ipcm n. 98 | March - April 2026

LIGHTNING FREE

Discover our selection of powder coatings designed to prevent electrostatic discharges and their consequences.

POWERING THE FUTURE OF ENERGY INFRASTRUCTURE

Our infrastructure doesn’t get a day off, so neither should its coatings. Discover ProGRID — an innovative portfolio of coatings by Sherwin-Williams engineered to meet the evolving demands of our energy infrastructure around the globe. Protection you can count on.

New coating line, new standards: superior quality, production continuity, operational safety, and streamlined maintenance for Cantoni & C.

New Color, where revamping and digitalising a line made technology more universally accessible

Application of FLG-LD in a polymer matrix in Dollcoat RS 103 and GP 107 nanotechnology-based pre-treatment products

Idrotecnica renews its range of demineralisers: introducing the new Idro CA series

Creating special effects in powder coatings: from formulation to sublimation

Function, form, and space perception: the evolution of pergolas according to

From galvanising to coil coating: UNICOIL’s chrome-free strategy to compete in Europe

Euroimpianti: half a century of innovation in coating systems

Automated application, water-based DTM coatings, and IR drying: DAB Pumps’ technical choices for the efficient, high-quality finishing of cast iron pumps

ANODIKIT® Zone: from the world’s first compact anodising line to a proven industrial model

MARCH/APRIL 2026

Understanding the real drivers of coating economics and sustainability: HangOn’s Coating Cost Calculator takes a major leap

Global technology meets local expertise: the Dürr–ERMA partnership behind a high-efficiency coating line for glass bottles

Efficient paint mist separation with edrizzi® Cube in Cube at LEICHT Küchen

Decoral Coil will present the new frontier of colour matching at PaintExpo

The growth strategy of Vernici Caldart

A conveyor designed to overcome the bottleneck in Decor Glass’ painting process

A century of colour, progress and family spirit

New self-learning robots with VR Tracking technology: the next level of coating at Pentax Industries

A 5.0 coating plant to support WAMGROUP’s growth and manage its diversified production

ON

At Metalprogetti, preventive maintenance ensures high-quality, effective pre-treatment

Coating and waterproofing with polyurea

OF

From catalysis to hydrogen: five decades of infrared innovation with Infragas

Officine Minelli: a new 24-metre coating booth for material handlers

FOCUS ON TECHNOLOGY

Tecno 3FP’s growth continues with a new powder coating plant

ReBox: the new reusable filters for coating booths, designed for the ‘Sustainable Paintshop’

ON TECHNOLOGY

Classic car restoration: process integration and end-to-end quality control at Motor Classic

Colouring with PVD: achieving premium decorative coatings with HiPIMS

ITAMID FL560S: performance evaluation in high-solid epoxy DTM coatings

206 HIGHLIGHT OF THE MONTH

Fire reaction and indoor air quality: new priorities for fire-retardant wood coatings

210

STORIES

World premiere: Dürr installs its Paint Shop of the Future for CEER

CAT anticipates future challenges with a water-based coating line for automotive components

218 COLOUR STUDY

The Way of Sportin’ Life. Lechler’s Colour Design at Fuorisalone 2026: exploring the role of colour in sport-inspired living spaces

222 HIGHLIGHT OF THE MONTH

How PVD meets demand for customisation and high-quality finishes in the decorative sector

228 HIGHLIGHT OF THE MONTH

The secret to perfect coating? Effective masking

230 SUCCESS STORIES

Interstuhl relies on Dürr products for seat surface coating

232 UCIF INFORMS

Industrial finishing is undergoing a paradigm shift 234 MEETING THE INDUSTRY

EDITOR’S LETTER

Alessia Venturi Editor-in-chief Direttore Responsabile

Inever thought I would revert to using a word so inflated that I would prefer any synonym over it, even if it meant losing some nuances of meaning. Yet, I cannot help but resort to the word ‘resilient’ to describe the mindset the Western manufacturing industry must adopt to avoid succumbing to the uncertainty, instability, and energy crisis looming on the horizon.

The crisis in the Strait of Hormuz, caused by the conflict in the Middle East, is diverting LNG flows intended for Europe towards Asia to compensate for the lack of supply directly from the Strait. The global market is seeing its prospects for rebalancing and downward price trends, expected for 2026-2027 following the 2022 peak, fade away. Future developments will largely depend on how this conflict is resolved and on the future stability of the Strait. The outlook for the Gulf states, which were expanding their international presence and generating steadily increasing demand for goods from Western markets, is also highly reliant on the outcome of the crisis1 Despite these uncertainties, the industry must show adaptability and foresight, responding pragmatically and investing in technological innovation and efficiency.

In my editorial just two issues ago2, I emphasised the importance, for both the industry and entrepreneurs, of embracing the unexpected to develop creative solutions. Today, this appears to be the only viable way to overcome the obstacles we are facing.

We must turn this crisis into an opportunity to rethink processes, materials, and production models, leveraging the numerous innovations of the last twenty years. Optimising energy consumption will become a matter of survival, not just sustainability. The importance of collaborating and sharing expertise across the supply chain will be clearly seen in our ability to develop effective solutions.

The upcoming PaintExpo trade fair, taking place from 14 to 17 April in Karlsruhe (Germany), will be a prime opportunity to unite the entire sector, address these issues together, promote research, and review or adjust investment strategies.

The pages of this extensive issue of ipcm® mark a milestone with 100 advertisers – nearly as many as the magazine issues published since 2010 – and offer a wealth of insights and detailed information on processes, operational methods, and efficiency analysis and enhancement technologies, provided by both companies exhibiting at the trade fair and other market players.

