection also boasts exceptional durability, as well as offering superior gloss retention, colour stability, and UV resistance. With a 25-year warranty and certifications such as Qualicoat Class 2 and GSB Master, the Trends Collection is built to withstand the test of time, making it ideal for demanding climates.
Sanal Limoncuoğlu, Commercial Director Powder Coatings South & East Europe, Middle East and Africa at AkzoNobel Powder Coatings, says the collection is more than just a colour palette - it’s an invitation to create: “At AkzoNobel, we believe that great design starts with the right finish. With the Trends Collection, we’ve created a range of colours and finishes that not only reflect the splendour of the Middle East but also offer architects and designers the freedom to bring their most innovative ideas to life. We are excited to continue supporting the architectural community with products that combine beauty, durability, and sustainability.”
The Trends Collection is available on stock (Ready-to-Ship) to ensure that even the most time-sensitive projects stay on schedule.
For further information: www.interpon.com/insights/new-middle-east-trends-collection
Henkel unveils Bonderite M-AD 2000A additive for aluminium anodising
Henkel’s Bonderite M-AD 2000A is a sustainable additive that allows anodising baths to operate at temperatures of up to 24 °C, compared with the conventional 18–20 °C. The higher operating range reduces the energy required for cooling and extends bath life, without compromising the performance or durability of the anodised layer.
Henkel has recently launched Bonderite M-AD 2000A, a new additive designed to make the anodising of aluminium both more efficient and more sustainable.
Developed specifically for companies engaged in aluminium anodising, whether as a direct surface treatment or as part of a pre-anodising process, the additive promises notable gains in process and energy efficiency. By operating at higher temperatures, cooling demand is reduced, while the formulation lowers sulphuric acid consumption by around 25 %. It also cuts aluminium loss by a quarter and shortens process times by an average of 15 %. With a more stable bath chemistry, service life is extended by up to 25 %, reducing the need for disposal and replenishment.
“Our customers are looking for ways to make their production processes more sustainable and cost-effective without compromising on quality. Bonderite M-AD 2000A delivers exactly that: an additive that demonstrably saves costs, energy, and materials while ensuring consistent results,” has stated Darshan Mehta, Business Development Manager, Light Metal Treatment, at Henkel.
The additive has been awarded Qualanod certification, underscoring its durability and quality. Tests in coastal regions such as Hook of Holland and Genoa confirmed its resilience under long-term outdoor weathering conditions. The product has now been approved for use by all member companies of the international Qualanod network.
Initial industrial trials carried out under real production conditions further demonstrated the benefits, including significant energy savings, reduced chemical use, and consistent coating results. With testing successfully completed and international approval secured, Bonderite M-AD 2000A is now available across Europe and will be gradually introduced to global markets where aluminium anodising is a key production process.
For further information: www.henkel.com
Henkel research in action: the development of Bonderite M-AD 2000A demonstrates how additives can make anodizing processes more energy-efficient, sustainable and cost-effective.
Anodized aluminium profiles in various colours: the new Bonderite M-AD 2000A additive ensures a consistently high quality of the anodized layer while reducing energy and material consumption.
Wood-effect decoration on aluminium: natural aesthetics, superior performance, and technical innovation
Edited by Viv Decoral Arcole (Verona) - Italy info@vivdecoral.it
With a portfolio of over 4,000 finishes and effects, the Decoral® Group has redefined the look of aluminium and given it the appearance of wood through its sublimation technology. The result is a product that provides architects and designers with high-performance, durable solutions certified to international standards, ideal for creating elegant and sustainable buildings.
In contemporary architecture, the choice of materials is never accidental. Modern buildings require solutions that combine aesthetics, durability, functionality, and environmental sustainability, capable of meeting increasingly high standards in terms of technical performance and energy efficiency. One of the fastest-growing trends is wood-effect decoration on aluminium. This technology enables reproducing the natural beauty of wood with extreme fidelity, from its grain to its warmest and most nuanced colours, without sacrificing the mechanical and resistance properties of aluminium.
More and more designers, architects, window and façade manufacturers, and contractors specialising in residential and commercial buildings are choosing this solution to give their projects a distinctive aesthetic value, combining warmth, elegance, and visual harmony with the strength and durability of a technologically advanced material. The possibility of obtaining natural-looking surfaces that are also resistant to atmospheric agents and require little maintenance is indeed a concrete advantage in terms of both design and management, ensuring reduced operating costs over time without compromising on the aesthetic quality of buildings.
Why is wood-effect decoration on aluminium an advantage for architecture?
“Wood has always had an unparalleled charm”, says Andrea Piva, from the Board of Directors and owner of Decoral® System Srl. “It is warm, welcoming, vibrant, synonymous with comfort
Thanks to its patented wood-effect metal sublimation technology, Decoral® Group is today a global reference point with over 4,000 tested finishes.
and timeless elegance. Its beauty, unique grain, and colour nuances make each piece unique, capable of bringing harmony to any residential and commercial environment. However, using wood in outdoor spaces also entails significant challenges, including the need for frequent treatment and the risk of deformation and wear due to sun, rain, and temperature fluctuations. Aluminium, on the other hand, is strong, lightweight, durable, and 100% recyclable. It is to overcome the limitations of wood that sublimation comes into play, as it enables aluminium surfaces to imitate wood’s elegance and natural shades while maintaining their strength and lightness.”
The
technological process behind wood-effect decoration
In 1993, the Decoral® Group, through its Viv Decoral division, patented the metal sublimation process, an innovation that would transform the industrial decoration sector. Thanks to this pioneering breakthrough, this Group now stands out as a global leader in over 60 countries, with unique technology and consolidated experience that allow it to combine aesthetics, performance, and durability in all its products. Specifically, sublimation is a decorative process that transfers designs and textures from a film (sublimation transfer) onto a powder-coated surface through the following steps:
metal surface pre-treatment and preparation to ensure excellent coating adhesion;
coating with high-resistance sublimation powders, which ensure colour stability and protection from UV rays, humidity, and salt;
application of the decorative film with the chosen pattern onto the aluminium profile or panel;
curing in a dedicated oven, which allows the colour to sublimate and penetrate deeply into the paint layer, giving it resistance and colour continuity;
removal of the decorative film.
The end result is a visual and tactile wood-like effect with textures that faithfully reproduce the grain, knots, and imperfections typical of natural wood.
This technology is therefore suited for profiles, doors, and windows with high thermal and mechanical performance, ventilated façades of residential, commercial, and public buildings, sectional doors and entrance doors, external cladding exposed to extreme weather conditions, and all projects where aesthetic consistency and high durability are essential requirements.
The concrete benefits of the Decoral® sublimation technology
Realistic aesthetics: the Decoral® technology allows applying high-definition, wood-effect finishes that imitate oak, walnut, chestnut, cherry, and many other woods with surprising results. The process guarantees not only the visual appearance of wood but also a material texture that imitates its tactile perception.
Exceptional durability: the treated surfaces are resistant to UV rays, rain, frost, humidity, and salt. Wood-effect aluminium does not crack, discolour, or deform: it is ideal for all climatic conditions and for both residential and public applications.
Reduced maintenance: compared to natural wood,
The sublimation transfer applied on powder-coated aluminium profiles.
decorated aluminium does not require periodic maintenance cycles. Simple cleaning is all that is needed to maintain its appearance over time, reducing costs and post-installation interventions.
Design versatility: wood-effect decorations can be applied to profiles, panels, sunshades, false ceilings, cladding systems, and ventilated façades, also resulting in aesthetic consistency among different structural and architectural elements while bringing a degree of creative freedom that only technology can offer.
Sustainability: Decoral® produces VOC-free powders through a process with a low environmental impact, making them a responsible choice for anyone seeking green solutions without compromising on quality.
The value of sublimation technology in contemporary architecture
Wood-effect decoration on aluminium is a choice that combines aesthetics, high performance, sustainability, and ease of maintenance, going beyond mere visual appeal. In this context, the Decoral® Group confirms its position as an international benchmark supplier bringing innovation, certified quality, and safety to every project. Its broad portfolio of over 4,000 tested finishes is the result of an in-depth research and development activity.
Its available effects can accurately reproduce the charm of wood (cherry, oak, walnut) but also the appearance of precious metals (copper, corten steel, steel), the elegance of marble, and even the creativity of customised patterns.
The Decoral® technology is also certified according to international standards such as AAMA 2603, 2604, and 2605, Qualicoat, and Seaside, as well as passing exposure tests in Florida over 1, 3, 5, and 10 years, thus confirming the resistance of its colours and finishes even in particularly challenging climatic conditions, including intense sun, humidity, and salt air.
“Relying on Decoral® means choosing a cutting-edge process and a partner capable of transforming the ideas of architects and designers into durable, elegant, and sustainable buildings. With our technical support, consultancy services, and certified tests, wood-effect decoration on aluminium truly becomes a high-performance and reliable solution for contemporary architecture,” stated Piva.
From top to bottom:
In the residential and commercial sectors, the choice of wood-effect aluminium structures is increasingly common, as they combine the warm aesthetics of natural wood with the strength of metal: in the photo, the Negritella Hotel in Andalo (Trento, Italy).
Perfect for windows, façades and external cladding, Decoral® technology ensures high performance, durability and aesthetic consistency.
The cladding of Northshore Plaza, the new shopping mall in Singapore, consists of wood-effect aluminium panels produced by Decoral®
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FOCUS ON TECHNOLOGY
The finish of an architectural envelope as an interface that synthesises technology, research, culture, and storytelling in a project: the experience of Focchi Spa
Alessia Venturi, ipcm®
Over the past fifty years, architectural façades have evolved from simple aesthetic claddings into complex technological systems capable of influencing energy performance, living comfort, and urban identity. Companies such as Focchi Spa have played a decisive role in this evolution, developing customized solutions that combine engineering, design, and technological research. The partnership with suppliers like TIGER Coatings underscores the importance of an integrated approach, where aesthetics and performance merge into unique and iconic projects.
Over the last fifty years, the role of façades and complex building envelopes in architecture has undergone a radical transformation, evolving from a purely aesthetic element to a strategic technological component. Contemporary façades are no longer simple cladding elements but rather integrated systems affecting energy performance, user comfort, and the architectural identity of buildings.
The outdoor showroom of Focchi Spa, located behind the factory, where full-scale mock-ups of the structures required for the completion of ongoing projects, manufactured in-house, are on display.
This evolution has been driven by several factors, including innovation in materials and construction techniques, growing awareness of environmental sustainability, and increasingly stringent energy efficiency regulations.
The 1970s and 1980s saw the spread of glass and aluminium curtain walls as symbols of modernity and transparency. Since the 1990s, however, attention has been shifting towards more efficient building envelopes, capable of reducing energy consumption thanks to advanced insulation solutions and solar shading systems. Today, intelligent and dynamic façades integrate sensors, natural ventilation devices, photovoltaic modules, and automated management systems, becoming technological platforms for optimising the building’s life cycle. At the same time, together with their colours and effects, they are what make a building iconic and memorable.
Companies such as Focchi Spa (Poggio Torriana, Rimini, Italy) have been playing a decisive role in the development of customised building envelopes, combining research, engineering, and design to meet the needs of contemporary architecture. In this interview, Technical Director Paolo Ermeti explores various aspects of the client-supplier relationship that Focchi maintains with its technical partners when it comes to choosing the ideal finishes for its structures, illustrating this complex and multifaceted the decision-making and procurement process and the importance of the services provided by companies such as TIGER
Coatings, Focchi’s powder supplier of choice for many years now, for the success of each project.
The finishing of architectural envelopes plays a crucial role that goes far beyond the traditional contrast between aesthetics and technical performance: it is the point of contact among the building, the urban context, and the end users, helping define not only the appearance of a structure but also its ability to interact with the surrounding environment and stand the test of time. Finishes determine the material and tactile perception of façades: they give depth, character, and identity to their architectural design. The chosen textures, colours, reflections, and transparencies become a narrative tool for conveying cultural, identityrelated, and symbolic values, enhancing the recognisability of a building in the urban skyline. At the same time, of course, they also continue to perform a complex functional role by protecting the architectural envelope against atmospheric agents, regulating its light and thermal behaviour, determining maintenance intervals, and affecting the entire life cycle of the building.
Opportunities, evolution, and innovation
These three words encapsulate the recipe for success of the Focchi family, who have been serving the architecture industry since 1914. Specialising in the development of complex building envelopes through comprehensive project management, from design to production and on-
site installation, this company provides customised and unique façade solutions for every building, with an artisan approach characterised by meticulous care and attention to detail. Thanks to its consolidated experience, Focchi is now a leading global player, present in all iconic construction sites in both the Italian and AngloAmerican markets. “We transform every architectural challenge into an opportunity for growth and technological research. Each façade system is designed as an innovative, high-performance product that emphasises the aesthetics and beauty of the architect’s concept, however bold it may be,” says Paolo Ermeti. “Our ability to tackle increasingly challenging projects and the need to strike a balance among aesthetics, costs, performance, and lead times enable us to create unique, high-quality works, while our consolidated know-how translates into the extreme customisation of each building envelope. Today, we can say without fear of contradiction that the Focchi Group is not merely at the service of architecture: it is also an instrument of its evolution.”
What kind of company is Focchi today?
Paolo Ermeti: “It is a company renowned in the market for its product quality, design expertise, and ability to develop customised details for architectural firms worldwide. Our role encompasses prototyping,
DOMINO SUGAR REFINERY, New York (USA)
production, and installation, offering a turnkey service with a focus on high-tech and the implementation of the latest technologies. We are particularly attuned to the needs of the Anglo-American markets, as well as the Italian one: after opening our London office in 1995, we also set up a branch in New York, where we have participated in the creation of iconic projects for the mid-to-high end of the market calling for complex and technological solutions.”
What is your flagship product?
“It is the structural silicone façade, a product with complex design requirements that meets modern demands for maximum exposure to light, maximum co-planarity of the façade, and very high technical performance. It is an evolution in curtain walls, favouring an ‘all-glass’ appearance thanks to the use of an adhesive sealant (structural silicone) to replace the metal profiles visible from the outside.”
You have a long-standing relationship with TIGER Coatings. How has it evolved over the years?
“TIGER is our preferred supplier: we always offer their products to specifiers and clients. It is a very reliable partner in terms of sampling speed, quality and colour consistency from batch to batch, colour
customisation, and coating performance and durability. In particular, we greatly appreciate the developments made by this company over the last ten years in terms of colours and effects that closely mimic oxidised finishes, imitating the peculiar surfaces created by oxidation but with the added guarantee of optimal repeatability and long service life: in the world of architecture, there is always a certain parallel between anodic oxidation and paint products. The final choice is up to the customer, but if the conditions are right, Focchi always honours its partnership with TIGER and encourages the use of its powder coatings. We are also very pleased with TIGER’s service. First of all, it is very quick to supply samples, which are essential for convincing the customers: assessing colours in a brochure or video rendering is very different from having real-scale samples to compare. Secondly, its laboratory offers great support in terms of colour and formulation customisation.”
Who is Focchi’s primary contact for specifying the finishes to be used in a project?
“In modern façade development, there is an investor who decides to construct the building and generally outsources the project to a main contractor, which in turn enlists the help of architectural firms, structural engineers, and façade specialists for the design phases. Firms specialising in technical design verification work with the architect to specify the required surface finishing processes and products. Focchi receives these specifications, evaluates them in collaboration with TIGER and checks their technical requirements. It is a team effort, a holistic job in which everyone plays their part to ensure maximum performance and the best aesthetics, without forgetting that price is also a variable to be taken into account.”
Does Focchi also handle the purchase of paints?
“No, it does not. We are in direct contact with TIGER only for sampling. Then, TIGER-certified applicators purchase the paint products and apply them to components, sheets, and profiles. We generally
validate the finishes together with the main contractor using full-size visual samples, i.e. on a 1:1 scale, which we produce in-house and display in our outdoor showroom located behind our factory. We accelerate the pre-design validation process by presenting various finishes, ranging from glossy to matte in different colours, to obtain final approval and initiate the project more quickly, considering that the actual purchase of the coatings by the applicators can take place up to ten months after the sample has been requested from TIGER.”
Which coating products do you prefer to use?
“Generally, Qualicoat Class 2 polyesters. Sometimes it is still possible to distinguish between the exterior and interior of a façade and, therefore, to use the same colour in both Class 1 and Class 2 variants, but increasingly Class 2 polyesters are specified for the entire project. In particular, the TIGER Series 75 of super durable coatings with a fluoropolymer base also meets the requirements of the AAMA 2605 specification, typically used by the American market, where, incidentally, the decision-making dynamics have been changing over the last few years: whereas previously the only option was PVDF liquid paints, now there is a greater tendency to use polyester powder coatings (PPC). They have probably realised that PVDF paints are more expensive, more difficult to apply, and also more costly to restore. In Europe, on the other hand, oxidation is the main competitor of powder coatings, especially in the UK.”
What dictates colour trends in architecture?
“Rather than trends, I would speak of different approaches to colours and finishes in different markets. Much depends on the preferences and technical knowledge of architectural firms: some opt for oxidation, whereas others are more open to PPC. In the US, solid colours are preferred; in the UK, anodised-like metallic finishes are more popular. Between 2000 and 2015, the grey palette dominated, including RAL 7040, 7047, 7035, 9006, and the timeless 9010. The following decade saw oxidation prevail over powder coatings and, among the latter, the
advent of reds, cream whites, as well as a revival of gold, especially in the UK, as it is the classic colour of gryphons and of the tips of 18th- and 19thcentury railings. Clearly, historical, cultural, and identity references vary from market to market. In Manchester (UK), for example, terracotta, green, and orange tints are also popular because they are typically associated with the ceramics that decorated the entrances of pubs in the late 19th century.