It could genuinely serve as a ‘survival guide’ containing the experiences of companies that have already adopted these technologies.

In times of crisis, end users seek reassurance, not just products: they want to verify the reliability, operational continuity, and adaptability of their suppliers. Perceived value shifts: issues such as energy efficiency, supply chain resilience, sustainability, and cost optimisation take centre stage.

The worst move anyone could make now is to halt marketing. Instead, marketing should shift towards technical and practical content, showcasing strength and expertise, and positioning the company as a strategic partner rather than just a supplier. Historically, businesses that have continued investing in communication during crises have emerged stronger, consolidating their brands, while others have faded from view.

Looking ahead with confidence does not mean ignoring challenges but recognising the technological and cultural resources already available to tackle them.

Richiedi la versione in italiano a info@ipcm.it

1 https://www.adipec.com/press-media/news-insights/2026/03/how-geopolitics-is-reshaping-the-global-outlook-for-naturalgas-and-lng/?utm_source=emarsys&utm_medium=email&utm_campaign=ENERGY_ADIPEC_2026_GEN_Newsletter_3_Europe-Africa&sc_src=email_1120753&sc_lid=128915560&sc_uid=FUIXYuAhFU&sc_llid=82851&sc_eh=5ab11b840d658a291

2 (ipcm® 96 November/December 2025 https://www.ipcm.it/en/open/ipcm/2025/96/13.aspx)

14 – 17 April 2026

Karlsruhe,

ANALYSIS

Turning hidden coating costs into competitive advantage

From an interview with Jonas Dubow, Global Commercial Director and Katja Viimavirta, Marketing Manager, Teknos Group Oy

At PaintExpo 2026, Teknos demonstrates how a process-driven approach can improve production efficiency, reduce energy and material waste, enhance coating quality, and turn hidden costs into both sustainable and economic competitive advantages for companies involved in industrial coating processes.

In the industrial coating sector, the cost of paint is often considered the primary factor when choosing one product over another. However, in today’s manufacturing environment—characterized by rising energy costs, increasing regulatory pressure, and the need to improve productivity— this perspective is no longer sufficient.

© Teknos

The real opportunity for optimisation lies in identifying and managing what Teknos defines as hidden costs: all those factors within the coating process that do not appear in the “price per litre” but have a significant impact on overall operational costs. Only by analysing these hidden costs can companies with a coating line turn them into competitive advantages. Hidden costs therefore include everything surrounding the coating material: energy consumption in drying or curing ovens, application of excessive film thickness, inefficient application parameters, unnecessary pretreatment steps, labour time, rework, scrap, and even the long-term durability of the coating system. If these factors are not properly monitored, the total cost of the coating process can quickly become extremely high.

To better understand how manufacturers and coaters can turn inefficiencies into measurable gains, we explored these topics with Katja Viimavirta, Marketing Manager, and Jonas Dubow, Global Commercial Director at Teknos Group Oy, one of the leading suppliers of industrial coatings and a key exhibitor at PaintExpo 2026, to be held in Karlsruhe, Germany, from April 14–17.

More than just a surface: creating added value

According to Teknos’ experience, the finishing process is often underestimated from both an organisational and strategic perspective. “While many manufacturers clearly assign specialised expertise to core operations such as welding or machining, coating is frequently managed without clear process ownership. As a result, inefficiencies related to material consumption, energy use, process parameters, durability, or other industrial coating challenges often go unnoticed, significantly impacting the total cost of the coating process”, states Jonas Dubow. This makes a thorough understanding of the entire coating workflow and solid technical know-how essential. The Finnish company has embraced a process-oriented mindset: rather than positioning itself simply as a supplier of liquid and powder coatings, Teknos focuses on identifying optimisation opportunities, as well as inefficiencies and bottlenecks, across the entire production chain. In doing so, the company provides customers with genuine added value, helping them understand the technology and enabling improvements across the entire coating process.

Jonas Dubow

© Teknos

© Teknos

Key challenges in coating processes

The Teknos technical team frequently supports customers with common challenges in industrial coating processes. On industrial coating lines, one recurring cost-driving factor is excessive paint application, which can lead to hidden inefficiencies in material usage and overall process performance. “In many facilities, operators either lack the tools or the technical knowledge to monitor film thickness accurately, which often leads to applying more paint than specified. For example, a typical specification may call for 100 microns in total — 40 microns of primer and 60 microns of topcoat — yet when our team measures the actual film thickness, it is often found to be 150 microns. This represents a 50% increase in paint consumption, translating directly into higher material costs and longer drying times, without any added benefit to durability or performance”, explains the Global Commercial Director.

Another common issue is the lack of understanding of the paint solid content. It refers to the percentage of non-volatile materials — such as resins, pigments, and binders — that remain on the substrate after solvent evaporation, directly affecting dry film thickness, coverage, and durability.

Although this concept may seem straightforward, it is often overlooked that coatings with higher solvent content — for example, 50% solvent compared to 20% — lose significantly more material through evaporation during curing. This not only results in wasted material but also increases energy consumption, as ovens must work harder to remove the excess volatile compounds. High-solid coatings are therefore more cost-effective and environmentally friendly, as they require fewer coats and produce lower VOC emissions compared to low-solid alternatives.