International projects completed with TIGER Coatings’ powders
DOMINO SUGAR REFINERY, New York (USA)
Located on the waterfront of Domino Park in Williamsburg, this 1880s historic industrial building has returned to life as a modern office space. Designed by PAU, the barrel-vaulted glass structure integrates history, innovative engineering, and sustainability in a forward-thinking adaptive reuse project. In a unique approach to refurbishment, the architects nested a brand-new building within the existing envelope, with a 12-to15-foot gap between the new and the old. By pulling back from the original walls, ideal and standardised floor heights could be achieved, creating best-in-class space designed to meet the needs of new tenants.
CITYWAVE, Milan (Italy)
A living landscape, featuring cascading vines, trees, and natural plantings, established a green ecosystem between the glass curtain wall and the brick masonry walls. Under the guidance of James Corner Field Operations, renowned for their remarkable transformation of the High Line, the landscaping was aimed at seamlessly reconnecting the vast area surrounding Domino Sugar Refinery (known as Domino Park) with the neighbourhood to the waterfront and transforming another abandoned site into a popular destination.
Focchi Technology
The curtain-walling of the new building mainly consists of a unitised system with an aluminium frame. The building envelope features flat units from level 2 to level 11 and curved units on levels 12 and 13. From level 14 up to the top of the barrel vault, the façade system is constructed with a grid of curved aluminium mullions and transoms, pre-assembled on steel mega panels (20 ft x 13 ft), then installed onto the structural steel ribs on the roof. The cap ends on the short fronts of the building feature flat units with a curved side to connect to the vault. Worth mentioning are the zinc sheet spandrel units as perimetral cladding of the East staircase and the zinc rainscreen parapet on the terrace at level 7.
TIGER Technology
RAL 7047, AAMA 2604: smooth, matte finish with non-standard powder (produced on request).
The CityWave project, created by the prestigious BIG – Bjarke Ingels Group studio, was based on an innovative idea for workspaces that focus on quality of life and are capable of redefining the concept of sustainability. Its iconic silhouette resembling a wave, its design focused on sustainability, and the use of renewable energy make CityWave a new-generation office building. Thanks to innovative energy solutions, it is exclusively powered by renewable sources, becoming the first example of office premises to overcome the concept of zero impact, with the aim of providing a positive contribution to the environment instead.
The impressive project includes two buildings of different heights, connected by a suspended structure that frames the existing Three Towers of the CityLife skyline to create a suggestive connection between
PADDINGTON SQUARE, London (UK)
the historic districts of Milan and these contemporary architectural elements. The roof emerging between the two buildings, 140 m (460 ft) long and supported by a series of vertical support elements, thus creates an extensive shaded public space. The curvature of this connection structure is entirely covered with photovoltaic panels: with a surface area of approximately 11.000 m2 (118,400 sq ft), it is the largest photovoltaic park in Milan and one of the largest in Italy. Its overall surface area is approximately 63,000 m² (678,200 sq ft), and the development extends over a length of over 200 m (656 ft). The West building consists of two underground floors, a basement floor and 21 floors above ground; the East building consists of two underground floors, a basement floor and 11 floors above ground.
Focchi Technology
As concerns the building envelope, the adopted solution consists of a unitised façade system composed of two repetitive modules that follow one another alternately: a double-chamber and triple-glazed unit and a spandrel unit featuring accessible balconies anchored to vertical steel elements.
RAL 9005, Qualicoat Class 1 and Class 2: smooth, matte finish with standard powder.
PADDINGTON SQUARE, London (UK)
This 17-storey mixed-use building is designed to float above the ground floor. When standing in the Piazza in front of the station, one looks up and sees a square screen of over 50 by 50 meters, expressing the geometry of the cube. This is the double-skin façade of the office building, protecting the solar-screening venetian blinds. This system makes the structure highly efficient, both to save energy and enable natural daylight to penetrate deep into the office floors.
The building is a cubic volume that provides prime quality working spaces for over 4,000 people, bringing valuable employment opportunities to the Paddington area. The façades under the building are set back to maximise the public realm.
Panoramic lifts take the public up to level 17, where a large terrace and a restaurant provide magnificent 270° views, including Hyde Park, the City, and virtually all of Westminster. At the heart of this transformation project is the new large Piazza, formed by the junction of London Street with the arrivals ramp at Paddington Station.
Focchi Technology
The glass cladding gives the building a sleek look and allows light to pour into even its darkest recesses. The main façade is characterised by a compact, ventilated double-skin system, with a bespoke configuration of the glass coating and solar measures (perforated venetian blinds and louvres), thus ensuring that the glass does not need any heat treatment for shock risks. The system consists of a double-skin façade featuring a castellated mullion with the external fins acting as structural elements for the façade. The design process was supported by detailed FEM structural models of the façade, including computational fluid
81 NEWGATE STREET – PANORAMA ST PAUL’S, London (UK)
dynamic (CFD) analysis to ensure its behaviour met the ambitious thermal performance targets.
Another challenge was posed by the large cantilevering ‘wing wall’: at each corner of the building, the external skin of the façade protrudes 1.5 m from the slab edge. It consists of a bespoke reinforcing plate inserted within the transoms of the last unit for tensioning and compression distribution at the top and bottom. These last units required a bespoke launching trolley for installation, which Focchi designed and crafted in an artisanal way. The company’s R&D department also conceived a special solution to adjust the design of the external shading devices (in cast aluminium) to extruded aluminium, thus saving costs without compromising aesthetics.
TIGER
Technology
RDS 2509005, Qualicoat Class 2: smooth, matte finish.
RAL 9022, Qualicoat Class 2: semi-gloss finish.
SQUARE GARDENS – FIRST STREET, Manchester (UK)
This sustainable co-living scheme brings a sense of community to the First Street neighbourhood in Manchester. Creating a new community and public green park within a key area of regeneration close to the city centre, Square Gardens – First Street provides 2,224 co-living bedroom spaces. Spread over four separate buildings that step in height from 10 to 45 storeys, the complex offers 11 different accommodation types that range from the traditional 1- and 2-bedroom apartments that meet nationally prescribed space standards to 19-m2 space-saving studio apartments with an ensuite. Three of the four buildings are arranged in a linear formation edging the North, East, and South sides of the site. The fourth building rises as a free-standing element in the First Street skyline, reaching a height of 45 storeys.
The scheme incorporates 9,900 m2 of new landscape, of which 5,800 m2 are accessible to the general public. It also houses a large wellness centre
and commercial activities. In addition to this, residents have exclusive use of co-working areas, private and communal kitchen/dining, along with private external landscape terraces and dog exercise areas. A large bookable dining and social amenity space will be provided at the top of the tower for use by residents, offering panoramic views of the city.
Focchi Technology
All four buildings have a unitised glazing system with bespoke frit patternation and anodised metal rapid vents. A horizontal frit accentuates the stepping form of Buildings A/B/C, which contrasts with the vertical frit pattern of Building D to emphasise the slender nature of the tower.
RAL 7021, Qualicoat Class 2: smooth finish, matte colour.
81 NEWGATE STREET – PANORAMA ST PAUL’S, London (UK)
This project transformed an outdated 1980s office into a sustainable, mixed-use building and a new destination on London’s ‘Culture Mile’. Through reuse, it ensured the lowest impact development for the site, saving up to three years of demolition/new construction and reducing overall embodied carbon while improving environmental performance, natural ventilation, and daylighting. More than 1,330 bicycle spaces and associated facilities are provided to encourage sustainable transport. Extensive planting and a large public roof terrace improve biodiversity and make a significant contribution to the greening of this corner of the City. The environmental impact was minimised by reusing Portland stone from the existing building, employing modular construction methods, specifying low-carbon materials, and adopting a zero-to-landfill policy. 81 Newgate Street will strive to be the first net-zero carbon-enabled office development in London.
2 FINSBURY AVENUE, London (UK)
TIGER Technology
Gray 201, Qualicoat Class 2: smooth finish, very matte colour, nonstandard powder.
2 FINSBURY AVENUE, London (UK)
2 Finsbury Avenue is a cutting-edge development in London’s financial district, designed with sustainability at its core. It comprises a 12-storey podium and 38 and 23-storey towers, with a focus on achieving BREEAM Outstanding and Net Zero Carbon certifications. The project incorporates forward-thinking environmental initiatives such as hybrid energy systems and circular economy principles, aiming to minimise carbon footprint during both construction and operation. The building is also designed for flexibility and promotes collaboration through green spaces and terraces. Additionally, it enhances pedestrian connectivity and offers diverse retail and social amenities. Through innovative approaches, it achieved
significant carbon reduction in construction while maximising usable space. Overall, 2 Finsbury Avenue sets a new standard for sustainable office design in central London.
TIGER Technology
RAL 9005, Qualicoat Class 2: smooth, matte finish with standard powder.
RAL 7015, Qualicoat Class 1 and Class 2: smooth, matte finish with standard powder.
RAL 7024, Qualicoat Class 1: smooth, matte finish with standard powder.
GMR: innovation and sustainability with cutting-edge polymer solutions for the coil coating sector
Edited by Galstaff Multiresine S.p.A. Mornago (Varese) - Italy sales@galstaffmultiresine.com
GMR is committed to supplying high-performance polyester resins to meet the needs of the most diverse industries, including food packaging, general industry, and building & construction.
Coil coating is an industrial process consisting of the continuousflow painting of metal coils, mainly in steel and aluminium. Once coated, the metal strips (tin-plated, chrome-plated, steel, or aluminium) are then processed directly on the production line through bending, cutting, and forming operations to obtain finished products for
various industrial and commercial applications. This continuous-flow process allows for uniform coating application and reduced waste thanks to the limited thickness of the applied film. Furthermore, the use of abatement towers and ovens significantly reduces emissions, contributing to improved sustainability. The main requirements for coil coating systems are regulated by the European Coil Coating Association (ECCA)’s standards and include characteristics such as formability, scratch resistance, aesthetic appearance, weather resistance, and printability. To meet them, multilayer systems are used, combined with suitable pre-treatment and surface preparation operations.
GMR (Galstaff MultiResine S.p.A.) offers its expertise in the field of polymers for coil coating, supporting customers in choosing the optimal resin for each type of substrate and required performance.
A strategic partner for the coil coating industry
GMR has historically positioned itself as a leading supplier of polymers for the coil coating sector, with a particular focus on high-performance, oil-free polyesters. Its product range, which has been revamped and is currently undergoing expansion, is designed to meet high sustainability
Table 1 - Comparison of the main industrial paint application methods.
and food compliance requirements without compromising on the technical and application performance demanded by its target markets. Based in Mornago, in the province of Varese (Italy), it offers polyester resins specifically formulated for coil coating and capable of ensuring as follows:
adhesion to different metal substrates;
high chemical and mechanical resistance;
UV stability;
uniformity of finishing grades.
Table 2 - The main ITALESTER resins developed for coil coating,
Production efficiency
Continuous-flow process, high speed, controlled thicknesses
Quality consistency High repeatability on large surfaces
Post-forming flexibility
Aesthetics
Resistance and durability
Environmental impact
Overall costs
Typical applications
Coating done before forming, resistant to bending and denting
Wide range of colours, effects, and finishes. Very high colour consistency
Excellent (corrosion, UV, scratch, chemical resistance)
Low VOCs, reduced energy consumption, reduced waste
Lower on large volumes (optimised for mass production)
ITALESTER 957 Branched Oil-free, promotes adhesion on metal Coil coating with high wettability/ adhesion -
DP - ITALESTER 950 (NEW) Branched PE 2K, flexibility, chemical inertia, adhesion on metals and ABS Coil & industrial finishing 20
DP - ITALESTER 222 (NEW) Linear Oil-free, flexibility, compliant with EU Reg. 10/2011 Coils, packaging, top coat on appliances 2
These characteristics make it possible to meet the needs of the most diverse sectors, including food packaging, general industry, and building & construction.
The added value of GMR: technical and commercial support and tailor-made coil coating solutions
GMR offers to the coil coating sector its extensive experience in supplying highperformance polymers, assisting customers in identifying the most suitable resin for each substrate and technical requirement. It provides technical and commercial support that ensures certified quality, industrial reliability, and the shared development of innovative solutions.
This approach has consolidated GMR’s position among the leading national and international players in the sector. Innovation and development drive its growth, as demonstrated by the launch of Italester H 27BB, a bio-circular water-dilutable polyester, as well as the expansion of the company’s entire product range throughout 2025.
In Table 1, a comparison of the main industrial paint application methods available.
GMR’s product range for the coil coating sector
Table 2 summarizes the main ITALESTER resins developed for coil coating, highlighting their chemical structure, key properties, applications, and glass transition temperature (Tg). Additionally, GMR’s curing resins and reaction partners, such as Itamin amines and isocyanates from the Uronal line, allow it to offer an integrated portfolio for ovencured systems that is also aligned with the company’s pursuit of production efficiency and environmental sustainability.
Growth opportunities and market trends
Looking ahead, partnerships with leading international players will enable GMR to further consolidate its role as a key player
GMR offers to the coil coating sector its extensive experience in supplying high-performance polymers, assisting customers in identifying the most suitable resin for each substrate and technical requirement.
The headquarters of GMR, located in Mornago, in the province of Varese.
Geographical area Size (USD, 2023-24) Predicted CAGR Key trends
Europe
Italy
Germany
~535 M (2023)
~4.2-6.9% (2024-31)
~85.7 M (2023) ~4.9% (2024-30)
Construction, regulations, innovation
Predominant use of polyester, growing use of plastisols
~139.8 M (2023) ~4.9% (2024-30) SMP growth
Global 4.6-5.0 B (2022-24)
~4.4–4.7% (future)
Asia-Pacific expansion, innovation
Table 3 - Overview of the market size, growth forecasts, and key trends by geographical area.
in the market of coatings for metal substrates in continuous-flow processes.
Table 3 provides an overview of the market size, growth forecasts, and key trends by geographical area.
Market data show a growth trend for the coil coating industry, driven by sustainable construction, innovation in materials, less energy-intensive processes, expansion in emerging markets, and digitalisation of production. However, companies in the sector will also face some challenges, such as volatility in raw materials and stricter environmental and safety regulations, which will call for increasingly advanced and sustainable solutions.
Engineering specialized in the supply of systems for surface treatment, painting and coating
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EcoDie: caustic soda recovery system for aluminium extrusion die cleaning
In Europe, dissolved aluminium in exhausted caustic soda baths, classified as hazardous waste, exceeds 120,000 tons annually. ALSAN’s EcoDie system recovers over 80% of the caustic soda for reuse, while precipitating the aluminium as pure, non-hazardous alumina. This approach reduces waste, lowers costs, and promotes circular economy principles in aluminium extrusion.
To ensure the quality of the final product, it is essential to keep extrusion dies clean by removing embedded aluminium through the use of caustic soda (NaOH) baths. These baths selectively dissolve aluminium without damaging the steel structure of the die. Over time, however, the concentration of dissolved aluminium (sodium aluminate) increases, reducing the bath’s effectiveness and its dissolution rate. Eventually, the bath is considered exhausted. This exhausted solution is classified as a hazardous waste due to its highly corrosive nature, leading to significant environmental impact and high management
costs. For reference, a plant with an annual output of 10,000 tons of extruded aluminium can generate over 300 tons of this waste. In Europe, this figure exceeds 120,000 tons per year — clearly highlighting the need for a recovery system for the caustic soda used in these processes. In response to this challenge, ALSAN has launched an in-depth study into various technological strategies aimed at recovering caustic soda from exhausted die cleaning baths, with the goal of achieving a more sustainable management approach.
Assessment of technological alternatives for caustic soda recovery
Effectively addressing the challenge of caustic soda recovery requires eliminating the element that renders the bath inactive: dissolved aluminium. The goal is to restore the reactivity of caustic soda by removing its main inhibitor.
At ALSAN, four selective precipitation methods were evaluated for this purpose (Fig. 1).
Three of these methods rely on the addition of external reagents (lime, sodium silicate, or a combination of CO2 and lime) which are continuously consumed as they react with the sodium aluminate in the exhausted bath, forming insoluble compounds that are later removed via filtration. While these methods are highly effective at removing aluminium, they require high operating temperatures (80–90 °C) and produce large quantities of sludge (6–15 g of sludge per gram of aluminium removed), some of which are classified as hazardous.
The fourth method — aluminate hydrolysis — is based on a natural chemical equilibrium that enables aluminium to precipitate as pure alumina without the addition of any reagents. It operates at ambient temperature under constant agitation. This method stands out as the most technically and economically favourable: it produces just 3 g of sludge per gram of aluminium removed, generates no hazardous waste, and allows the alumina to be recovered as a potentially valuable by-product. Furthermore, it requires no ongoing reagent consumption, making it the most cost-effective solution. ALSAN brings this natural chemical equilibrium into practice through its EcoDie system, designed as a continuous process for alumina precipitation. At the heart of the system lies a crystallization reactor, where aluminium is precipitated. In the first stage, the reactor is filled with exhausted baths, which naturally cool to ambient temperature and are subjected to constant agitation to encourage alumina precipitation and caustic soda recovery. The process continues until chemical equilibrium is reached between free caustic soda and dissolved aluminium — a balance governed by the solubility of alumina. Once equilibrium is achieved, the reactor outputs regenerated caustic soda to feed fresh die cleaning baths.