“Energy consumption is another critical factor. Many manufacturers set curing ovens at temperatures higher than necessary, believing that more heat leads to faster production. In reality, the chemistry of the coating system is designed to achieve optimal curing at lower temperatures, and excess heat only increases energy costs without improving the final coating result. Beyond the final coating outcome, with energy prices remaining volatile across Europe, optimising curing parameters, such as temperature, dwell time, and airflow, is now a priority not only for cost reduction but also for managing the CO₂ footprint”, continues Dubow. Surface pretreatment can also be a significant source of hidden costs.

Teknos

Conventional processes often require large volumes of water for cleaning steps, along with a substantial input of thermal energy to dry the substrate, contributing heavily to operational costs.

“Finally, durability is another essential factor. The lifetime of a coating determines how long a component can remain in service before maintenance, repainting, or replacement is required. Poorly applied coatings or inappropriate specifications can therefore lead to early scrapping or frequent repainting, increasing both material and operational costs”, adds.

Turning hidden costs into measurable gains

Teknos leverages its technical expertise to tackle coating inefficiencies, positioning its commercial team as a true process partner. Their role goes beyond sales, encompassing an understanding of the customer’s production, the identification of bottlenecks, assessment of potential savings, and guidance in process optimisation.

The process typically begins with an on-site coating line review, during which Teknos’ specialists analyse key parameters such as material consumption, transfer efficiency, film thickness distribution, curing conditions, bottlenecks, and overall line productivity. The outcome is a

structured report that highlights inefficiencies, quantifies potential savings, and provides actionable recommendations. Beyond technical consultancy, Teknos has expanded its portfolio over the years with innovative solutions that help manufacturers optimise their coating processes.

“Single-layer coatings, which combine primer and topcoat in a single application, such as direct-to-metal (DTM) solutions, enable manufacturers to reduce material consumption, process steps, and labour requirements. This approach eliminates intermediate curing stages, reducing handling time, line length, labour demand, and energy consumption, while maintaining the required level of corrosion protection and the desired aesthetic performance.

Another important solution is represented by moisture-accelerated curing systems, which enable coatings to cure under ambient humidity conditions. By eliminating the need for thermal ovens, these technologies can significantly reduce energy consumption—by up to 90% in certain industrial applications.

As for powder coatings, Teknos has developed low-cure formulations that allow either shorter curing cycles or lower curing temperatures while maintaining high surface hardness and chemical resistance, thereby minimising overall energy use”, explains Dubow.

HIGH QUALITY COATING SYSTEMS

Real-world examples illustrate the impact of these solutions. In the railway trailer sector, Teknos helped clients save up to 90% on energy costs by shutting down curing ovens and introducing moisture-accelerated curing systems. Compared to the 50–100 kW required by conventional industrial ovens, moisture-accelerated curing consumes less than 1 kW. Similarly, at another client producing agricultural equipment, daily energy costs of approximately €3,200 were significantly reduced using the same product.

Unlocking efficiency and value in coating:

See Teknos at PaintExpo 2026

As energy costs remain high and volatile, regulatory pressures increase, and production demands continue to grow, manufacturers are facing a new reality: efficiency, sustainability, and cost control are no longer separate objectives but interconnected priorities. For those looking to uncover hidden costs, the first step is to shift from a product-focused perspective to a total process cost approach, monitoring key indicators such as actual dry film thickness, paint consumption per square meter, transfer efficiency, oven parameters, energy usage, rework rates, and pretreatment requirements.

“Reducing paint consumption or optimizing process parameters may seem counterintuitive for a coating supplier, but transparency and process optimisation create long-term value for both the manufacturer and the supplier. Paint that does not end up on the part is simply waste—both economically and environmentally.

By identifying, quantifying, and eliminating these hidden costs, companies can transform the coating process from a routine operation into a strategic lever for efficiency, competitiveness, and sustainability”, adds Katja Viimavirta, Teknos’ Marketing Manager.

For those interested in exploring these opportunities in practice, Teknos invites you to visit booth 2338 at PaintExpo 2026 in Karlsruhe, Germany, from April 14–17, where experts will demonstrate how a process-oriented approach can deliver measurable benefits and real added value.

© Teknos

WATER SOLVENT MODIFIED ALCOHOL

PPG and Imel join forces to deliver global solutions in the coatings industry

The partnership between PPG Industries and Imel integrates advanced coating technologies and digital automation to deliver efficient, sustainable solutions focused on high-quality finished products, already validated in a project carried out with a Tier 1 automotive supplier.

The partnership between PPG Industries, a global leader in coatings supply, and Imel, an Italian company with over 60 years of experience in the design and delivery of painting systems, marks an important step towards integrated, efficient solutions focused on finished product quality.

PPG is internationally recognized as a leading manufacturer of paints, coatings, and specialty materials, with a presence in over 70 countries and annual revenues exceeding $15 billion. Its industry leadership is further strengthened by its ability to support automotive and industrial manufacturers with advanced technologies and products that meet the most stringent performance and sustainability requirements. Imel, drawing on decades of experience, designs and supplies high-tech, turnkey painting systems, integrating advanced automation and data management solutions. Its proprietary i4PaintShop platform, developed through years of research and development, transforms each facility into a smart control centre, enabling real-time monitoring of consumption, quality, and production performance.

The collaboration between the two partners has already been successfully tested during the commissioning of a major plant for a Tier 1 automotive supplier. In this project, PPG Industries optimized paint-related process parameters, while Imel developed the plant’s entire technological infrastructure, delivering a complete, ready-to-use solution. A key feature of the project is the i4PaintShop platform, which enables clients to track every production batch and generate product sheets where actual process data are compared with nominal values.

The platform also supports OEE (Overall Equipment Effectiveness) measurement and paperless maintenance management, optimizing downtime and operational costs. Additionally, monitoring consumption provides a crucial tool to ensure compliance with environmental regulations in line with Industry 5.0 principles.

Thanks to this synergy - combining PPG Industries’s advanced coatings formulations with Imel’s technological expertise - the project delivers a state-of-the-art solution to the industrial painting sector, offering reliability, flexibility, and top-quality finished products.

For further information:  www.ppg.com/en-US/autocoatings/ppg-coatings-services and www.imelspa.com/en/

Eisenmann to showcase automated wheel handling solutions at PaintExpo

Like every edition, Eisenmann will exhibit at PaintExpo with its automated wheel handling solutions for paint shop.

The world’s leading trade fair for industrial coating technology, PaintExpo, is approaching. Eisenmann, an international plant manufacturer, will present proven technologies for nearly all paint shop processes. Among these is the E-Gripper Wheel, a hybrid gripper designed for precise and gentle handling of standard wheel sizes from 14 to 24 inches. Its advanced control system allows operation either pneumatically or servo-electrically, providing a versatile solution for diverse handling requirements. The E-Gripper Wheel can manage delicate objects, demonstrating its precision and adaptability. The Eisenmann team will be available to discuss new

areas of application beyond conventional paint shop processes. Eisenmann’s expertise in automated wheel handling—over 200 installations worldwide—can be combined with the E-Mover driverless transport system to extend operational capabilities. For PaintExpo attendees interested in an energyefficient, clean solution for dry overspray separation, Eisenmann will present a vivid augmented reality demonstration of the E-Cube filter system. Demonstrations and further information will be available at Hall 1, Booth 1220.

For further information: www.eisenmann.com

© Eisenmann

AkzoNobel Powder Coatings launches Eco+ portfolio to spotlight most sustainable powder coating solutions

New Eco+ designation brings together high-performing sustainable products from Interpon and Resicoat, offering customers clear, data-backed sustainability benefits without compromising performance.

AkzoNobel Powder Coatings has unveiled Eco+ products, a dedicated portfolio highlighting its most sustainable powder coating solutions. The new designation brings together selected products from the Interpon and Resicoat portfolios under a single, clearly defined sustainability label, designed to give customers confidence and clarity when choosing more sustainable coatings. The Eco+ portfolio focuses on powder coatings that deliver measurable sustainability improvements alongside proven performance advantages. These include reducing energy use, waste and carbon emissions, extending product lifespan and improving process efficiency—helping customers lower their environmental impact while enhancing operational performance. Products qualify for Eco+ status based on measurable sustainability

performance, assessed against a robust, datadriven set of criteria. Each Eco+ product must demonstrate improvement in at least one of six defined sustainability benefit areas:

 Reduced energy consumption through lower curing temperatures and faster curing cycles

 Increased productivity with single-layer systems, fewer process steps and less rework

 Less waste during manufacturing and application, including reduced leftover powder

 Reduced material consumption through right-first-time performance and optimised coverage

 Longer-lasting performance, with durable and super-durable coatings that protect assets for decades

 Reduced carbon footprint, enabled by smarter raw material choices, including bioattributed resins

“Powder coatings are already one of the most sustainable coating technologies available. With Eco+, we make it easier for customers to see where sustainability genuinely adds value. Whether it’s lower energy use, greater efficiency or longer service life, Eco+ highlights the powder coating solutions that help customers reduce their impact while improving how their operations perform. That’s what value-driven sustainability means to us,” has stated Jorrit van Rijn, Marketing Director of AkzoNobel Powder Coatings.

By making sustainability performance transparent and comparable, Eco+ enables customers to better understand where improvements are achieved, why they matter and how they support both business goals and environmental responsibility.

The Eco+ portfolio spans a wide range of industries and applications, including architecture, automotive, appliances, functional uses and general industrial markets. Benefits include low-temperature curing, high durability, extended service life through enhanced corrosion protection and improved material efficiency.

For further information: www.interpon.com/sustainability/ecoplus-powder-coatings

© AkzoNobel

The coating industry, between stability and new frontiers

Interview with Andrea Codecasa Head of Industry at Assovernici

Andrea Codecasa, Head of Industry at Assovernici, the Italian association representing leading producers of industrial powder and liquid coatings and paints for the building sector, analyses the sector’s performance during a historical period marked by apparent stagnation, highlighting differences across geographical and sectoral markets, new technological trends, and the growing role of sustainability as a competitive lever.

At a time when the world of industrial coatings seems to be experiencing stagnation, Andrea Codecasa, Head of the Industry Sector at Assovernici, takes stock of the current situation, highlighting the dynamics that continue to operate beneath the surface, from the emergence of new markets to the drivers of sustainable innovation. He also emphasises that, in order to navigate a market that remains tricky and complex, it is important for companies to be practical and realistic.

Andrea Codecasa, how would you summarise the last few months and the future of the industrial coatings sector in two keywords?

We could say, with a touch of irony, that the market had never seen such a flat calm as it did at the end of 2025 and the beginning of 2026: even the first few weeks of the year began with a decline, despite expectations of a slight upturn. However, we should not forget that industrial values before 2020 were much lower, and that the high figures seen immediately after Covid, i.e. in 2021, are unlikely to be repeated. It is also important not to underestimate the value of stability, as current geopolitical turbulence is generating uncertainty about the future and dampening many companies’ willingness to invest.

Looking at the global markets, which sectors are showing the most dynamism and which are struggling the most?