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When these become exhausted, they are returned to the reactor, thus restarting the purification cycle. A full cycle - i.e., the purification of one exhausted bath - takes approximately 24 hours to complete (Fig. 2). The EcoDie system is estimated to recover at least 80% of the caustic soda used in die cleaning processes. As shown in Figure 3, this results in substantial savings in both raw materials and waste management costs. The only by-product is pure alumina, a nonhazardous solid with potential for valorisation, offering extrusion plants a modest but tangible economic return. This approach optimizes resource use, aligns with circular economy principles, and actively reduces the environmental impact of aluminium processing. In conclusion, ALSAN presents the EcoDie system, designed to recover a minimum of 80% of the caustic soda used in die cleaning processes. This represents a significant economic saving for extrusion plants and, in many cases, allows for a rapid return on investment. Through this innovative solution, ALSAN reaffirms its commitment to reducing the environmental impact of the aluminium industry, promoting circular economy principles and sustainability across its operations.
From top to bottom:
Figure 1 - Comparative overview of the four recovery methodologies evaluated.
Figure 2 - Cyclical operation of the EcoDie system. Diagram of the caustic soda recovery process through alumina precipitation.
Figure 3 - A three-dimensional representation of the EcoDie system is shown, along with the projected economic savings in terms of raw materials (caustic soda) and waste management.
Super durable sublimation films: wood-like effects and extreme performance for aluminium
Ilaria Paolomelo ipcm®
Lacalum, a coating contractor specialising in the treatment of aluminium profiles and sheets, has been working with I.DEK for over fifteen years to achieve high-quality wood-like effects for architectural projects with a strong visual impact. The combination of Class 2 powder base coats and super durable sublimation films ensures colour stability and resistance to UV rays and atmospheric agents, guaranteeing excellent performance over time.
Have you ever felt an immediate connection with nature while walking among skyscrapers and modern buildings? In contemporary cities, designers and developers are increasingly trying to recreate this feeling through materials and finishes that bring warmth, harmony, and naturalness to built spaces. Vertical forests among skyscrapers, green walls in offices and co-working spaces, façades
evoking natural textures: this is not just an aesthetic trend but also a concrete response to people’s desire to live in more welcoming, healthy, and pleasant environments.
Architectural research in recent years has confirmed that the presence of natural elements like wood has a profound effect on the well-being of those who live in or frequent a space. Visual contact with natural materials can improve mood, increase productivity, promote concentration, and create a sense of comfort and security. As a result, buildings are no longer just functional containers but become tools to affect emotions and perceptions, spaces where aesthetics meet health and quality of life. In many situations, however, real wood is not a viable option: façades exposed to the elements, external doors and windows, and structures that must withstand sun, rain, wind, and temperature changes would be at risk of rapid deterioration, requiring constant maintenance. That is where aluminium comes into play as an extremely light, resistant, and versatile material suited for advanced finishing technologies that can completely transform its appearance. Sublimation, for example, creates surfaces that faithfully reproduce the grain, colour, and visual warmth of natural
wood to combine aesthetics and functionality. In this way, aluminium retains its strength and resistance, while the wood-like effect enriches the environment with naturalness and visual comfort, contributing to its occupants’ well-being.
Lacalum S.L. (Talavera de la Reina, Toledo, Spain) has been a benchmark contractor specialising in the coating and surface treatment of aluminium profiles and sheets for over twenty years. It stands out for its ability to apply a wide variety of colours and finishes, from standard to special hues and with the most realistic wood effects. Thanks to its long-standing
collaboration with I.DEK (Legnano, Milan, Italy), Lacalum offers a complete range of sublimation films that faithfully reproduce the grain and texture of wood, combining aesthetics and durability. In the last few years, it has further expanded its offering thanks to I.DEK’s Qualicoat Class 2 powder coatings, which it also uses as base coats for the sublimation process, and SD (Super Durable) series sublimation films. This combination of products creates finishes that enhance the aesthetics of profiles and sheets while ensuring high resistance to atmospheric agents, UV rays, and temperature fluctuations.
Top left: overview of the dip pre-treatment cycle.
Top right: Lacalum’s horizontal coating line.
Dunique luxury residential complex in Marbella. For the sublimation phase, Lacalum uses wood-effects film developed by I.DEK.
Founded in 2000 in the Torrehierro industrial park in Talavera de la Reina, Lacalum has built a solid reputation over the years thanks to the quality of its finishes, the precision of its processes, and its constant attention to customer needs.
“In 2011, it changed ownership,” says Jesús Pulido Barrado, one of Lacalum’s current owners. “Together with my partner, Jorge Fernández Mercado, who was already working with me in the company, I took over the reins following the economic crisis of 2007-2008 and steered Lacalum towards stable and solid growth. It was not easy to get through that period, but for us, service could never be compromised. Therefore, from the very beginning, our guiding principle has been clear: to put our customers and their needs at the centre of our daily work, guaranteeing quality, professionalism, and reliability.”
“We are exclusively a contracting company,” explains Pulido Barrado. “Our success does not come from producing our own materials, but from the care, passion, and attention to detail that we put into every project.
Everything that enters our factory comes from our customers, and our strength lies in transforming it with impeccable service and the highest finishing quality. We offer a wide range of solutions, from standard to special colours and from glossy to matte finishes, including wood-effect ones. It is this level of customisation and precision that sets us apart in the market and makes our company a trusted partner for every project.”
To date, Lacalum is the only totally independent company (not belonging to any large industrial Group) in central Spain specialising in contract coating of aluminium products. “Our autonomy allows us to offer tailormade, flexible, and rapid solutions, always adapted to the specific needs of each project,” states Jesús Pulido Barrado. “Our customers know they can count on us not only for excellent results but also for a comprehensive service paying attention to every detail, where precision, quality finishes, and daily dedication really make the difference.”
Description of the coating cycle
“We receive components already machined by our customers: our work
From left to right: The coating application phase; The Gema OptiCenter booth;
only focuses on finishing, which may consist of applying powder coating only or a base coat followed by wood-effect decoration,” illustrates Pulido Barrado.
In both cases, the parts are hung on a bridge crane and subjected to a dip pre-treatment process consisting of seven stages: an initial acid attack, several rinses with mains and demineralised water, and a passivation step with chemicals developed by Proquimia. “In the first stage, i.e. acid attack, we use a chemical designed specifically for aluminium sheets, as these extremely delicate products require thorough surface preparation to ensure a perfect finish,” adds Pulido Barrado.
After pre-treatment, the profiles are unloaded from the overhead crane and taken manually to the drying oven before entering the coating line. This includes a manual loading and unloading area, a Gema OptiCenter booth equipped with eight spray guns per side for the automatic, dense-phase application of powders, and a curing oven where the components dwell for approximately 22 minutes, with
times varying depending on the type of product applied. “Our catalogue includes an extensive range of powder coatings, from RAL colours and standard finishes to special and textured finishes, which are currently among the most popular on the market. The choice depends on customer requirements.”
“In the case of sublimation, the base coat application phase is the start of the process. The parts can be coated with either traditional or Class 2 powders, depending on the degree of resistance and stability required by each customer,” indicates Lacalum’s owner. At the end of the coating cycle, components that only require powder application are unloaded, checked by operators, packaged, and shipped, whereas those requiring wood-effect decoration reach the sublimation line. “To offer our customers both quality and speed of service, we work in three shifts and handle up to thirty colour changes per day to ensure delivery the very next day,” says Pulido Barrado. Lacalum also has a second carousel coating line, designed to handle high-volume jobs or orders with special characteristics.
When aluminium turns into wood
Currently, wood-effect decoration accounts for approximately 20-25% of
Lacalum’s work volumes. “This percentage varies depending on market trends and local contexts,” explains Pulido Barrado. “In luxury residential areas or seaside resorts, for example, wood-effect finishes are particularly popular for façades, pergolas, gates, and railings. A significant example is the Dunique project in Marbella (Spain), which we recently completed in collaboration with architectural firm Miaz y Diaz (Marbella) and its customer Alu Stock S.A, for which we chose the products developed by I.DEK to achieve wood-effect finishes with a striking aesthetic impact and perfectly integrated with the surrounding environment. In contrast, in large cities such as Madrid, which is currently our main target market, the demand for decorated aluminium is more limited.”
“To perform this decoration cycle, after powder coating and curing, we unload the components and transfer them manually to the sublimation area. Here, our operators manually apply the decorative film, ensuring it adheres correctly to the entire surface of the component. The parts then enter a vacuum machine to ensure the film adheres evenly to the powder base coat. The final stage takes place in the sublimation oven, where heat and pressure transfer the film’s pigments into the paint layer, permanently fixing its design. Once cooled to room temperature, the profiles are checked, packaged, and prepared for delivery.” With this technology, the
Left: a powder-coated profile before sublimation; right: a sublimated profile with a wood-like effect.
grain, shades, and texture of wood are replicated with remarkable faithfulness while also ensuring resistance to atmospheric agents, UV rays, and temperature fluctuations.
Decorating aluminium with light colours is now possible with super durable sublimation films
“In sublimation processes, using light hues for the powder base coat on which the sublimation film is applied has always been a challenge. Neutral and bleached colours, which are currently in high demand in the furniture and architecture sectors, are difficult to maintain over time with traditional technologies, especially in terms of resistance to atmospheric agents. Standard films applied on light backgrounds tend to show signs of colour degradation quickly under UV rays; this problem is less noticeable on dark backgrounds, where any colour alterations are partially concealed,” notes Ambrogio Cacia, the owner of I.DEK. To meet this need, I.DEK has developed its SD
(Super Durable) sublimation film collection. Thanks to pigments with extremely high colour stability, designed to degrade ‘in the same shade’ as the base coat, the resulting decorations maintain visual consistency even after long periods of exposure to sun, rain, and temperature changes. The result is a finish that not only faithfully reproduces the grain, colours, and texture of wood but also preserves all its beauty and integrity over time. Indeed, when combined with Qualicoat Class 2 base coats, the SD series films allow obtaining Qualideco Class 1 certification even on light-coloured bases.
“A few years ago, we added the SD sublimation films developed by I.DEK to our catalogue, complementing the range of standard films we have been using for over fifteen years. Whenever possible, we recommend the SD series to our customers,” emphasises Pulido Barrado. “These coatings provide superior quality and protect the components from discolouration or other problems caused by external agents. No one wants to be left with a compromised result after a few months
Operators manually apply the decorative film, ensuring it adheres correctly to the entire surface of the component.
Vacuum allows the film to adhere evenly to the powder base coat.
or years: this range of super durable products guarantees long-lasting performance, impeccable aesthetics, and greater peace of mind for customers.” “We have devoted a lot of time to developing these products, carrying out numerous tests and trials,” Cacia states. “Accelerated ageing tests have demonstrated this line’s exceptional resistance properties: over 1,000 hours of exposure to UV rays, equivalent to approximately 3 years in the equatorial region or 5 years in Europe, without any deterioration in aesthetic quality.”
“Lacalum has also obtained Qualicoat Seaside certification, the highest quality level required for the treatment of painted aluminium intended for architectural use,” concludes Pulido Barrado.
A collaboration that makes a difference
The partnership between Lacalum and I.DEK has lasted for over fifteen years and, as Pulido Barrado points out, “We are absolutely satisfied: every time we meet, the I.DEK team presents us with new developments, innovations, and future projects. This innovative company is always up-to-date with new technologies and market trends, and it is capable of developing concrete solutions and innovative ideas. Even when some products are not directly applicable to our processes, we appreciate the continuous updating and the ability to constantly bring new ideas to the table. Our partnership is simply extraordinary.
“Every year and a half or two, we review market trends and adapt our colour chart. Some effects and finishes are removed because they are no longer in demand, whereas new colours are tested with our customers to gauge their reception. This is the case, for example, with the SD series – and customer feedback has been very positive.” Lacalum’s top priority is to meet customer needs and guarantee absolute quality. That is why it also has an in-house laboratory where all materials undergo thorough checks and tests.
Sustainability is another pillar of this company. Its coating line is equipped with a purification system for the cleaning water used in the pretreatment phase. Photovoltaic panels on the roof cover part of its energy requirements. And a Green Stripping system from Proquimia removes paint from load bars using environmentally friendly chemicals.
Lacalum chose I.DEK sublimation films to give the aluminium profiles used in the Dunique luxury residential complex in Marbella a wood-like effect.
Lacalum regularly monitors market trends to offer an up-to-date range of colours and wood-like effects.
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Interpon D Natural Metals: the quality and style of metal, encapsulated into a powder coating
Edited by AkzoNobel
Interpon D Natural Metals transforms any surface into a metal work of art, combining refined aesthetics with super durable performance. Thanks to the patented stabilised particulate technology, it offers deep colours, glossy finishes, and certified sustainability to enable architects and designers to bring innovative and elegant projects to life without making compromises.
Metals can give buildings and projects an immediate feeling of quality and style.
Powder coatings are designed to help architects bring their imagination to life.
The Interpon D Natural Metals range combines all of this into a metallic powder coating, which has the advantage of being more affordable, easier to handle, and more durable than real metal.
The Natural Metals collection features the patented stabilised particulate technology developed by AkzoNobel Powder Coating’s researchers, which provides for a more concentrated and deeper metallic finish than traditional metallic powder coatings. This new range, in particular, is the result of years of research by Interpon’s colour experts, ensuring that our customers’ projects are always in line with the latest trends in colours, finishes, and special effects. It is also perfect for companies that value sustainability because its durability ensures high resistance to the test of time, even in the most challenging environments.
Interpon D Natural Metals is part of the super durable Interpon D2525 Matt and Interpon D2525 Sablé series: the smooth matte finishes have a gloss of 25±5% and the sablé ones of 5±2%. All metallic finishes are bonderised. The collection includes 12 products in stock with a wide range of trendy colours, ranging from copper, brass, steel, and nickel to silver and iron.
Patented stabilised particulate technology
This technology influences the fundamental behaviour of electrostatically charged powder particles, enabling the micaceous pigments to remain more anchored to the base and resulting in a more concentrated and deeper metallic colour. This improved management of the charged particles’ behaviour enhances metallic powder coatings and facilitates their use, allowing users to apply them without any special precautions. This technology has been tested on different coating lines and with different application requirements, proving to be a ‘future-proof’ stabilisation mechanism. It also improves:
70 years of experience and innovation in surface finishing lines
ALUMINIUM
vertical plants
application performance: the mica particles and the base remain stable in a wide range of application conditions;
the use of micaceous pigments: the finishes obtained achieve a much brighter appearance than is usually possible;
electrostatic charge: charge homogeneity and reduction of the ‘bare edge’ effect, greater colour stability, optimised recycling;
operational performance: booth cleanliness is improved as the mica particles remain strongly bonded to the powder ones instead of adhering to the walls during spraying.
The Interpon powder coatings in the Natural Metals palette that incorporate this patented technology are the ones in Warm Brass, Sunset Copper, and Red Copper shades.
Durability and sustainability
As part of the D2525 super durable powder coating series, products in the Natural Metals palette offer up to a 25-year global warranty on coating performance when applied by an Interpon D Certified Applicator. They are Qualicoat Class 2 and GSB Florida 3 certified and meet the requirements of BS EN 12206 and AAMA 2604. In terms of sustainability, as per the Environmental Product Declaration (EPD), the raw materials and operations entailed in the production and transport of Interpon D have been assessed by an independent body to ensure transparent sustainability credentials.
The quality of metals, the efficiency of powder coatings Interpon D is the ideal solution for architects, builders, and system manufacturers who want to bring their creations to life and leave a lasting legacy that will inspire future generations. The new collection was created with the primary aim of reproducing the aesthetics of metals such as copper, bronze, and gold, which until now could only be achieved by using actual metal particles, resulting in costly products. And while reproducing the appearance of metal, it also provides super durable performance and the sustainability benefits of powder-coated aluminium.
FOCUS ON TECHNOLOGY
NIBAV Home Lifts: elegance meets innovation in the world of vertical transport
Alessia Venturi, ipcm®
In recent years, India has been experiencing a significant evolution in the concept of living. Urban areas, characterised by increasingly limited spaces and constantly rising land costs, are pushing families to develop vertical houses often spread over several floors. This architectural trend has brought with it a growing focus on solutions to improve liveability. Among these, domestic lifts are taking on a leading role no longer as a luxury reserved for prestigious residences but as a practical and accessible element, capable of giving comfort, safety, and added value to properties. NIBAV Home Lifts (Chennai, Tamil Nadu, India) has been a leader in the production of air lifts for domestic use for many years. For their finish, it uses a last-generation coating plant and smart masking systems supplied by Hexagon India, Gema’s distributor for South India and a partner of HangOn India in Chennai.
NIBAV Lifts of Chennai, India, is a leading manufacturer of air-driven home lifts, a cutting-edge technology with a luxury design that provides an elegant and seamless way to move between floors while enhancing the home.
Aerial view of the NIBAV Lifts headquarters in Kancheepuram, about 60 km from Chennai.
In India’s contemporary urban landscapes, the drive to build vertically developed houses is not only a response to population density but also a reflection of new habits and lifestyles. Multistorey homes, now widespread in both large cities and expanding towns, call for internal mobility solutions that guarantee comfort and functionality without disrupting their architectural spaces. That is why domestic lifts are becoming increasingly important, transforming from a luxury option to a smart and accessible feature. The most innovative technologies in this field include pneumatic or air-driven lifts, which use differences in air pressure to raise and lower the cabins. This solution eliminates the need for complex shafts, machine rooms, or bulky hydraulic systems, adapting flexibly to modern houses. Compact, safe, and energy efficient, they are the perfect answer to the needs of Indian families who aim to combine practicality and design while enhancing the value of their homes in an increasingly competitive property market.