The sector in the most favourable position is that of contractors, i.e. specialised companies that coat products manufactured by other businesses. This is the case in Italy, a country with a solid manufacturing tradition, and across the rest of Europe, where architecture is another

thriving industry. By contrast, the household appliance and automotive sectors have been suffering for some time. In Asia, all industries are experiencing a positive period. However, compared with Europe, the contracting segment is less solid, as the East is home to large manufacturers that do not need to outsource coating services. In the United States, the outlook is generally positive but without any peaks. In South America, and in Brazil in particular, the construction industry is experiencing significant growth.

Amid the introduction of tariffs on raw materials and a complex international landscape, how is the supply chain adapting to remain competitive?

Having moved past the difficulties associated with anti-dumping measures on titanium dioxide from China, raw material availability now exceeds demand, resulting in stagnant prices. Asian products remain important because Europe lacks several essential resources: for example, precursors for epoxy resins and polyesters must be purchased from Asia. As for tariffs, the most significant issues are those experienced by façade builders, as they are affecting materials such as processed aluminium. The current strategy is to await developments, although some processing operations will likely move to the US.

In which countries is industrial coating showing the most promising signs?

The African market is showing particularly promising signs, except in South Africa, which has been a declining area for some time. The northern and central regions are experiencing structural and general growth,

Andrea Codecasa

Order the expertise that keeps production flowing

Your production line never slows down, and neither should the support behind it. Through My Interpon Portal, you can now purchase a wide range of specialist coating services online, exactly when your business needs them. Whether the focus is precision color development, lab testing, application optimization, technical audits, training or sustainability analysis, every service is designed to sharpen performance, improve consistency and protect your reputation, even on the most demanding jobs.

Fast to order. Built around your operation. Backed by Interpon expertise. Log in to My Interpon Portal and turn expert service into your next competitive edge.

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

although there is still some way to go in terms of infrastructure and supply chains. Despite the current uncertainties, I believe significant production growth can be expected in the near future.

How is sustainability being integrated into production processes?

Sustainability is now an ever-present issue: all companies are required to pay the utmost attention to the environment in their products and processes. This requirement poses significant challenges for formulation: among the most promising solutions are products made from biomass raw materials. In general, these alternatives still have an upward impact on prices. Nevertheless, the need to pursue this path is clear and shared by all operators in the industry: we are well aware that ‘innovation’ is now synonymous with ‘sustainability’. At the same time, we should distance ourselves from speculation on this topic and ‘greenwashing’, i.e. superficial respect for the environment based on false promises.

What are the most promising innovations in terms of technology?

As mentioned, petroleum-free raw materials, technologies that reduce baking temperatures, and solvent-free liquid products: these are the three main areas of focus. However, we need to be careful: while European

guidelines are very clear – think of the restrictions on substances such as bisphenol A – we must keep an eye on what we import to ensure it does not compromise end products.

As for areas of application, are there still relatively unexplored fields that will see significant development in the coming years?

The most promising frontiers involve extending powder coatings to heat-sensitive substrates such as wood and plastic. The main limitation is thermal: traditional powders require excessively high cross-linking temperatures, which could deform or damage these materials. The real challenge, therefore, is to develop formulations and processes that drastically lower the curing threshold.

In addition to technical performance, we are seeing new aesthetic trends: are any particular colours or finishes becoming popular in specific applications?

We have witnessed different colour eras: while the automotive industry has moved from classic whites and metallics to matt greys and blacks, architecture is shifting from neutral, sometimes aseptic colours towards glossy finishes, natural hues, and deep reds and burgundies. In the

Turn key solutions for industrial wastewater treatment - Design and manufacturing of plants and chemicals for industrial wastewater treatment Chemical-physical plants - Sludge treatment and compactor systems - Ion exchange demineralization systems and reverse osmosis systems - Oil separators - Filtering systems

Batch type systems - Flotation units - Chemicals and spare parts for water treatment - Technical service, support and maintenance of wastewater treatment plants

Get more from water

We don’t just treat water — we give it a second life. Every drop matters: our ongoing commitment to zero discharge and total water reuse drives every solution we design.

industrial sector, colour is never merely decorative but also a decisive performance factor: it should ensure chemical stability and protection even in extreme conditions. Similarly, in the construction industry, the choice of colour has a direct impact on the physics of buildings: dark hues accumulate heat and affect thermoregulation. Aesthetics and engineering must therefore go hand in hand.

At an organisational level, what elements should be leveraged to respond to market challenges with resilience and flexibility?

The key to combining resilience and flexibility currently lies in greater process standardisation: a defined operational structure makes the organisation more practical and, paradoxically, better prepared to deal with unexpected events. Streamlining one’s offering, for example by limiting excessive fragmentation, frees up valuable resources that can be reinvested in responsiveness and customer service. In short, reducing internal complexity is the only way to increase one’s ability to lead and adapt to external changes.

In such a volatile context, how can the periodic market analyses provided by Assovernici become a strategic decision-making tool for companies planning for the coming months?

The market analyses provided by Assovernici are not mere snapshots but indispensable ‘compasses’, as access to accurate, segmented statistics allows companies to make even more informed choices based on objective data. At such an unstable time, these analyses offer a realistic interpretation that enables the definition of solid strategies, transforming uncertainty into a competitive advantage planned for the medium term.