From a technical point of view, air-driven lifts offer several advantages over traditional solutions. First of all, energy consumption is reduced significantly: the electric motor only operates during the ascent, whereas the descent happens thanks to the simple force of gravity controlled by a valve system, making the unit extremely efficient.
Efficient and space-saving powder management, equipped with OptiSpray All-in-One application pump technology and DualSpeeder. The OptiCenter uses MultiColor Switch technology, which enables the fastest switching between OptiSpeeder containers and the cleanest color change between alternating colors.
Pneumatic or air-driven lifts use air pressure differences to lift and lower the cabin.
Maintenance is also simplified, as there are no hydraulic fluids to replace or machine rooms to manage. In addition, the self-supporting cylindrical structure allows for installation in small spaces without the need for invasive building work, which is particularly convenient in existing homes. From a safety point of view, finally, pneumatic technology is inherently reliable: in the event of a power failure, the cabin slowly descends to the lowest floor through natural decompression, thus avoiding sudden stops. For a multi-level single-family home, therefore, air-driven lifts provide the ideal combination of practicality, sustainability, and contemporary design. NIBAV Lifts (Chennai, India) is a leading manufacturer of domestic air lifts with cutting-edge technology and luxurious design, offering an elegant and smooth way to move among floors while enhancing the value of any home. “Domestic lifts are not only requested by senior citizens; in fact, only 10% of our orders are related to the limited mobility needs of elderly people. Indians simply tend to prefer investing in domestic lifts over designer staircases. We design our lifts in-house, with some being customised by our technical teams spread across various regions of India
to promptly take measurements and collect customer requests. This data is then transferred to us for the design, planning, and subsequent production phases,” explains Yasin, Plant Head.
The production process
NIBAV’s Indian-made products are available worldwide in over ten countries, including the United States, Canada, Australia, the United Arab Emirates, Malaysia, and others. With forty-four showrooms already operating worldwide and many more about to open, this company is renowned for its impeccable service and its mission to guarantee excellence. It has two modern production facilities and two special engineering and design centres in Chennai, a workforce of around 1,000 people, and a production capacity of 8,000 domestic lifts per year. For finishing the profiles required in its lifts, it has opted for powder coating technology. At its Kancheepuram site, about 60 km from Chennai, it has recently installed a last-generation plant for that.
“Our production process begins with manufacturing the various
NIBAV operates a best-in-class powder coating plant supplied by Hexagon, Gema’s distributor for Southern India. On the right: the pretreatment tunnel.
components, mainly by laser cutting and welding, followed by powder coating and, later on, assembly, testing, packaging, and delivery,” explains Yasin. “We work with aluminium, steel, and galvanised steel. Last year, we commissioned a best-in-class coating plant from Hexagon, which came into operation in January. After a start-up and ramp-up phase lasting a few months, it now operates in three shifts.”
The coating plant
“The coating system we supplied to NIBAV starts with an 8-stage spray pre-treatment with a final nanoceramic conversion stage. This is followed by drying in a hot air oven and powder application in a booth equipped with four last-generation manual units from Gema, two on each side,” explains Venu Raju CEO of Hexagon.
“We opted for manual application because of the extreme variety in the shapes and sizes of the parts produced by NIBAV, some of which are also characterised by several tiny cavities, which means that an automated application operation would translate into excessive powder waste. The cycle is completed with the oven-curing and unloading phases. The maximum length of the treated parts is 2 m.
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Manual application of powder coating.
A rewarding partnership
“In addition to this semi-automatic plant, NIBAV Lifts has a manual, batchbased system for small volumes of parts to be coated in specific colours or that are not hung on the automatic conveyor. NIBAV applies polyester powder coatings in eight different tints, mainly cream, optical white, black, and grey. Previously, there were four coating plants at the Group’s various sites: with this new system supplied by Hexagon, NIBAV has streamlined its operations, concentrating them here at the Kancheepuram site and in Akkarai, where it has a production unit with a second coating line.”
“As a partner of HangOn India,” adds Hexagon, “we also supply NIBAV with the masking products needed to protect the (sometimes very numerous) cavities and holes on their parts. This is essential to comply with the tolerances required for assembly. As for the hanging systems, since it only coats profiles, NIBAV simply uses traditional hooks.”
With extensive experience in coating, NIBAV Lifts knew precisely what to ask of its supplier, Hexagon, to obtain a modern, efficient, and sustainable coating system. “We are very satisfied with our investment, and especially with our new Gema equipment. We still have some way to go to reach our production target of 8,000 lifts per year, which would bring the plant to full capacity, but the finishing quality guaranteed by this plant is very high, and our customers have already noticed that,” states Yasin.
One of Gema’s manual units for powder coating application.
Yasin, Plant Head of NIBAV with Alessia Venturi of ipcm®
Engineers develop breakthrough method for aluminium surfaces, enabling advancements in cooling, self-cleaning and anti-icing technologies
Alexandra Becker Rice University, Houston (TX) – United States alex.becker@rice.edu
An international team of engineers has developed a scalable and cost-effective method to create topography-patterned aluminium surfaces with controlled liquid behaviour. By combining vinyl masking with physical and chemical treatments, the researchers achieved enhanced droplet shedding, improved thermal emissivity, and anti-icing properties. These advances hold strong potential for industrial applications in electronics cooling, automotive, aerospace, and energy systems.
An international team of engineers has developed an innovative, scalable method for creating topography-patterned aluminium surfaces, enhancing liquid transport properties critical for applications in electronics cooling, self-cleaning technologies and anti-icing systems. The research, published recently in Langmuir1 and conducted by groups at Rice University and the 1 https://pubs.acs.org/doi/10.1021/acs.langmuir.4c03891
University of Edinburgh as part of the Rice-Edinburgh Strategic Collaboration Awards program, demonstrates how cost-effective vinyl masking techniques can produce surfaces with high-resolution wettability contrast, paving the way for improved phase-change heat transfer applications.
The research team developed a novel technique using blade-cut vinyl masking and commercially available lacquer resin combined with scalable physical and chemical surface treatments to create patterned aluminium surfaces. These surfaces exhibit distinct wettability contrasts, significantly improving the droplet shedding during condensation. The patterns, with feature sizes as small as 1.5 mm, offer a range of wettability behavioursfrom superhydrophobic to hydrophilic - depending on the treatment.
“This method represents an important step in tailored surface engineering,” said Daniel J. Preston, assistant professor of mechanical engineering at Rice and a co-corresponding author of the paper along with Geoff Wehmeyer, assistant professor of mechanical engineering at Rice, and Daniel Orejon from the University of Edinburgh. “By enabling precise control over surface wettability and thermal properties, we are opening new doors for scalable manufacturing of advanced heat transfer surfaces.”
The research employed a multistep methodology to develop and analyse the patterned aluminium surfaces. Vinyl masks were first applied to polished aluminium substrates, followed by a two-step etching process that created micro- and nanotextured zones. The team then used advanced imaging techniques to characterize the patterns’ resolution and wettability properties. To evaluate performance, condensation visualization experiments demonstrated enhanced droplet shedding on the patterned surfaces compared to homogeneous ones. Additionally, thermal emissivity mapping using infrared thermography revealed significant contrasts in emissivity between smooth and textured regions, highlighting the surfaces’ potential for advanced thermal management applications.
“Aluminium is widely used in thermal management devices like heat
Left: Aluminium coupon samples patterned with alternating stripes of smooth (lighter) and etched (darker) topographies display contrasting wettability.
Right: Topography patterning results in distinct frost morphologies, as demonstrated on etched 'UoE' and 'RICE' letters compared to a smooth aluminium background.
exchangers due to its high conductivity, low density and low cost,” said Wehmeyer. “Our method adds a new dimension to its functionality by integrating surface patterning that is both cost-effective and scalable, allowing engineers to fine-tune the condensation heat transfer. This work brought together expertise from Edinburgh and Rice to develop and characterize these advanced surfaces.”
The findings have significant implications for industries that depend on phase-change heat transfer with applications in everyday technologies. In electronics cooling, enhanced droplet shedding reduces thermal resistances associated with large droplets during condensation, which could enable new cooling strategies for data centre servers or other electronic devices that rely on effective heat dissipation to prevent overheating. Tailored thermal emissivity patterns optimize heat dissipation in high-temperature environments, benefiting systems such as automotive engines and aerospace components. Additionally, superhydrophobic regions expedite water removal, preventing ice formation on critical surfaces like airplane wings, wind turbines and power lines during freezing conditions. These advancements offer practical solutions to enhance the performance and reliability of technologies people use and depend on every day.
“Traditional methods like photolithography are typically expensive and limited to small areas,” Preston said. “Our technique uses affordable, accessible materials to create intricate patterns on larger surfaces, making it suitable for industrial applications and a promising technique for designing next-generation condensers and heat exchangers.”
The lead authors on the work are Trevor Shimokusu (Rice mechanical engineering doctoral graduate, now a faculty member at the University of Hawaii) and Hemish Thakkar (Rice graduate with a double major in chemistry and mechanical engineering, now a doctoral student at Princeton University).
This work was supported by the Rice-Edinburgh Strategic Collaboration Award program, a NASA Space Technology Graduate Research Opportunities award and grants from the National Science Foundation.
The most versatile paint stripper on the market: suitable for every surface, system, and coating
Edited by ALIT Technologies S.p.A.
San Bonifacio (Verona), Italy info@alit-tech.com
When ALIT Technologies S.p.A. developed Metalstrip 1334, it aimed for one thing: practicality. A stable, effective, and easy-to-use formula: a product that performs with intelligence and versatility. The result? A medium-temperature stripping solution that now works quietly in many plants, optimizing cycles, reducing waste, and restoring surfaces ready for a new life.
Strategic versatility
Metalstrip 1334 is a medium-temperature chemical paint stripper (40–75 °C) designed to act on a wide range of coatings, from thermosetting powder paints (polyester, polyurethane) to liquid paints. It removes coatings selectively, without damaging metal substrates, including ferrous and aluminium alloys as well as yellow metals.
It ensures operator safety, environmental protection, and long-term chemical stability of the bath. It is ideal for aluminium profile stripping and works effectively in both immersion and spray systems, but the real strength lies in its operational flexibility. Metalstrip 1334 is compatible with all major ALIT systems: it performs efficiently in spray systems like FASTRIP S, as well as in immersion systems with ultrasound (FASTRIP T2), mechanical agitation (T5), or automated movement of parts (MT, AP).
Simplified management
One of the most common issues with stripping baths is rapid solution degradation, but not with 1334: its ability to retain large amounts of dissolved paint extends the bath’s life, reducing system downtime. Combined with FASTRIP FP filtration systems, it ensures long-term performance, both in stripping effectiveness and surface quality. Energy is also an oftenoverlooked factor.This system offers an energy-saving advantage: operating at lower temperatures reduces heating costs without compromising performance or stripping time, which remains in line with production needs. Several customers have confirmed excellent results at around 50 °C, and there is a double benefit: lower evaporation also significantly reduces chemical consumption. In short: lower operating costs and better energy sustainability.
Where it really works: real-world applications
Metalstrip 1334 is already delivering excellent
results across various production environments.In a facility in Southeast Asia specializing in stainless steel and perforated aluminium mesh, Metalstrip 1334 played a key role in reactivating a long-idle stripping line. The system had been shut down due to high operating costs and previously ineffective chemicals. Thanks to the Metalstrip 1334 + FASTRIP FP filter press combo, the process was fully optimized. Tests showed that immersion at 50 °C with mechanical agitation achieves complete stripping in 30–60 minutes. The treated surfaces are clean and undamaged. Where the bath once had to be replaced monthly (producing over 8 tons of waste), it now runs continuously with only simple top-ups—cutting environmental impact and management costs.
The perfect balance between performance and savings
There’s no one-size-fits-all formula in paint stripping—and no single “perfect” temperature. Each plant has its own pace, balance, and needs. That is why ALIT talks about tailored approaches, not ready-made solutions. Metalstrip 1334 was developed with this mindset: a solid, reliable tool that adapts to the context.
It reduces waste, simplifies bath management, and helps control hidden costs that often go unnoticed in initial assessments. It is not designed to disrupt processes, but to improve them steadily and concretely. And sometimes, choosing a more coherent chemical solution is exactly what makes the difference.
Total Finishing Systems is a leading designer and integrator of high-quality and complex industrial finishing systems Whether you need an in-depth process analysis or require finishing equipment and components, our equipment exceeds expectations and our innovation and automation is industry leading.
HIGHLIGHT OF THE MONTH
Air filtration: an invisible barrier protecting health and the environment in industrial and civil contexts
Edited by Defil Srl Sesto San Giovanni (Milan), Italy info@defil.it
Activated carbon filters are an all-important solution for controlling air quality and protecting health and the environment in civil, industrial, and healthcare settings.
Activated carbon filters are essential for ensuring a cleaner, safer, and more environmentally friendly environment. Not only do they improve air quality in a wide variety of contexts, but they also play a crucial role in protecting human health and safeguarding sensitive environments or those at high risk of pollution. One of the most common applications of this technology is in air conditioning systems. Found in public and private buildings, whether
civil or industrial, these units use activated carbon filters to eliminate unpleasant odours and gaseous contaminants coming from outside or produced during operation, helping to create healthier indoor environments.
Coating booths are another environment where the effectiveness of activated carbon filters is paramount, as they can contain solvent vapours and volatile organic compounds that may be harmful and need to be captured before they are released into the atmosphere. Installing activated carbon filters significantly reduces pollutant emissions, ensuring compliance with environmental regulations and protecting the health of operators.
Chemical hoods in laboratories and industrial plants are also equipped with carbon filters. These devices trap toxic vapours and gases during
delicate chemical processes, ensuring a safer work environment and compliance with occupational safety regulations.
In welding and laser cutting plants, the vapours generated are rich in fine particles and volatile substances that can compromise air quality: here, activated carbon filters effectively absorb harmful substances, thus protecting the health of operators and the surrounding environment.
Chemical processing and laser marking operations also require special attention. In these cases, carbon filters capture the corrosive and organic vapours produced, preventing them from spreading into the air and minimising their environmental impact. Industrial and domestic kitchens are everyday environments where air treatment is crucial. Activated carbon filters eliminate unpleasant odours and cooking vapours, ensuring cleaner air and improving comfort for guests and workers.
In high-security, high-traffic environments such as airports and museums, carbon filters are used to preserve indoor air quality and protect the health of visitors and staff, especially in the presence of substances that could damage artwork or affect air quality.
Refineries, considered among the most polluting facilities, also benefit from the installation of activated carbon filters, especially for capturing petroleum vapours and volatile substances that are processed or stored in these plants.
Finally, air quality is a top priority in hospital wards. As part of ventilation and disinfection networks, carbon filters help to eliminate pathogens, odours, and chemicals, ensuring a sterile and safe environment for patients and healthcare workers.
The widespread use of activated carbon filters in all these environments reinforces the commitment to protecting public health and the environment. Indeed, the presence of adequate filtration systems in strategic and sensitive locations highlights the importance of adopting sustainable technologies that help maintain a balance between human activity and respect for the planet.
Leading companies rely on vacuum distillation systems for the sustainable treatment of industrial wastewater.
Do you want to benefit from a zero liquid discharge production with VACUDEST aswell?
DEA Italian Worklab expands its coating expertise through a partnership with its pre-treatment chemical supplier
Monica Fumagalli, ipcm®
The surface coating of furniture, even in less conventional contexts such as car repair shops, must combine aesthetics and functionality to withstand particularly critical conditions of use. DEA, an integral part of the RO&Co. Group and a manufacturer of modular furniture for workshops, has tackled this challenge together with Chemtec, with which it has developed a pre-treatment cycle capable of guaranteeing high corrosion resistance and aesthetic quality, but also launched a training and skills consolidation programme to improve its coating process, which it insourced a few years ago.
Any mechanic or technician who works in a car repair shop is well aware that the quality of the furnishings is not just a matter of aesthetics. Benches, cabinets, and trolleys are work tools in their own right, which should withstand impacts, scratches, oils, solvents, and constant loads without compromising their functionality or value.
“For service managers working in the automotive sector, choosing the right materials for furnishing
DEA Italian Worklab has been specialising in the production of modular workshop furniture since 2010.
workshops, dealership premises, and official maintenance centres is a strategic decision that can profoundly affect the operational efficiency of these places,” states Rino Giliberti, Senior Manager - Product Engineering at DEA (Fano, Pesaro and Urbino, Italy), which since its foundation in 2011 has positioned itself at the high end of the market by manufacturing modular workshop furniture that combines Italian design with long-term durability.
“Among the core elements, the workshop workbench is the key piece of equipment around which daily operations revolve, from routine to more critical tasks, from maintenance to precision work: each of its components must therefore meet the highest standards of robustness, reliability, and functionality.”
To guarantee this level of performance, DEA has chosen steel to combine mechanical strength and structural stability. “This material,” Giliberti adds, “lends itself to specific treatments, such as powder coating, which
increase its resistance to corrosion and wear caused by liquids, oils, and industrial solvents. Thanks to these characteristics, powder-coated steel workbenches are a long-term investment capable of maintaining their performance degree even after years of intensive use.”