Application of FLG-LD in a polymer matrix in Dollcoat RS 103 and GP 107 nanotechnology-based pre-treatment products

F. Aiello, G. Assanelli, L. Bonoldi, M. Bruscagin, and M. Notari

Eni DowR&D - San Donato Milanese (Milan), Italy

André Bernasconi

DN

Chemicals Srl – Milan (Italy) bernasconi@dn-chemicals.com

The partnership between DN Chemicals and Eni has led to the development of some innovative nanotechnology-based products in the Dollcoat series, formulated with FLG-LD in a polymer matrix for multi-metal anti-corrosion pre-treatments. Tests have shown a significant increase in corrosion resistance compared with traditional technologies, as well as high performance on various metal substrates and full compatibility with complex and nanoceramic processes.

Developing a groundbreaking innovation with no market equivalents, one that would surpass existing expertise and necessitate the creation of new technical knowledge, was the goal set during the first meeting of the DN Chemicals-Eni team in January 2022. The project was complex and ambitious from the beginning, with numerous critical issues to address and skills to develop, even in areas that had not been explored by the research group until then.

DN Chemicals, a company specialising in the production of chemicals for coating pre-treatment and water purification, could rely on a solid technological foundation: over twenty years of experience with its Dollcoat SA products based on synthetic oligomers obtained from silanes, the use of atomisation modules developed and refined with partners, Qualicoat and Qualisteelcoat certifications, and approvals from major customers. Incidentally, these certifications would have had to be re-obtained as part of the new project, but with significantly higher performance levels.

Eni brought its consolidated expertise in the production of graphite suspensions for different applications. Similarly, however, these suspensions had to be reformulated and optimised for combined use with the products developed by DN Chemicals. The company’s previous experience in the production of stable single-walled carbon nanotube (SWCNT) suspensions also played a significant role.

The project

The concept was to create a polymer matrix in which to disperse the graphite suspension (Fig. 1, see also the Technical Insight at the end of the article).

The research project, therefore, started with selecting a polymer that:

 could be emulsified;

 had excellent corrosion resistance;

 had excellent mechanical properties, especially when applied in sectors that involve post-forming operations, such as coil pre-treatment;

 could promote the adhesion of any type of paint;

 was fully compatible with cataphoresis processes.

The identified polymer was then functionalised using specific polysilsesquioxanes, on whose synthesis the Dollmar group, to which DN Chemicals belongs, has developed considerable experience over the years.

This first product was marketed under the name Dollcoat RS 103, establishing itself as a radical innovation with the following key characteristics:

 no-rinse multi-metal product, usable at room temperature;

 very high resistance to pollutants and, therefore, suitability for recirculation in normal pre-treatment operations for months without any deterioration in performance;

 also applicable via atomisation modules, provided they are suitably modified;

 no sludge formation.

The industrialisation of Dollcoat RS 103, which began at the end of 2022, enabled the further refinement of its formulation and the identification of some simple but effective plant engineering adjustments to optimise technical performance and consumption in extended recirculation processes.

The formulation of Dollcoat GP 107

Simultaneously with the industrialisation of Dollcoat RS 103, the DN Chemicals-Eni team developed Dollcoat GP 107, a product offering even higher performance thanks to the use of an FLG-LD suspension engineered in Eni’s laboratories, which was the subject of a joint international patent filed in November 2024.

The aim was not only to develop a product with superior anti-corrosive properties compared with Dollcoat RS 103 while maintaining the general characteristics described above, but also to optimise the pre-cataphoresis process by using a ‘conductive’ matrix capable of promoting better coverage, particularly on complex geometries. Thanks to the use of electrochemical impedance spectroscopy (EIS), ACET technology and, more recently, Raman spectroscopy, the selection process among the numerous suspensions identified by Eni laboratories was much faster than would have been possible with traditional techniques such as salt spray testing.

Figure 1 - The polymer matrix for the dispersion of the graphite suspension.

The application of Dollcoat GP 107

Over the last two years, Dollcoat GP 107 has been tested on four industrial plants, two of which are equipped with atomisation modules and one with a chemcoater for coil pre-treatment. Like Dollcoat RS 103, Dollcoat GP 107 is a no-rinse product that can be used on any type of metal alloy using relatively simple processes. An example is a pre-treatment cycle consisting of alkaline degreasing, two rinses, phosphodegreasing with Dollcoat SA 127, two further rinses (the last of which with demineralised or osmotised water), and nanotechnology application with Dollcoat RS 103 or Dollcoat GP 107. Naturally, more complex process cycles deliver a corresponding degree of corrosion protection. The strong synergy created between the nanoceramic processes and the subsequent application of Dollcoat GP 107 is also worth noting.

Corrosion protection performance on various metal substrates

The performance levels achievable on industrial plants treating different metal substrates are shown in Table 1. The comparison highlights the significant increase in performance achieved with this new family of products compared with conventional polysilsesquioxane-based technologies. The industrial process used for all metal substrates included multi-metal alkaline degreasing, nanoceramic conversion, and the application of products from the Dollcoat line.

Table 1: Performance comparison between traditional polysiloxane-based technologies and Dollcoat technology.

The polarisation resistance (Rp) values show a marked increase from Dollcoat SA 118 to Dollcoat RS 103, with the overall increase approaching one order of magnitude for Dollcoat GP 107. The presence of graphene also significantly reduces ‘porosity’, thus considerably reducing water uptake, as shown by the ACET analysis in Fig. 2

Figure 2 - Results of the ACET analysis relating to water uptake.

The same panels were then coated with polyester powder, either directly or after applying a primer or cataphoresis layer, and subsequently tested using both the ACET and neutral salt spray methods. Due to space constraints, we cannot report all test results, but the comparison we find most interesting is between the panels coated with polyester powder alone and those subjected to both cataphoresis and polyester powder application, as shown in Table 2

Table 2: Comparison between panels coated with polyester powder alone and with cataphoresis followed by polyester powder application.