When DEA decided to insource coating in 2020, it did so with the same approach that guides all its projects: starting with total control of the selected materials and processes to achieve finishes that meet the requirements of all major automotive brands. This led it to collaborate with Chemtec (Corbetta, Milan, Italy), a company specialising in chemical solutions for coating pre-treatment. Chemtec did not just supply the most suitable chemicals but also made its expertise available to develop a finishing cycle that combines aesthetics and durability, as guaranteed by advanced tests such as the ACET one, but also to train DEA’s operators who found themselves managing coating (one of the most complex processes in the entire production cycle) for the first time.
Products with smooth or semi-gloss finishes undergo ‘cosmetic’ welding: the metal is processed, sanded, and finished so that no joints are visible.
The entrance to the pre-treatment tunnel: Chemtec’s PHOSCLEAN TTS3 is used for the first stage, i.e. phosphating.
Focus on DEA Italian Worklab
Since 2011, DEA has been an integral part of the RO&Co. Group, a leading international organisation recognised for its solid market leadership position. “While preserving our DNA and identity, we can now benefit from powerful synergies that give us access to new resources, advanced technologies, and a global network. These advantages have enabled us to tackle the challenges of a constantly evolving market more effectively, accelerating our path of innovation and growth,” says Giliberti. “With this in mind, a few years ago, we decided to insource all our production phases, including coating, with the clear objective of gaining full control of our manufacturing cycle and ensuring the highest quality of our premium solutions, thus continuing to achieve the competitive advantage that has always characterised us within our sector.”
In 2022, the RO&Co. Group inaugurated a new production plant in Fano covering approximately 10,000 m² and equipped it with the latest
technology and cutting-edge automation systems. These investments have optimised time, costs, and resources, thanks in part to real-time production monitoring via an MES system. As Giliberti explains, “The production cycle is now completely vertically integrated: from the receipt of pickled steel sheets, managed through an automatic warehouse, to machining, coating, and welding, and then assembly, testing, packaging, and installation at the customer’s workshop. Every stage is monitored and controlled down to the smallest detail. Our products are recognised precisely for this attention to detail: for example, in the case of smooth or semi-gloss finishes, we carry out aesthetic welding to ensure that the joints between the various components are invisible.”
Steel selected for high-performance coating cycles
The choice of sheet metal also reflects DEA’s focus on first-class production, as it uses lightly oiled, pickled, glossy sheets whose high
The exterior of the pre-treatment plant.
The first pre-treatment station.
quality has been confirmed by tests conducted by Chemtec’s team. In the coating department, the hanging system automatically recognises the most suitable handling method before taking the parts to the four-stage pre-treatment tunnel, which performs phosphodegreasing, two rinses (one with mains water and the other with demineralised water), and norinse nanotechnology passivation. The components are then subjected to drying (after blow-off for components with complex geometries) and finally enter the clean room for coating, a pressurised room housing two booths, of which one is manual and one automatic, as well as pre-finishing and post-finishing stations. After powder application, the parts reach the curing oven, with temperatures ranging from 170-190 °C, depending on the type of product. Finally, once cooled and unloaded manually, they undergo quality control, which includes various checks, such as the cross-hatch test to assess coating adhesion.
YOUR SYSTEM SUPPLIER FOR INDUSTRIAL COATINGS
ADHESIVES/ SEALANTS
POWDER COATINGS
LIQUID COATINGS
The inside of the tunnel.
A training partnership with Chemtec Insourcing coating operations means coming into contact with complex products and processes, which must be understood and managed in every aspect. “Our collaboration with Chemtec began with the supply of chemicals for pre-treatment,” explains Giliberti, “and soon turned into an exchange of know-how and, later on, a training opportunity for our operators. Its team was very helpful in guiding us through what was a completely new experience, as we had no experience in running this type of plant. Our only certainty was the result we wanted to achieve.”
“The first step,” indicates Beatrice Turri, Sales & Marketing Manager at Chemtec, “was to identify products that not only met the high quality standards required but were also easy to use for a team new to pretreatment processes. We opted for two of them: PHOSCLEAN TTS3 and PRONORTEC MM02. The former is a one-component product that acts
as both a phosphating agent and a degreaser, eliminating the need for additives or surfactants. It is managed by only measuring pH values; it is eco-friendly, meaning it is neither toxic nor harmful, and guarantees high corrosion resistance.
“For the nanotechnology passivation stage, we selected PRONORTEC MM02, applied by spraying without the need for rinsing. Unlike traditional chromium-based passivating agents, it is formulated with organic phosphorus compounds, making it non-toxic but guaranteeing anticorrosion performance comparable to that of trivalent passivation. Over the last two years, this product has received considerable recognition, including QUALISTEELCOAT and QUALICOAT certifications, thus confirming Chemtec’s goal of providing the most complete, sustainable, and high-performance solutions possible.”
The system for applying Chemtec’s passivating agent.
Powder application in the booth.
Advanced quality control with ACET testing
In addition to supplying pre-treatment products, Chemtec has signed a service contract with DEA that includes both on-site technical support and continued quality control, carried out through laboratory analysis and specific coating tests, including ACET and salt spray tests. “Chemtec is a small company that always puts customer needs first. Providing quality products is the starting point, but assistance and consultancy are critical: our laboratory is the actual heart of our company,” emphasises Beatrice Turri.
“We are constantly striving to develop new solutions to identify any critical issues in the coating process,” adds Emanuele Zepponi from Chemtec’s technical sales department. “With the ACET test, for example, we can verify the correctness of a process in just 24 hours and provide immediate
feedback, whereas salt spray testing provides long-term data. The ACET method is based on applying a potential difference (electrochemical stress) to a coated sample, and then, after a relaxation interval, measuring the impedance of the system, i.e. the resistance of the coating to the passage of current; the stress-relaxation-measurement sequence is repeated six times or until the material is completely degraded. Thanks to a mathematical algorithm that we have developed in-house, the ACET test results can also be correlated with salt spray resistance. The same algorithm also enables us to identify any underlying causes of corrosion, such as coating porosity, moisture absorption, or insufficient electrical insulation of the organic film, and to compare multiple samples to determine which paint performs best. It is a fast, reliable, and conclusive tool that provides valuable support to customers such as DEA.”
Gema’s OptiCenter powder feeding unit.
The conveyor takes the freshly coated parts to the buffer.
DEA Italian Worklab’s roadmap to consolidate its coating expertise
“Thanks to Chemtec’s support, we can constantly improve our coating operations, which confirms we have chosen the right partner,” states Rino Giliberti. “For a product intended for indoors like ours, we have already achieved excellent results. PRONORTEC’s QUALISTEELCOAT certification guarantees that, should we wish to raise the bar even higher in terms of performance, for example with furniture for outdoor use, we will already be in place to start the new production. This is also proof of our determination: many other businesses would have hesitated to insource their coating processes, but we knew that there was no other way to achieve the goals we had set ourselves. And for a company starting from scratch, we have already acquired considerable expertise over the last four years.”
DEA is currently working on its internal organisation to consolidate its coating department’s know-how. “The initial period taught us what we did not know how to do; now, we are structuring ourselves by bringing specific skills on board to continuously strengthen our position. We are on a path of constant growth, listening carefully to the advice of our customers, who are our most valuable asset. Within our company, we have a research and development department dedicated to constantly perfecting our products in terms of design, execution, and performance. Improvement is in our DNA because the sector demands it.
“We began our manufacturing journey by serving the world of car repair shops, which remains our core business, and we have been honoured to collaborate with leading automotive brands, where our furniture is likened to car doors or bonnets. Therefore, we have to comply with extremely high aesthetic standards, adapting to the most stringent requirements. We
DEA Italian Worklab offers a wide range of colours, from RAL tints to custom colours, with smooth and semi-gloss finishes.
DEA Italian Worklab also utilises its workbenches within its own factory.
Long-lasting attractiveness of facades, buildings and industrial products made of aluminium, steel and galvanized steel
offer a wide range of colours, from RAL tints to customised colours based on specific brand identities, with smooth and semi-gloss finishes, which are the most popular but also the most complex to produce. We are currently working on a new catalogue to diversify our market segments and expand our offering to the industrial sector. Further consolidating our coating skills, as we have been doing in the last few years together with Chemtec, will once again prove to be strategic to meet this new challenge.”
From left to right:
Rino Giliberti, Senior Manager - Product Engineering at DEA Italian Worklab, with Beatrice Turri and Emanuele Zepponi from Chemtec.
Compact and smart industrial handling solutions: the case of coating contractor Air.ver.
Monica Fumagalli, ipcm®
Air.ver., a powder and liquid coating contractor based in Lecco (Italy), has optimised its production space with customised and flexible handling equipment thanks to its long-standing collaboration with Se.Po., which has specialised in the design and installation of these systems since the early 1970s.
Nowadays, one of the main obstacles for many manufacturing businesses is managing production spaces. Purchasing new land or additional halls is not always a viable option: on the one hand, costs related to the property market and industrial leases are constantly rising, and on the other hand, urban planning and geographical constraints make it challenging to find available areas in the immediate vicinity of existing factories.
This is the main reason why companies that do not have large production areas tend to focus increasingly on optimising internal space, designing compact solutions and flexible systems for integration into their existing departments to make the most of every available square metre while improving production performance. Those involved in plant design in our sector are well aware of the importance of this aspect: from the dimensions of pre-treatment tunnels and coating booths to ovens, air and water treatment systems, and of course, the key elements that enable the movement of parts throughout the entire department, namely conveyors.
In addition to being a customer, Air.ver is also a supplier of Se.Po., as it powder coats the conveyor components manufactured by the company based in Olginate (LC).
“The main challenge, especially for contractors like us,” explains Stefano Colombo, the owner of Air.ver. Srl (Airuno, Lecco), which has been providing contract powder and liquid coating services since 1991, “is that we need to handle components of very different sizes and weights within a compact space and quickly modify our process cycle according to the diverse requests of our customers, ranging from the construction to the industrial sectors.”
Power & free and monorail conveyors are ideal when there is unlimited space available, but when space is minimal, the perfect solution is a large or small manual conveyor designed with more variables in mind to adapt to specific space, weight, and process requirements.
“Since the 1990s, when our company was founded, we have been working with Se.Po. Srl (Olginate, Lecco), which specialises precisely in solutions for industrial overhead and floor handling: the conveyors of all our five coating plants have been either manufactured or revamped by this company, of which we are not only customers but also suppliers.”
In fact, Stefano Colombo from Air.ver. and Marco Pozzi from Se.Po. maintained this partnership started by their parents and based on mutual trust, which goes much beyond a simple professional relationship.
“Se.Po. remains our point of reference not only for any new automation project related to loading, unloading, and handling parts but also for revamping, maintenance, and minor adjustments to existing automation systems.”
Air.ver., contracting at the service of the industry
“Our company,” explains Colombo, “can coat any iron, galvanised iron, and aluminium surface using thermosetting (epoxy, polyester, and plastic) powder products. On request, we can also offer cycles with anti-corrosion pre-treatment phases and apply specific paints certified for food contact or with antibacterial properties, which are particularly in demand in the medical and hospital industry.”
Se.Po. conveyor components in the process of being painted on the Air.ver. line.
The lubrication system installed on line #1. The powder application booth of line #1.
Currently, one of the main markets served by Air.ver. is the electrical panel and modular fencing sector. “Our standard process includes a chemical pre-treatment phase, but for special requests, such as those from industries that require marine anti-corrosion cycles, we can also carry out mechanical shot blasting operations. We also collaborate with some companies specialising in cataphoresis, a treatment particularly suitable for tubular or complex-shaped components, as immersion ensures uniform coverage and high salt spray resistance.”
Currently, Air.ver. is pursuing a growth plan that includes new partnerships with other coating contractors, greater attention to the environmental impact of its processes with a view to the circular economy (especially in terms of powder recovery), and the expansion of its production capacity (also with an eye on new artificial intelligence tools). “If everything goes according to plan,” confirms Stefano Colombo, “by the end of 2026, we will start an additional shift on at least one of our five lines. Today we have 20 people in our staff, but we aim to reach 45 within three or four years.”
Air.ver.’s five lines and Se.Po.’s tailor-made solutions
Air.ver.’s first factory, initially covering a surface area of 1,000 m², housed an automatic powder coating system. Over time, the facility was expanded to 2,500 m² to accommodate a sandblasting system, two automatic powder coating lines, and two manual plants, one for powder and one for liquid application. In 2005, the company moved to its current location, continuing its activities in a 1,100 m²-wide site equipped with an automatic and a manual powder coating system, as well as a mixed manual powder/liquid application system. In 2010, a second hall, initially used for storage, was converted into a production department to house an additional automatic coating system for small metal parts. Air.ver. now has two additional halls used for storage, bringing its total production area to 2,700 m².
Air.ver. was one of the first companies in Lombardy to believe in Nordson’s dense phase technology.
The Se.Po. trolley conveyor of line #2.
Manual shot blasting/cleaning and coating booths.
1. Automatic powder coating line for large batches
This line can treat panels up to 3,000 × 2,500 mm and box-type profiles up to 2,200 × 2,000 × 700 mm. The pre-treatment tunnel performs a phosphating stage followed by two rinses with mains water and one with demineralised water. After drying, the components reach the coating booth equipped with Nordson dense phase application technology and then the 100-m² curing oven, where the conveyor makes a double internal turn.
“In 2017, we were probably the first company in Lombardy to believe in the dense phase technology, which had just been launched on the market,”
Colombo points out. “Last year, we upgraded this plant with last-generation Nordson devices, including a dual system developed by Siver, which significantly increased productivity, improved transfer efficiency, and allowed for rapid colour changes in line with customer demands, which are increasingly oriented towards reduced delivery times.”
Se.Po. has divided the 7-metre load bars into two 3.5-metre sections, which can be joined if necessary.
On this long-running line, which is Air.ver.’s most important, Se.Po. has revamped the loading/unloading area and the drive unit and has recently installed a new lubrication solution to replace the previous drip system, which did not ensure adequate lubrication of the chain and caused oil to leak onto the parts and the floor, with risks to operator safety. “The new spraying system implemented by Se.Po. allows the lubricant to be sprayed directly onto the bearings. The same modification was also made to our smaller automatic plant,” adds Colombo.
2.Manual powder coating line for small batches or individual workpieces
This plant is designed for large parts: it can handle components up to 3,000 × 7,000 × 2,200 mm with a maximum weight of 2,000 kg. Surface preparation before coating is carried out by shot blasting (with components that weigh up to 5 tonnes, placed on a floor support) or manual degreasing with solvents, depending on the specific requirements. “This plant treats components from our general industry customers,” illustrates Colombo, “especially medium-sized mechanical engineering and metalworking companies, which account for the greatest use of our manual lines.” This line’s handling system was custom-designed by Se.Po. to meet space constraints. “We developed a specific technical solution to ensure the flexibility needed to paint any workpiece, from the smallest ones to those measuring 7 metres,” explains Marco Pozzi, “namely dividing the load bars into two sections each measuring 3.5 metres, which can be joined together if necessary.” At the same time, the loading area was designed to eliminate the presence of pillars that could have obstructed the path of larger components. “This solution,” notes Colombo, “also allowed us to speed up processing and increase the overall flexibility of our department.”
Overview of the monorail handling system on line #3.
Some details of the conveyor.
ipcm
3. Automatic powder coating line for large batches and high thicknesses
This is Air.ver.’s smallest automatic plant, designed for coating components up to 350 × 400 × 1,100 mm.
The cycle starts with chemical pre-treatment (phosphodegreasing and rinsing), followed by powder application using Gema Venturi injectors. Curing takes place in an oven designed for large batches of small components, which operates at higher temperatures than that of line #1. The chain moves back and forth four times to ensure optimal curing even for thicker components.
“We revamped about 60% of this line,” illustrates Marco Pozzi, “replacing the 104 m-long conveyor, installing new hooks to support the load bars with a maximum load capacity of 80 kg, and implementing an almost completely renovated rail, although retaining the original drive. We integrated a new lubrication system into this plant, too, to resolve the same issues encountered on the larger line.”
4. Manual powder coating line for small batches or individual workpieces and high thicknesses up to 300 mm
This plant can paint components measuring up to 2,000 × 4,000 × 1,800 mm, with a maximum weight of 600 kg. “Its conveyor was designed entirely by us at Se.Po.,” states Pozzi.
“The limited space available led us to design a monorail system equipped with numerous cross-shaped rotary switches, which facilitate the orthogonal movement of the workpieces inside the oven.”
Colombo points out: “In this case, we recovered a system transferred from the adjacent factory hall, of which we only retained the oven, now serving both this powder application line and the liquid application one (line #5), which was introduced at a later date.”
5. Manual liquid and multi-layer liquid coating line for small batches and individual workpieces
“We have noticed that the market, particularly in the oil and gas sector, has recently been favouring liquid painting, a treatment that we had scaled back in the past but that is now experiencing renewed demand,” explains Colombo.
“This convinced us to add a fifth plant to the four already present in our factory, which can paint parts up to 4 metres in height. However, this size was not suitable for the conveyor connected to the static oven, which could handle components with a maximum height of 2.5 metres. However, once again, a detailed analysis enabled Se.Po. to identify the only possible solution: a mobile track that can be shifted out of the way to allow the positioning and coating of taller parts.”
The second lubrication system, installed on line #3.
A phase of the powder application process performed on line #3.
An eye on the future
Air.ver. has many projects in the pipeline. “One of the most significant is implementing AI into our company management system,” states Colombo. “We are training a ‘digital person’ who will be available 24 hours a day to respond to customer requests, to the point that one day, after gathering the necessary information, it will be able to send us an email directly with a request for a quote. In addition, an internal system will be available for our operators to check the parameters of all the coating cycles to be performed without having to move from their workstations.”
From a business development perspective, Air.ver., which is already ISO 9001 and 14001 certified, aims to obtain ISO 45001 and gender equality certification by the end of the year, while its goal for 2026 is Qualisteelcoat certification. “To achieve these objectives, we will continue to work on improving our lines,” Colombo adds. “We would like to implement nanotechnology in the chemical pre-treatment tunnels and further upgrade the handling systems.”
“Our growth path will once again lead us to Se.Po. Every time, we challenge its team with increasingly complex revamping or modification requests, especially because our production area cannot be expanded further. Over the years, its collaboration has been key to the evolution of our processes. Its advice has been crucial in the past, is crucial now, and will continue to be crucial in the future: for these projects, I can only trust Marco,” says Colombo with great enthusiasm.
Some details of the Se.Po. conveyor installed on line #4.
Line #5: in the photo above, the mobile track designed to allow coating components taller than 2.5 m.
ANALYSIS
Dispersions hold the key for carbon nanotube success, finds IDTechEx
Dr. Conor O'Brien Senior Technology Analyst at IDTechEx Ltd - Cambridge, United Kingdom research@idtechex.com
Dispersion is the decisive factor for unlocking the potential of carbon nanotubes. Properly dispersed CNTs can enhance mechanical, electrical and thermal properties in polymers and coatings, opening the way to multifunctional and more sustainable materials.
The effective dispersion of carbon nanotubes (CNTs) is critical to their commercial success in applications such as energy storage and polymer composites. Their high aspect ratio and strong van der Waals forces lead to agglomeration, limiting performance if not properly managed. Achieving a uniform, stable dispersion is essential to fully realize CNTs’ electrical, mechanical, and thermal benefits, while also reducing required loadings and improving processing. As the market evolves, dispersion is increasingly seen not just as a technical challenge, but as a key factor in product performance and scalability.
The IDTechEx report, “Carbon Nanotubes 2025–2035: Market, Technology, Players”1, provides a comprehensive overview of the CNT market, including in-depth analysis of key application areas, leading industry players, and granular 10-year forecasts for CNT demand (in tonnes per annum) and market value (in USD), segmented by application. With over a decade of experience covering the nanocarbon sector, IDTechEx delivers an independent, third-party assessment offering valuable insight into this evolving market.
Multi-walled carbon nanotubes (MWCNTs) are used in various applications, but their most impactful roles are as additives in energy storage and polymer systems. With growing demand for electrification, the CNT market is rapidly expanding. In lithium-ion batteries, MWCNTs enhance conductivity and mechanical strength, enabling higher energy density, thicker electrodes, and broader operating conditions.
The IDTechEx report provides detailed analysis of dispersion methods, binder compatibility, and additive interactions, and also explores emerging developments in supercapacitor applications.
Key applications for dispersions
Whether used in standalone polymer matrices or fibre-reinforced composites, CNTs offer valuable benefits as additives, including improved interlaminar strength and enhanced electrostatic discharge performance. While established in applications like fuel systems and electronic packaging, increasing volumes from the energy storage sector and declining costs are expected to enable wider adoption across new markets over the next decade.
The main incentive for dispersing nanocarbons in polymer composites is to provide multifunctional properties. Mechanical properties are typically at the fore. Fracture toughness can be improved through mechanisms such as crack deflection and/or crack bridging, while applied stress and strain can be transferred from the matrix to the nanocarbon reinforcing agent through interfacial contact. Further mechanical properties that could be improved include impact resistance, interlaminar shear strength and compressive strength. Beyond mechanical properties, conductivity can be imparted with low loadings (<3 wt%) above the percolation threshold. Multifunctional conductivity can enable applications such as lightning strike protection, de-icing and thermal management.
Technical challenges
A major problem for CNTs is translating the often hyped, superlative qualities to the macroscale in a tangible product. CNTs boast impressive properties, including tensile strength, thermal conductivity, electrical resistivity and charge carrying capacity, but CNTs are not a magic powder that can be sprinkled into a composite formulation to unlock increased performance. Incorporating the material into a polymer can involve masterbatches, while energy storage applications typically use a conductive slurry containing CNTs and other carbon materials such as carbon black.
Many challenges exist when considering CNT dispersions. Achieving a homogeneous dispersion of nanocarbons through a polymer matrix is not a straightforward activity, especially when considering the forming and moulding of plastic components. Adding nanocarbon additives can impact the flowrate and viscosity of composites for extrusion moulding, while multistep processes for fibre laminates may require alterations to the curing times given the presence of the new additive. Since being acquired by leading carbon black player Birla in 2023, Nanocyl has developed a hybrid carbon black and CNT material for conductive polymers. The hybrid material bridges the gap between the two materials, but some difficulties remain, particularly around dispersion.
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CNTs disperse under high shear, while CB disperses at low shear. To overcome issues with dispersion for end users, masterbatches are provided in PP, PC and HIPS, all with a combined 30 wt% of the hybrid nanocarbon.
An often-seen misunderstanding for nanocarbon composites is the concept that one size fits all - in that one material can provide all property enhancements, in all matrices. Different grades of CNTs are suited for different applications, while the amount of additive required varies by application. Typically, optimal mechanical improvement can be seen for loadings around 0.1 to 1 wt% and even lower, while the conductivity threshold usually exists at a higher loading. As such, multifunctionality is difficult to optimise across a range of metrics such as mechanical and conductive properties, however thermal and electrical conductivity are often seen operating complementarily.
Commercial success
A key challenge in utilizing CNTs is achieving a homogeneous, nonagglomerated dispersion, which is essential for maximising performance and enabling lower loadings. While many companies claim in-house capabilities for effective dispersion, there is a growing trend toward
outsourcing this process to specialised third-party providers. Specialist players such as Toyocolor and NanoRial are emerging, with the latter operating in partnership with companies such as CATL and NEO Battery Materials.
Internal and in-house capabilities should not be dismissed, with several CNT players moving downstream and seizing more of the value chain. LG Chem have established extensive vertical supply chains to provide CNTs for energy storage applications, typically applied as a conductive slurry. Cnano are a global leader by manufacturing capacity and provide both CNT powders and pastes to the market, with IDTechEx analysis showing that the sale of pastes has accounted for more than 95% of received revenue, annually, over the period from 2018 to 2024 showing the importance of moving downstream for CNT suppliers.
“Carbon Nanotubes 2025–2035: Market, Technology, Players” offers a definitive analysis of the CNT market. Drawing on IDTechEx’s extensive experience in nanocarbons, the report combines in-depth technical insight with an interview-led approach to deliver objective market forecasts, thorough benchmarking, and detailed evaluations of key players in this fast-evolving industry.
COLOUR STUDY
AkzoNobel unveils the 2026 Colour of the Year: Rhythm of Blues™
Edited by AkzoNobel N.V. Amsterdam - The Netherlands
AkzoNobel presents Rhythm of Blues™, the colour family selected as the 2026 Colour of the Year. The palette is versatile and inspiring, designed to create spaces that are at once calming, connected, and creative.
It’s time to dance to the Rhythm of Blues™ and celebrate AkzoNobel’s Colours of the Year 2026 – an upbeat and versatile colour family that’s calming, connecting and creative. There’s a trio of shades for next year – the light blue Mellow Flow™, the dark blue Slow Swing™ and the vibrant Free Groove™ – so everyone can find a style that works for them. See them in detail:
Slow Swing™: this tone was designed for a quiet, calming space where you can pause, focus on what truly matters, and recharge your energy. Its contemplative shades create an atmosphere of tranquillity.
Mellow Flow™: this shade is intended to bring warmth and harmony to a space, inviting people in and encouraging connection. It’s perfect for creating a welcoming and cosy environment.
Free Groove™: created for playful and energetic spaces, this vibrant tone inspires creativity and imagination. It’s ideal for injecting energy and encouraging out-of-the-box thinking.
The harmonious collection of signature indigos is just what we need in our homes, according to the results of the company’s extensive annual trend research. “With everything that’s happening in the world, we see that people are reacting in various ways,” explains Heleen van Gent, Creative Director of AkzoNobel’s Global Aesthetic Center. “They’re either slowing down and recharging their batteries, wanting to feel in tune with others and celebrate kinship. Or they’re choosing to be bold, have fun and feel carefree.” She adds that the three colour palettes will help create living environments that fit everyone’s individual decorative needs. “To reflect these various moods – and because we understand that colour is emotion and therefore personal – we’ve chosen a family of colours for 2026. They’re centred around three different rhythms that offer endless scope for changing the pace of your space.”
The colours, textures and special effects that take centre stage in the Rhythm of Blues collection have been designed to strike a chord in a wide range of markets.
Along with decorative paints, inspirational palettes have also been created for the aerospace, automotive, consumer electronics, metal furniture, lighting, cabinetry, flooring, building products and architecture markets.
“We pride ourselves on setting the tone together with architects, interior designers, trend specialists and product developers – who all make important contributions to our in-depth research,” says Daniel Geiger Campos, Global Director of AkzoNobel’s Decorative Paints business and member of the Executive Committee. “Our Rhythm of Blues family is perfectly in tune with evolving trends in various industries and will help us deliver market-specific solutions to customers so they can more confidently apply their own style to their projects.” AkzoNobel’s Global Aesthetic Center has been translating trends into desirable colours for more than 30 years. Its annual ColourFutures trend forecast meeting brings together in-house experts, international architects, designers and journalists to share insights into how our reactions to the world around us impact our colour choices.
Slow SwingTM
Mellow FlowTM
Free GrooveTM
Scan the QR code to watch the 2026 Colours of the Year presentation
Siemens’ all-electric paint line sets new standard for decarbonisation in manufacturing
Siemens’ all-electric paint line is a powerful demonstration of how innovation in even the most overlooked processes can drive real climate progress.
Siemens is turning heads in the finishing industry with a bold leap forward in sustainability: the installation of an all-electric paint line at its Electrical Products facility in Grand Prairie (Texas, USA).
Long viewed as a challenging area for carbon reduction, paint finishing has now emerged as
a surprising front-runner in decarbonisation, thanks to this major innovation.
Siemens reports that, while paint lines may seem an unlikely source of environmental progress, the impact of transitioning from traditional fuel-based systems to a fully electric setup has been dramatic. The
new system significantly cuts emissions, improves energy efficiency, and serves as a model for other manufacturers seeking to modernise operations without compromising performance.
This industry-leading development took centre stage at the IHEA 2025 Industrial Heating Decarbonisation SUMMIT, held from 29th September to 1st October 2025 at the Conrad Indianapolis. Siemens detailed how its next-generation paint line not only reduced carbon output but also set a blueprint for sustainability in industrial finishing.
In addition to Siemens’ showcase, the SUMMIT featured:
Six in-depth case studies highlighting realworld decarbonisation success stories.
Expert presentations on topics such as lowcarbon fuels, grid electrification, and managing environmental risk.
A tabletop exhibition featuring top-tier suppliers and innovative technologies.
Actionable ideas for improving energy efficiency and meeting sustainability goals.
Extensive networking opportunities with peers and industry leaders.
ROAD TO 2050
GARDCO announces global transition to PFAS-free products
This strategic decision aligns GARDCO with emerging international regulations and growing market expectations, while underscoring the company’s commitment to environmental protection and customer wellbeing.
GARDCO, distributors, producers and designers of high-quality physical and inspection instruments for the paint, coatings and related industries, has announced a significant sustainability milestone: the worldwide phase-out of all products containing PFAS. The move covers all products containing Teflon, including Tecom applicators, Teflon-coated thermometers and disperser blades. PFAS, widely referred to as “forever chemicals” due to their persistence, bioaccumulation and ecological toxicity, have become the subject of increasingly stringent regulations across the globe. Several individual PFAS compounds, including PFOA and PFOS, are already restricted, and the European Union has introduced the first group-wide ban.
James Fusco, Product Manager at GARDCO, explained: “Due to restrictions under chemical regulations there was an urgent need to phase out the PFAS products in our portfolio.” He continued: “Our decision is driven by an urgent need to protect sustainability, comply with global laws, and meet the needs of our customers.”
Key benefits of the transition include:
Environmental: Eliminating highly persistent and toxic substances, helping to safeguard ecosystems.
Regulatory compliance: Ensuring alignment with global standards and anticipating future legislation.
Business opportunities: Attracting customers who are actively seeking PFAS-free solutions.
Efficiency: Reducing regulatory complexity across departments and strengthening organisational sustainability.
Market acceptance: Enhancing perception by removing harmful chemicals from product ranges.
PFAS-free alternatives
GARDCO’s technical teams are managing the changeover to ensure customers experience no disruption to service or product performance. Effective non-stick alternatives such as Cerakote and other substitute materials are already in place for the affected lines.
The company is closely monitoring progress, keeping customers regularly updated, and introducing innovative, sustainable formulations designed to deliver the same trusted results without environmental compromise.
SUCCESS STORIES
Dürr building a CO2-efficient paint shop as a turnkey project for Volkswagen
Dürr has built a paint shop designed to slash CO2 emissions at one of the Volkswagen Group’s biggest manufacturing facilities. The plant in Puebla, Mexico, was inaugurated in January 2025. The turnkey project includes two identical painting lines that are particularly environmentally friendly due to their electrified equipment, such as the electric drying system. Dürr is also implementing key components of its new “Paint Shop of the Future” concept with a high-bay warehouse and driverless transport systems.
Since January 2025, the Puebla Volkswagen plant paints 90 vehicle bodies per hour of different models. Dürr was awarded the contract in 2022. The innovative paint shop is engineered to seamlessly accommodate additional models and emerging future technologies. This adaptive capability aligns with the high-output nature of the production plant and is made possible by a central highbay warehouse and the EcoProFleet driverless transport system. DXQ
software controls the AGV (automated guided vehicle) developed specifically for paint shops that predictively sorts the bodies in combination with the high-bay warehouse and brings them to the right work deck or collects them with pinpoint accuracy. Dividing rigid production lines is a central tenet of Dürr’s “Paint Shop of the Future” concept and shortens the overall process by tailoring the process time exactly to the individual vehicle. This fact alone significantly reduces overall CO2 emissions.
Painting technology for high model variance
The two identical painting lines feature 170 sealing and painting robots, with the corresponding application technology for sealing and coating the different Volkswagen models in the future.
This encompasses EcoRS Clean F, a prime example of Dürr’s efforts to bolster system technology to equip it for growing model diversity. It combines the thorough, gentle cleaning prowess of a feather roller system with the high flexibility inherent to a robotic setup. This makes it perfect for lines that paint many body variations with complex contours. The contract scope also includes the complete paint and PVC supply and software solutions with AI applications from Dürr’s proprietary DXQ product family.
Dürr’s EcoInCure ovens operate with electricity, reducing CO2 emissions.
Substantial reduction in CO2 emissions
A central factor in CO2 emissions reduction is body drying since it consumes the most energy in the painting process. Operating the ovens with regenerative energy, like green electricity, reduces the CO2 emissions from the overall system by around 40 percent compared to a paint shop using natural gas. “This was one of the reasons why Volkswagen opted for the EcoInCure electric drying system,” explains Bruno Welsch, COO Automotive at Dürr. “Another is its special air duct system that heats the bodies from the inside out. This technology results in more uniform heating and cooling behaviour and reaches solid body components like the rocker panels more directly than conventional systems, cutting the body heating times by 30 percent.”
Electric package concept for oven and exhaust air purification
Another cornerstone for minimizing CO2 emissions is linking the electric oven to an electric air pollution control system. Dürr is the only provider on the market with an overall blended concept of this kind. It combines the EcoInCure with an Oxi.X.RV, an electric exhaust air after-treatment system that purifies the polluted exhaust air using the principle of regenerative thermal oxidation (RTO) - with no open flame. Unlike conventional combustion processes, no additional CO2 is produced by the operation. The system is also extremely energy efficient and achieves autothermal operation even with small quantities of solvent, i.e., it maintains its operating temperature by itself. It uses the significant energy produced during oxidation of the solvents to keep its process going. Dürr has also installed an energy-saving, environmentally-friendly system for overspray separation. EcoDryScrubber uses limestone powder as a natural binder to separate paint overspray. Highly efficient HEPA12 filters remove all particles from the process air. The saturated limestone powder is disposed of fully automatically via a piping system – with no process interruption. The dry separation system at Volkswagen Puebla minimizes the required fresh air supply to 5 percent maximizing the proportion of recirculated air. This reduces the paint booth’s energy consumption by well over 60 percent compared with wet scrubbing.
EcoDryScrubber uses limestone powder as a natural binder to separate paint overspray.
Dürr’s EcoRP painting robots will paint the Volkswagen bodies in Puebla in the future.
When colour picks up speed: Color Trend Consultant – Bicycles is born
Lechler Tech presents Color Trend Consultant – Bicycles, a colour proposal divided into four collections – Racing, Off-Road, Touring and City – offering 24 selected shades, which can be combined and applied with either solvent- or water-based technology, in matt or glossy finishes.
Colour is no longer a simple aesthetic detail: it’s an extension of personality, a technical choice, a style statement. Lechler Tech presents Color Trend Consultant – Bicycles, born from this vision, while transforming the frame into a design canvas where design, chemical innovation, and context of use merge.