WE ENVISION SOLUTIONS

The results show substantial equivalence among the panels at least up to corrosion category C3H. In category C4H, the panels coated exclusively with polyester powder still maintain high performance compared with those also treated with cataphoresis. It is important to highlight the decisive role of the paint used: during this industrial test, the first series of panels showed widespread blistering and significant signs of corrosion after only 250 hours in neutral salt spray. The ACET analysis revealed very high water uptake, correlated with reduced salt spray resistance performance. With a different batch of the same paint, however, the water uptake value decreased by about an order of magnitude and, as a result, the impedance loss dropped from 65% to 6.5% (Table 3).

Fields of application

This new class of products has many fields of application, especially those that require at least C3H corrosion resistance with a single coat of polyester powder. Besides contract coaters, these include industries such as household appliances, coil coating, architectural aluminium (coils and profiles), automotive components, pre-cataphoresis/anaphoresis, aluminium or steel wheels, and earth-moving, agricultural, and construction machinery (ACE). Dollcoat RS 103 is already Qualisteelcoat approved up to corrosion category C4H, and approval for category C5H is currently underway. Qualisteelcoat and Qualicoat approvals are also expected to be obtained for Dollcoat GP 107.

Conclusions

This new Dollcoat family introduces innovative technologies to the market that provide significantly enhanced anti-corrosion performance without requiring complex processes or the use of heavy metals like chromium, including in trivalent form. These products have very high pollutant resistance, allowing application by spraying through conventional nozzles, with the product being recirculated for months; they can also be applied using atomisation modules or by immersion. Their use in combination with nanoceramic conversions has proven particularly synergistic, delivering optimal corrosion protection.

3: ACET test results on two batches of the same paint.

Application with a chemcoater

Another available application is the pre-treatment of aluminium coils using chemcoaters. The chosen benchmark was a competing Cr³⁺-based product. Table 4 demonstrates that the use of Dollcoat RS 103 enhances polarisation resistance by almost an order of magnitude, while Dollcoat GP 107 provides a substantial increase of around four orders of magnitude.

-based product

Table 4: Application of Dollcoat RS 103 and Dollcoat GP 107 on aluminium coils using a chemcoater.

Table

Few Layer Graphite-Liquid Dispersion: innovation in the production and application of few layer graphite

Thanks to its consolidated experience in the dispersion of nanoparticles in lubricating fluids, Eni has developed an advanced technology for producing few layer graphite, called Few Layer GraphiteLiquid Dispersion (FLG-LD). The resulting dispersion acts as an additive for coating systems, which can impart specific properties depending on the intended application.

FLG-LD technology description

The core of the FLG-LD technology lies in a liquid phase (water or organic solvent) exfoliation process carried out using typical high shear mixers. The dispersion obtained is achieved using the following components:

 exfoliation promoters, for the controlled reduction of the number of graphite layers;

 surfactants, to ensure the stability of the FLG dispersion in the liquid medium;

 boosters and specific additives, selected according to the intended end use (e.g. for antimicrobial, anti-corrosion, or antifouling paints and coatings).

In terms of process management, it should be noted that the operating conditions are extremely simple: the process takes place at atmospheric pressure and without external heating. The application of specific mixing methods and the use of selected additives effectively prevent FLG from recombining into its original graphite structure.

The FLG-LD dispersion is characterised by planar dimensions on a micrometre scale (200-1,000 nm) and a nanometric thickness (≈ 6-10 nm) corresponding to the number of carbon layers (≈ 2030). This structural configuration is the main strength of this technology, as it is extremely effective in generating a ‘protective/active’ surface within the treated component. Graphite was chosen as the main raw material over ready-to-use graphene to optimise both management procedures and the health, safety, and environmental (HSE) aspects of the finished product. In summary, the FLG-LD production process is based on low-cost components, does not involve significant energy consumption as it takes place at room temperature and atmospheric pressure, and does not present any particular health, safety, or environmental issues during handling, production, and packaging.

FLG-LD as an anti-corrosion solution for surface pre-treatment

Eni’s collaboration with DN Chemicals has resulted in the development of a corrosion protection coating designed to safeguard metal surfaces from aggressive environmental corrosive agents. A dedicated FLG-LD formulation was utilised for this purpose, composed solely of FLG and process aids, which DN Chemicals subsequently incorporated into the final version of this anti-corrosion coating.

continues on the next page

The product entered the industrialisation phase in 2023 on several plants operating in various sectors, such as contract coating, electrical panel manufacturing, and coil coating. All pre-treated metal substrates (the main ferrous or aluminium alloys and HDG) were consistently characterised using EIS and ACET electrochemical techniques, RAMAN spectroscopy, and SEM microscopy. They also underwent accelerated corrosion tests in salt or acetic mist (ISO 9227), depending on the substrate.

Exploring new opportunities

Carbon Capture and Storage (CCS) technology

The design and construction of wells for CCS projects demand increased efforts in selecting appropriate materials capable of enduring harsh CO2 environments. Currently, CO2 injection conditions include:

 low temperatures;

 presence of impurities (e.g. H2O);

 abrasion and wear.

As expensive corrosion-resistant alloys (CRAs) are commonly used in CCS for completion pipes and string accessories,

research on internal pipe lining systems could potentially lead to significant cost savings by reducing the time needed to procure materials and equipment. FLG-LD could be considered an option alongside leveraging in-house developed solutions, but it requires assessment due to the considerably more severe well conditions than those it was originally designed for.