Four colour collections – Racing, OffRoad, Touring, and City – express the heart of bicycles through 24 selected and matching hues, each conceived to interact with the environment, riding style, and application technology. It’s not just about colours, but about effects, finishes, and versatility: the range allows for monochrome and dichromatic variations, brightness adjustments, material contrasts and special effects obtainable in solvent-base and water-borne products.
This is just a small preview of what customised bicycle colour offering can become, thanks to the support of Lechler’s R&D Colour Department.
The proposal is not limited to just colour possibilities, but also introduces chemical innovations.
Most of the presented solutions can be applied with both solvent-based and water-borne technologies, in matt or glossy versions, as described in the guide.
The diagram positions the four collections according to colour contrast, temperature, saturation, and finish. The horizontal axis represents the transition from matt to gloss and from warm to cool tones. The selected colours are inspired not only by the style of bicycles, but also by the natural and urban contexts in which they are used.
The four colour collections
Racing: colour schemes highlighting speed and dynamism when racing. The palette ranges from bright and dark colours to desaturated neutral pearl effects.
Off-Road: Colour schemes with complementary colours and continuity with the wild nature. The palette is composed of lively and luminous tones of medium intensity.
Touring: Colour schemes with dark and shadowy neutral colours, enriched with effects dedicated to long-distance travel with specific equipment.
City: Colour schemes with solid colours, low and medium saturation and brightness, designed to harmonise with the urban lifestyle, the inhabitants’ clothing and the surrounding architecture.
Colours
A multi-coloured range including yellow, orange, red, purple, blue, and green, available in different brightness, saturation, and effects. Many of the collection’s colours, thanks to the applied effects, create the impression of multiple shades depending on the shape and intended use of the bicycle frame.
Finishes
In line with current trends in the cycling industry, satin-matt (approximately 20 GU) and gloss (over 90 GU)1 finishes are available. The range includes solid colours and special effects, such as pearl and Starglass.
It’s not just about choosing a colour: it’s about building identity, differentiation and perceived value. And today the collection is in customer hands.
For further information: www.lechler.eu/en/
Boost viscosity performance of silica without impacting transparency
Evonik’s TEGO® Viscoplus 105 is an innovative addition to the Coatings Additives portfolio, specifically developed to enhance the rheological performance of fumed silica in coating formulations. It allows for improved rheological control without compromising transparency – particularly beneficial in systems where fumed silica usage is limited.
This product is ideally suited for applications such as automotive OEM clear coats, gel coats and unsaturated polyester systems, as well as general industrial solvent-borne coatings.
Scan the QR-Code to download the fact sheet!
Kolzer becomes Kolzer International: a new industrial group
connecting Europe and the United States
Kolzer Srl joins a team of established U.S. industry experts with a new U.S. base and a shared global vision.
Kolzer Srl, a historic European manufacturer of vacuum coating systems using PVD (Physical Vapor Deposition) technology, has officially joined Kolzer International, a new industrial group formed in collaboration with a team of established U.S. industry experts in advanced manufacturing and surface technologies.
The merger, completed on July 10, 2025, marks a strategic industrial and commercial turning point for Kolzer. The company is now part of an international organization with operational hubs in Milan and Minneapolis, combining European engineering excellence with direct presence in the North American market.
“Kolzer International is not just a new name, it is a technology and business platform built to serve key markets with precision, while staying true to our technical DNA,” said Davide D’Esposito, CEO of Kolzer Srl.
PVD 2.0, 75 years of innovation
Founded in 1952, Kolzer has spent over 75 years developing advanced vacuum coating technologies, delivering high-performance, customized solutions to industries such as automotive, fashion, electronics, cosmetics, aerospace, and luxury packaging. With more than 1,300
systems installed worldwide, the company is recognized as a pioneer of the “PVD 2.0” generation: efficient, flexible, and sustainable vacuum coating systems.
The new U.S. facility, Kolzer International Company (KIC), will offer high-profile machine manufacturing, lab coating services, and local after-sales support. KIC will focus specifically on decorative and designdriven applications, working closely with American customers and partners.
Kolzer International also plans future expansion in the Asian market, with the goal of scaling global manufacturing capabilities and meeting the demands of a fast-evolving industry. Depending on project needs and logistics, machines may be manufactured in either Europe or the United States.Kolzer International represents the evolution of a highly specialized European company into a global, scalable, and operational industrial group. It combines advanced technology with industrial reliability to lead the new generation of high-performance, sustainable surface finishing solutions.
For further information www.kolzer.com
X-Rite showcases colour innovations and smarter digital workflows at plastics and coatings events across North America
From cloud software to precision instruments, X-Rite empowers manufacturers to digitise colour workflows, accelerate approvals, reduce waste, and prepare for an AI-driven future.
X-Rite Incorporated is set to present its latest innovations in colour management at key industry events across North America this autumn. These include Coatings Trends & Technologies, Western Coatings, and Advanced Design & Manufacturing.
The company will be demonstrating its new Judge LED light booth and Autura™ Effects formulation software, both designed to help plastics and coatings manufacturers digitise workflows, streamline approvals, reduce waste and prepare for an AI-enabled future.
“To embrace AI and other advanced manufacturing technologies, manufacturers need quality data, and that starts with digitising processes, including colour workflows. X-Rite offers connected, end-to-end digital colour workflow solutions that make it easy to specify, produce, control, and monitor colour across the supply chain. This allows manufacturers to create a strong colour data foundation to accelerate approvals, reduce waste, and fully leverage AI-driven automation,” has stated Matthew Adby, Product Management Director, X-Rite.
X-Rite will highlight its latest solutions designed to enhance each stage of the colour journey—from design and formulation through to quality control:
Autura™ Cloud-Native Software: This cloud-based platform streamlines colour formulation for effect finishes using advanced prediction models. Autura reduces colour corrections from seven steps to just two or three, cutting material use and approval timelines.
Judge LED Light Booth: Enables accurate assessment and evaluation of colour under standard LED light sources, in line with the global move towards energy-efficient and sustainable lighting.
Colour iQC: Available on subscription, this quality control software tracks colour from specification to production and assembly, with tools to intelligently automate processes and minimise errors.
Ci7860 Sphere Benchtop Spectrophotometer: Provides industryleading inter-instrument agreement and repeatability across opaque, transparent, translucent and brightened samples.
“By combining advanced prediction models and digital workflows, customers can achieve greater precision, faster results, and more sustainable outcomes,” has added Matthew Adby.
For further information: www.xrite.com
IGM Resins announces reclassification of Omnirad® 184:
1-Hydroxycyclohexyl-phenyl ketone
The reclassification underlines the growing importance of safer and more sustainable solutions in the industry. IGM Resins affirmed its commitment to guiding partners through this change with reliable alternatives.
IGM Resins has announced that
1-Hydroxycyclohexyl-phenyl ketone (CAS no. 947-19-3), commercially known as Omnirad® 184 and Omnirad® 184D, has been reclassified as a Reproductive Toxicity Category 1B substance under EU REACH regulations. The photoinitiator, widely used in the energy curing industry for its consistent performance across diverse applications, is registered in Europe by IGM Resins under Annex IX.
“The new toxicological results are showing that the product is a reprotoxic substance. As a result, Omnirad® 184 is now reclassified with immediate effect as Reproductive Toxicity Category 1B under EU REACH regulations. This regulatory shift introduces new compliance obligations for formulators and manufacturers, especially in Europe and North America,” has stated the company.
The reclassification follows additional in vivo genotoxicity testing (OECD 414) required by the European Chemicals Agency (ECHA), for which IGM Resins acted as lead registrant. This regulatory change is expected to impact the handling and use of Omnirad® 184 across the industry.
IGM Resins emphasised its commitment to supporting customers in identifying suitable alternatives. “While a universal substitute may not suit every formulation, we recognise the importance of offering options that align with both performance needs and regulatory compliance. Thanks to our constant innovation and ongoing development of photoinitiators, iGM Resins is well positioned to offer a broad range of solutions, from standard products to advanced, high-performance alternatives.”
The company recommends the following options:
Omnirad® 1173 – A low molecular weight photoinitiator with good reactivity under Hglamp, low yellowing, excellent formulation compatibility, and liquid form for easy handling. Its higher evaporation rate may result in easier dirty collection on lamps and a stronger perceived odour during use. Produced at IGM Resins’ Mortara, Italy site, it offers reduced delivery times in Europe and a complete Life Cycle Analysis.
Omnirad® 601 – A solid photoinitiator suited for applications requiring high reactivity and very low yellowing. Its higher molecular weight and functionality lead to reduced odour and emissions, though solubility is more limited than Omnirad® 184.
Omnirad® 2509 – An intermediate, economical liquid photoinitiator that delivers good surface cure, low yellowing, and formulation stability for both inks and clear varnishes.
Omnirad® 184 belongs to the class of alpha hydroxy ketones (AHK), which are Type I photoinitiators. IGM Resins offers a range of mono- and di-functional AHK products, with the full list available in its product brochure.
“IGM Resins’ technical experts are ready to support customers in identifying the most suitable alternatives to Omnirad® 184. We work case by case, ensuring each application— whether in coatings, inks, or adhesives— receives a tailored approach. This includes formulation guidance, performance testing, and regulatory advice to ensure minimal disruption during the transition,” has added the company.
For further information: www.igmresins.com
Improved electrophoresis performance with ultrafiltration membrane technology
SG Projects supports Italian companies in the advanced management of cataphoresis processes, offering targeted solutions and ongoing assistance to optimise their ultrafiltration lines. The adoption of membrane systems improves coating quality, reduces waste, and ensures a more sustainable closed-loop production process.
Among the membrane technologies available today, ultrafiltration stands out for its versatility and reliability. It is a process that uses pressure-driven semi-permeable membranes to separate the components of a solution based on their size and molecular structure. The smallest particles, such as water, solvents, and some dissolved substances, pass through the membrane and are collected as permeate, whereas macromolecules, polymers, and impurities are retained, concentrated on the opposite side of the membrane, and recovered as concentrate. This technology is now widely used in many sectors, from industrial water treatment to the food, chemical, and coating industries. Its strength lies in the ability to set up closed-loop systems, thus reducing waste and ensuring greater process efficiency.
Applications in the cataphoresis sector
One of the areas in which ultrafiltration has found a role of primary importance is dip coating and, more specifically, cataphoresis. The heart of this process is the cataphoretic bath, in which metal components are immersed and coated by electrodeposition. At the end of this phase, the coated parts are rinsed with ultrafiltrate. This is where ultrafiltration comes into play. In cataphoresis plants, the permeate obtained through ultrafiltration consists mainly of water and solubiliser and is generally reused in the rinsing section of the coating line. This creates a closed-loop circuit that allows recovering the paint’s solid component, called ‘drag out’. In some cases, part of the permeate may be sent to the drain to keep the conductivity of the paint solution under control.
Yield-affecting factors
The paint recovery degree achieved depends on several operating variables, first and foremost the amount of rinse water introduced into the bath. This value corresponds directly to the volume of filtrate generated, and it is related to the surface area of the membrane and the recirculation of paint to determine the ‘specific capacity’ of the filtrate. This parameter varies depending on the type of paint product used and can be influenced by additional factors such as operating pressure, temperature, solids
From left to right:
The ultrafiltration membranes supplied by SG Projects.
An ultrafiltration system.
Filtration processes.
concentration, cross-flow, and any contamination generated during pretreatment. To ensure consistent performance, it is therefore essential that the replenishment products are always compatible with ultrafiltration.
Recovery and sustainability
From an environmental point of view, ultrafiltration is an important ally in reducing the impact of electrophoretic coating processes. When the treated components are removed from the bath, up to 30% of the paint used can end up in the wastewater as residue: without an adequate recovery system, the coating solution would be lost, resulting in additional costs and greater volumes of waste to be treated. Thanks to membranes, however, water and paint can be reintegrated into the production cycle, significantly reducing both consumption and waste. In many plants, this translates into a reduction in operating costs of up to 30%, as well as an overall improvement in coating quality.
The advantages of ultrafiltration in cataphoresis
The use of membranes brings numerous concrete benefits:
High-quality, clean, and transparent filtrate, suitable for reuse in rinsing;
Compact and automated systems, easy to manage and safe for operators;
Reduced energy consumption thanks to the robustness and efficiency of the equipment;
High water flow rate, suitable for the recovery of cathodic and anodic paints;
Greater resistance to contamination, with prolonged operational continuity.
It is therefore not surprising that ultrafiltration is now established as a benchmark technology for the electrophoretic coating of car bodies, household appliances, metal accessories, and other components for various industrial sectors.
Best practices for membrane maintenance
To ensure consistent performance over time, it is essential to adopt targeted maintenance procedures. After a few hours of operation, the flow through the membranes tends to decrease until it stabilises; when a drop of approximately 30% compared to the reference value is detected, thorough cleaning is necessary to prevent irreversible scaling.
One of the main critical issues to be monitored in the operation of ultrafiltration systems is unscheduled shutdowns: paint should never remain stationary inside the circuit, as this could cause permanent contamination of the membranes. In the event of a shutdown, it is essential to immediately drain the system, rinse with demineralised water, and start a chemical cleaning procedure.
The addition of resins, pigments, or solvents to the coating solution also demands attention. These must be introduced gradually and away from the inlet of the ultrafiltration pump so as not to compromise the efficiency of the process. Similarly, any sediments and agglomerates in the paint can damage the membranes, making a pre-filtration phase critical.
Paint fouling is another significant issue: when dispersion is unstable, the particles tend to aggregate and form rubbery agglomerates that hinder the flow through the membrane. To ensure correct operation, it is therefore fundamental to preserve the paint’s stability by carefully checking the pH value, solubiliser levels, the presence of any metal contaminants, and the recirculation flow rates throughout the system.
A constantly updated maintenance log, finally, allows preventing critical issues, identifying the causes of any drops in flow, and ensuring efficient management of the entire system.
The future of finishing among AI, new talent, and sustainability: building tomorrow’s supply chain today
Manuela Casali
UCIF – Italian Surface Treatment Equipment Manufacturers’ Association, Milan, Italy
ucif@anima.it
The surface treatment industry is undergoing a transformation that goes far beyond technology. Three trends are redefining the boundaries of industrial finishing: artificial intelligence, young talent, and sustainability. Investing in these assets today means laying the foundations for a solid and competitive supply chain in the future.
UCIF is always attentive to the signs of change, as also demonstrated by SMART, whose fourth edition is already planned for 2026. After focusing on innovation and sustainability in 2024, we will take a closer look at AI, which is now a key topic in finishing, too – it is no coincidence that the title of SMART’26 is designed to be an actual prompt. So, how do finishing and these trends interact and integrate?
AI as the new standard in finishing
These are no longer futuristic visions: AI is already entering finishing plants.Artificial vision algorithms enable real-time quality control, reducing waste and improving accuracy. Predictive maintenance, based on data analysis, optimises plant efficiency and prevents machine downtime. The next step? Integrated systems that allow process parameters to be adjusted autonomously, thus reducing energy, water, and product (e.g. paint) consumption.
Young talent, a key resource for the finishing sector
Innovation demands new skills. That is why it is essential to attract and train young engineers, technicians, and researchers.
Universities and technical institutes are launching more and more courses on surface engineering and treatment technologies. At the same time, companies have the opportunity to promote internships, internal academies, and joint projects that bring young people closer to the world of finishing. Even more than machines, human capital is what is going to make the difference.
Sustainability as a competitive advantage
Sustainability is no longer just a regulatory obligation but rather a competitive driver. Low-energy consumption plants, powder recovery systems, water-based paints, and emission reduction solutions are already a reality. Companies that have taken this path are reaping not only environmental but also financial and reputational benefits. The key is to move from a logic of compliance to one of creating sustainable value.
Building tomorrow’s supply chain today
AI, new talent, and sustainability are not separate matters, but rather gears in the same mechanism. A competitive sector arises from integration: advanced technologies managed by competent and motivated people, capable of generating more sustainable processes.
We should not be waiting for the future of finishing: we should build it today. And this requires a concerted effort, calling for collaboration among companies, institutions, and new generations.
3D animation: the future of industrial presentations
Davide Franceschini
Timecore, Monza (Italy)
Visual communication is taking on an increasingly central role in today’s industrial world. Among the technologies that are revolutionising the way products and processes are presented, 3D animation is emerging as a strategic tool capable of transforming technical complexity into a clear, engaging, and accessible language.
3D computer graphics have become a key tool for companies in the mechanical and industrial sectors. Renderings and, above all, three-dimensional animations allow exploring products in every detail, overcoming all the limitations of photos and technical data sheets. With 3D animation, it is possible to show a machine in operation, ‘explode’ it to view its internal components, and simulate its use in authentic contexts. This dynamic approach not only clarifies the operating principles of complex products, the dynamics of material or fluid flows, thermal cycles, and automation sequences but also communicates innovation and professionalism. In manufacturing, for example, it becomes possible to show the path of a metal sheet inside a press or the course of a coating process, highlighting each stage with extreme clarity.
Striking realism for an immersive experience
Unlike traditional static images or simple renderings, 3D animations can illustrate the inner workings of machines, plants, and production lines with surprising realism. Through dynamic simulations, it is possible to show not only the external appearance of a component but also its mechanisms, assembly stages, and the energy and material flows that pass through it. This approach is particularly valuable in fields such as automation, mechanical engineering, and robotics, where the complexity of systems calls for a high level of detail. 3D animations are not only a technical tool but also a powerful marketing and training medium. For example, at trade fairs, they allow bulky machinery to be presented without the need to physically transport it, offering visitors an immersive experience. In corporate educational programmes, they support learning by reducing the time and costs associated with practical training. These videos are also perfect as corporate presentations or to support the sales force, as they capture attention and overcome technical and linguistic barriers.
How Timecore can help you
Looking to the future, it is clear that 3D animation will become increasingly central to industrial communication. It is not just a matter of aesthetics but also a competitive advantage, as using it effectively enables conveying value, innovation, and expertise in an immediate and memorable way.
In addition to 3D animation, Timecore specialises in the design and construction of stands and exhibition corners for trade fairs, events, and conferences. A well-designed stand can be a valuable communication tool, and integrating it with technologies such as LED walls or large screens is now simply essential, especially if showing engaging, eyecatching videos.
This ensures two advantages: on the one hand, it creates a strong visual impact during the trade fair, and on the other, it optimises the investment because the videos produced can be easily reused on different channels, including websites, social media, conferences, or workshops. In this way, every piece of content becomes a true asset, capable of communicating in a way that is always relevant. Timecore can thus help companies grow by transforming visual communication into a fundamental strategic tool. Nowadays, offering good-quality products is no longer enough: knowing how to communicate it and making it understandable and, above all, memorable is also vital.
Visibility and recognisability: corporate videos, 3D animations, and renderings can make a company stand out from its competitors.
Sales support: a video that shows how a machine or complex process works in a few seconds is much more effective than a technical brochure, also making negotiations more successful.
Event enhancement: a well-designed and constructed stand with LED walls and large screens is more appealing and professional-looking.
Versatile and long-lasting content: videos become reusable tools, multiplying the return on investment.
Perceived innovation: communicating with modern and visually impactful tools strengthens a company’s image.
Tailored training: customised in-company courses from ipcm® Academy
Federico Melideo, ipcm®
Over the years, ipcm® Academy has developed a high-quality offering dedicated to the world of industrial coating and surface treatments. Alongside its calendar of standard courses with theoretical and practical modules, it provides an exclusive service of customised training courses, carried out directly at companies’ premises and designed to target any specific operational need.
In the industrial coating market, training has become a strategic factor in maintaining process quality, increasing production efficiency, and promoting the development of technical skills. ipcm® Academy’s programme provides a solid foundation for this: our courses are structured into theoretical and practical modules that offer fundamental, up-to-date knowledge for companies to maintain high standards of expertise and professionalism.
Alongside this established offering, ipcm® Academy also provides customised courses developed in collaboration with individual companies and held directly at their premises. Each training programme is designed to take into account the specific characteristics of the materials handled, the technologies used, and the workflows’ structure, translating into tools that can be immediately applied in everyday work.
Thanks to this tailor-made approach, the theory acquired is immediately put into practice: participants learn how to manage their company’s processes more effectively, reduce errors and waste, make the most of available resources, and adopt clearer and more standardised procedures to optimise their day-to-day tasks. At the same time, the company consolidates its internal expertise, strengthens the professionalism of its technical team, and enhances its ability to address new production challenges with greater competitiveness and flexibility.
Why opt for personalised in-company training?
Every company operating in the industrial coating sector has its own specific characteristics in terms of processes, equipment, and work organisation. To respond to these peculiarities, ipcm® Academy’s customised courses are designed to adapt to the concrete needs of each business.
The most suitable curriculum is developed in full collaboration with the company to identify the most significant subjects and tailor the topics to the participants’ needs. Each module focuses on the materials, technologies, and procedures in use, with practical examples that reflect the daily activities of the department. The schedule is also defined flexibly in collaboration with the customer to avoid interrupting production and optimise time and resources. Training thus becomes an integral part of the company’s activities, with a concrete and immediate impact on its processes.
From the initial needs analysis to the final course design, ipcm® Academy works closely with each customer to offer effective, targeted training courses built on its real production and organisational needs.
Modular and customisable content
The courses available cover a wide range of topics that are of fundamental interest to the industrial coating and surface treatment sector, from corrosion prevention and pre-treatment to the application of powder and liquid paint products. Control methods, measuring instruments, systems, and equipment, as well as safety maintenance activities, are thoroughly examined.
The programme can also cover more specific aspects, including failure analysis, process documentation, investment management, industrial accounting, and reference standards, such as ISO 12944 for the protection of steel structures. It is also possible to incorporate modules on PVD coating, coil coating, and plastic coating. Each course combines theory and practice based on the participants’ initial skills and the objectives to be achieved. As a result, our training programmes are never standardised but provide concrete and immediately applicable tools for improving the quality, efficiency, and safety of production processes.
Training turned into a real strategic investment
Opting for a personalised learning path means understanding training as a strategic element that can generate long-term value for the company. In addition to improving the technical skills of staff, tailored courses promote the development of a shared culture of quality, safety, and efficiency in production processes. The company benefits from increased operational flexibility, thanks to teams that are better equipped to tackle production challenges and departments that can quickly adapt to new requirements or technologies.
In addition, investing in customised training strengthens staff motivation and loyalty, as they perceive training as a concrete tool for professional growth. The skills acquired become internal assets, increasing the company’s ability to innovate, make informed decisions, and maintain a competitive advantage in the market. In short, a customised course is not just about upgrading technical skills, but an investment that strengthens the structure, skills, and resilience of the entire organisation.
Highly qualified teaching staff
The teaching staff at ipcm® Academy is made up of professionals who combine solid technical training with many years of practical experience in the industrial coating sector. This expertise becomes even more valuable in customised in-company courses, in which the trainers analyse the company’s specific processes, assess the characteristics of the materials and equipment in use, and design lessons based on the real operational needs of participants.
On-the-job training enables professionals to interact directly with experts, discuss real-world problems, and experiment with solutions that have been tested in actual contexts. This approach ensures that each module is not generic but tailored to address the specific challenges of the company, making the training immediately applicable, practical, and relevant. In addition, direct dialogue with instructors promotes the exchange of best practices and the acquisition of knowledge that becomes a permanent asset to the team, consolidating internal skills and strengthening the company’s ability to innovate and continuously improve its processes.
Concrete examples of personalised training experiences
The effectiveness of ipcm® Academy’s customised courses is proven above all by the results achieved by the companies that have already chosen them.
In a manufacturing company in the taps and fittings industry, for example, the need to reduce defects and optimise the coating phase led to the design of a training programme organised in several modules and held directly at its premises, with theoretical lessons supplemented by practical tests. This approach enabled the company to enhance the quality of its finishes, minimise waste, and implement more standardised procedures, resulting in a positive impact on the overall efficiency of its coating line. Another significant experience was with a manufacturer of furniture components. Here, we launched a comprehensive programme developed in close collaboration with the company’s staff, involving more than ten operators from the department. The course offered an in-depth examination of key issues related to paint application and quality control, aiming to establish a common technical language and consolidate internal skills. At the end of the training programme, the company could count on a more qualified and autonomous team, capable of facing daily production challenges with greater confidence and efficiency. These examples confirm that ipcm® Academy’s customised courses can transform training into a concrete and strategic tool for companies. In addition to transferring technical skills, each course helps consolidate internal knowledge, develop autonomy and responsibility among team members, and foster a culture of quality and efficiency.
To find out how to design a training programme tailored to your company’s needs, contact us at corsi@ipcm.it.
For more information, visit the official ipcm ® Academy website: https://ipcmacademy.com.
Surface & Coatings Expo: the global hub for coating solutions and innovations
Confederation of Indian Industry (CII) has organised the 5th edition of “Surface & Coating Expo” (SCE2025) - India›s Largest and Exclusive Event Focused on Surface Engineering, Preparation, Coatings, Finishing, Corrosion Protection, Environmental Engineering and Technologies, that took place from 17 - 19 July 2025, at Chennai Trade Centre, Chennai, India.
This 3-Day Exhibition and Conference is a platform for all the stakeholders of the Surface Coating Industry - manufacturers, distributors, solution providers, traders, end users and policy makers across the globe to meet, network, interact and establish new opportunities.
The CII works to create and sustain an environment conducive to the development of India, partnering Industry, Government and civil society, through advisory and consultative processes.
CII is a non-government, not-for-profit, industry-led and industry-managed organization, with around 9,000 members from the private as well as public sectors, including SMEs and MNCs, and an indirect membership of over 300,000 enterprises from 286 national and regional sectoral industry bodies.
Understanding the importance and need for surface preparation, treatment and coating in some or the other forms, Confederation of Indian Industry (CII) has conceptualized a new initiative “Surface & Coating Expo” in 2014, to benefit various industrial sectors. Over the years, the event has evolved as India’s Largest and Exclusive Event Focused on surface treatments, under the guidance of a strong industry-led Steering Commitee.
The India Paints and Coatings Market size is expected to reach USD 15.00 billion by 2029, growing at a CAGR of 9.38% during the forecast period (2024-2029). The decorative paint category constitutes almost 75% of the overall market and the industrial paint category constitutes the balance of 25% of the paint market.
South India has established itself as a gateway of the Country with large manufacturing hub for Automobile, Auto-components, Petroleum, Chemical, Steel, Sugar, Cement, Power, Electronics, Heavy Engineering and Engineering products at various industrial clusters.
The Surface & Coating Expo had received an overwhelming response from the stakeholders of the industry across the globe. The event had attracted international participation from China, Denmark, France, Italy, Germany, Japan, South Korea, Sweden, Switzerland, Turkey UAE, UK USA & Vietnam.
“The SCE 2025 event at Chennai, India, brought together thought leaders, innovators, industry professionals, and visionaries from across the globe to discuss, showcase, and explore the latest technologies and developments in the Surface Coating Industry” stated Dr. U. Kamachi Mudali, Chairman of CII Surface & Coating Expo 2025 and of CII Corrosion Management Division. “Chennai, the capital city of Tamil Nadu state, has a strong economic base with automobile, software services, medical tourism, hardware manufacturing and financial services, and industries in petrochemicals, textiles, and apparels. Chennai is also nicknamed as The Detroit of Asia due to the presence of major automobile manufacturing units and allied industries around the city.”
For further information www.ciisce.in
SFCHINA2025 - A leading platform for future tech
SFCHINA2025 will take place in Shanghai from November 25 – 27, uniting the surface finishing community.
With legacy since 1983, SFCHINA2025 is the leading platform for electroplating, coating applications, anodizing, coatings, surface treatment and environmental technologies. Over 290 exhibitors are going to showcase their cutting-edge solutions to visitors. Join us at Shanghai New International Expo Centre (SNIEC), Shanghai, P.R. China to explore innovations, attend expert-led Technology Forums and connect with peers. Always stay competitive in a rapidly evolving market.
Gain insights with concurrent technical programmes
A series of concurrent Technical Programmes will be held during the exhibition to foster knowledge exchange and idea sharing:
Technology Forums
Industry leaders will share insights on transformative trends shaping the future of surface finishing:
- Day 1, Nov 25 (14:00 – 16:00): Opportunities Brought by New Energy Vehicle to the Surface Finishing Industry
- Day 2, Nov 26 (10:30 – 12:30): High-End Manufacturing, Technological Innovation: Future Chip Electroplating Process
Technical Seminars and Webinars
- Explore expert perspectives on cutting-edge technologies, eco-friendly solutions and evolving industry dynamics.
Driving the future of surface finishing
As the surface finishing industry faces rapid transformation and intensifying competitions, SFCHINA2025 empowers businesses to accelerate technological advancements, embrace green manufacturing and foster intelligent production. The exhibition connects key stakeholders across finishing, functional coatings, precision plating, surface engineering and sustainable technologies. Whether visitors
are seeking breakthrough innovations, strategic partnerships or market insights, SFCHINA2025 serves as a hub for sourcing, knowledge sharing and networking, paving the way for sustainable growth and future-ready solutions.
Register before October 17 to enjoy VIP visitor experience
Industry professionals are welcome to register at www.sfchina.net or via our WeChat platform (ID: ChinaCoat_SFChina) now. Overseas visitors who successfully register by October 17 can enjoy special rate on the original registration fee, exclusive access to the Overseas & Invited Visitors Lounge and receive complimentary Exhibition Directory along with a souvenir (while stocks last). Stay updated and informed by following SFCHINA on Facebook, X, LinkedIn and YouTube, or contact the Organizer for any latest event highlights.
For further information: www.sfchina.net
Tubotech and Wire Brasil reinforce their strategic role in innovation and national reindustrialization
Tubotech and Wire Brasil will take place simultaneously from October 29 to 31, at São Paulo Expo, Brazil.
Debates on automation, energy efficiency and sustainable materials bring leaders closer and drive the industry.
While Brazil seeks to accelerate its reindustrialization and expand competitiveness in the global market, technological innovation and the transition to more sustainable processes take centre stage. In this context, the recent increase in U.S. trade tariffs on steel, aluminium and other manufactured products — the so-called “tarifaço” — raises a red flag for Brazilian companies to rethink their commercial strategies, open new markets and reduce dependence on international supply chains. Tubotech and Wire Brasil, which take place simultaneously from October 29 to 31, at São Paulo Expo, emerge as key venues to understand the moment, exchange information with specialists and map the trends that are shaping the future of the industry.
Trade shows grow in 2025 and expand opportunities
With more than 180 confirmed companies — 60 Brazilian and 120 international — the 2025 edition is 43% larger in number of exhibitors, expanding opportunities for business generation, networking and concrete results.
More than showcases for new releases, the events serve as convergence points for trends that are redefining the industry, from digitalization to energy efficiency, including the adoption of lighter, recyclable materials with higher conductive capacity.
“The performance of the last edition showed that the market is strong and open to innovation. By bringing the entire production chain together in a
single space, we are able to generate connections that respond directly to the industry’s challenges and opportunities, which today is going through a decisive phase of modernization and sustainability”, says Maurício Macedo, CEO of Fiera Milano Brasil, responsible for organizing the trade shows.
Strategic sectors in transformation
Brazil’s reindustrialization is also directly linked to the incorporation of new technologies and to the energy transition. According to the National Confederation of Industry (CNI), infrastructure investments are expected to grow 4.2% in 2025, reaching BLR 277.9 billion — equivalent to 2.21% of GDP.
Although below the level considered ideal (around 4% of GDP), this advance drives sectors such as energy, gas, sanitation and urban mobility. The pipes and fittings segment follows this trend with the expansion of gas, water and sewage networks, in addition to the resumption of strategic projects in the oil and energy industry. The electrical wire and cable sector is moving toward large-scale electrification and the adoption of automated systems, directly connecting industry and smart cities.
“The expansion of power transmission networks and the integration of solutions focused on urban mobility are at the heart of this transformation. At the same time, demand is growing for lighter, recyclable materials capable of conducting a greater electrical load, a trend that drives innovation and guides the development of new solutions for the industry”, explains Macedo.
Business rounds with major buyers
In addition to the exhibition, one of the main new features of the 2025 edition is the Business Round, which already has 65 exhibiting companies interested in presenting their solutions directly to highly qualified buyers. To date, 30 companies with a buyer profile have confirmed interest in taking part in the initiative, among them heavyweight names such as Petrobras, Braskem, Tenaris, Bunge, Gerdau, Vale, ArcelorMittal, Vallourec, Usiminas, Odebrecht/ Tenenge, CSN, Intelbras, Eurofarma, Eletrobras, EDP Brasil and Equinor.
The estimate is that 160 business meetings will be held over the three days of the event, promoting strategic connections between buyers and suppliers.
“The trade show is more than a business space — it is where the market moves, where companies listen to each other, test ideas, seek paths in the face of new scenarios and reposition themselves for the future. For more than 10 years, the shows have been connecting decision-makers with those who transform the market. The experience of those who lead the sector is what guarantees your next deal”, explains Augusto Andrade, Director of Portfolio & International Sales at Fiera Milano Brasil. The Round is part of a broad strategy for business generation and relationship-building, which also includes the Top Buyers Campaign. Among the differentiators are exclusive benefits for top buyers, such as free parking, priority registration and special access to the show’s networking areas. “Many of these large companies have already completed their pre-registration, which shows the high business potential of this edition”, the executive adds.
International reach reinforced in 2025
“Tubotech and Wire Brasil bring the whole world together in one place. We feature brands from major industrial powers and emerging economies that come to Brazil to create opportunities and accelerate business. We have practically quadrupled the number of international players in 2025 — and that says a lot about the relevance and international reach of the events”, highlights Augusto Andrade.
“While many trade shows still promise results, Tubotech and Wire Brasil already deliver real connections and concrete opportunities. Those who are not present, may lose ground in markets that are moving quickly”, concludes the director. In order to register for Tubotech and Wire Brasil, the following links may be used, respectively: https://easyexpo.com.br/v3/fmilano/25/vistubotech, https://easyexpo.com.br/v3/fmilano/25/viswire
For further information: www.wirebrasil.com.br and www.tubotech.com.br
The
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myFAIR is a free web app that can be accessed from both desktop and mobile devices, which allows you to stay up-to-date with the leading events of the surface treatment sector.
Material Engineering and Industrial Technologies, University of Trento - Product Design
Kevin Biller ChemQuest Powder Coating Research
Gianmaria Guidi Consultant for industrial and anticorrosive coating processes
Gianmaria Gasperini
Head of the Paint&Coatings Laboratory of Innovhub SSI Divisione Oli e Grassi
Paolo Rami
Director of ipcm®Academy, expert in anticorrosion, coating defects analysis, and process optimization
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