Drinking water

The upcoming EU regulation mandates new coating methods for products intended for contact with water. In this context, ‘Hf-free coatings’ will be used to prevent the release of hazardous metals (e.g., Bi, Ce, Hf, Mo, Pr, Sr, Ti, Y, and Zr). The regulation aims to eliminate harmful substances to protect drinking water supplies from contamination. Manufacturers, therefore, must adjust their production processes to comply with the new guidelines on coating for enhanced safety. DN Chemicals, using Dollcoat GP 107 along with selected powder coatings, has already industrialised a high-performance anticorrosion process for the sanitary water sector that removes the need for coating.

The image shows one of the properties resulting from the use of FLG-LD in polymer matrices: reduced matrix porosity and, consequently, improved corrosion resistance of the final workpiece.

FLG-LD observed by scanning electron microscopy.

Small beginnings. Powerful impact. Inspired by the transformative energy of magenta, Origin Bloom – Trend Color 2026 stands for strength, dynamism, and individuality.

With TIGER Drylac® powder coatings, surfaces unfold their full potential – from architecture and interiors to retail, appliances, and sports equipment. Vibrant, durable, and expressive, every application becomes a bold statement of color, energy, and transformation. www.tiger-coatings.com

Idrotecnica renews its range of demineralisers: introducing the new Idro CA series

From an interview with Federico Marcenaro Idrotecnica srl, Genoa (Italy) federico.marcenaro@idrotecnica.com

A long-standing manufacturer of state-of-the-art water treatment systems and equipment for forty years, Idrotecnica presents Idro CA, its new range of demineralisers, the result of a redesign process aimed at meeting the needs of its increasingly international target market.

Idrotecnica (Genoa, Italy) specialises in designing and manufacturing water treatment solutions for industrial processes. Over the years, it has built solid expertise in the purification and demineralisation of water used in industrial applications, and it stands out for its ability to support customers through all project phases, from analysing plant requirements to selecting the most suitable technological solution. It does not just supply products but is committed to providing a comprehensive service that includes technical assistance, customised design, and after-sales support. This service-oriented approach is one of the company’s distinctive features: ongoing technical support and assistance help customers maintain operational continuity and maximum efficiency of their installed plants. At the same time, Idrotecnica continually invests in technological upgrades to stay ahead of market developments and meet high quality standards. This is precisely why it has developed the new Idro CA series of demineralisers, aiming to establish a presence in the international market with its unique features.

The new Idro CA series

The new Idro CA range was created by redesigning the previous 2CA demineraliser series to meet the latest technological and technical standards adopted by Idrotecnica. The Idro CA plants produce demineralised water through ion exchange, a reliable process that uses special resins to remove dissolved salts from water. Their simple, functional design guarantees longterm reliability, longer component lifespan, and low maintenance needs.

“The restyling of this series addressed two main needs: ensuring the long-term availability of components and spare parts, and making our product increasingly suitable for global installation, in line with our growing focus on international markets,” says Federico Marcenaro, the CEO of Idrotecnica.

“Among the key features of the updated series is the new control unit, designed according to our latest standards. The LCD panel allows selection from up to six languages, easing use in international contexts. The new interface also offers more comprehensive and clearer communication of the plant’s status, enabling the operator to monitor operation and manage the resin regeneration process more efficiently. Another important aspect is the increased modularity of the range. The Idro CA demineralisers are available in three different sub-versions, developed to better meet various application requirements and market demands.” Such a high flexibility makes it easier for plant engineers and end users to integrate Idrotecnica’s demineralisation systems into their production processes.

“The redesign of the Idro CA series is part of a broader renewal-focused strategy that has always characterised Idrotecnica’s approach. We view innovation not only in terms of technological upgrades to our products but also as an ongoing process that encompasses our organisation and the service we provide to our customers,” says the CEO. In this context, attention to the quality of technical assistance is crucial. “Our added value lies not only in our technologies but also in our ability to support each customer before and after installation, identifying the most suitable solutions and providing consistent support over time.

Looking forward to PaintExpo

The new Idro CA range will be presented alongside an increasingly extensive portfolio of reverse osmosis demineralizers, which are in growing demand for supplying coating systems. The launch will also take place at PaintExpo, the leading international event for industrial coating technologies, scheduled from April 14 to 17 in Karlsruhe, Germany. “For Idrotecnica, participating in PaintExpo is a strategic opportunity to establish new contacts and partnerships with coating system designers and retailers operating in the surface finishing sector,” says Marcenaro. In particular, Idrotecnica aims to strengthen its position as a technology partner for industrial coating and cleaning machine manufacturers, capable of providing solutions for the production of demineralised water used in cleaning tunnels and surface preparation systems. “The goal is to offer added value to plant engineering companies that need to provide their customers with complete and reliable solutions, supporting them with specialised expertise in water treatment. That is why we are looking forward to welcoming visitors to our Stand 1529 in Hall 1,” the CEO concludes.

over

POWDER POINTS

Creating special effects in powder coatings: from formulation to sublimation

Nathan Biller Vice President, The ChemQuest Group, Inc. nbiller@chemquest.com

Powder coatings are often regarded as the finish of choice for their durability, efficiency, and environmental benefits. In addition to these highly desirable attributes, powders can offer distinctive aesthetics created by inherently unique special effects. These special effects can be integrated into a powder coating at various stages during the manufacturing process.

Most powder coating formulas include additives and clever chemistry that impart a specified appearance like color, gloss, matte finish, or texture. These formulation techniques are incorporated into the original formulation prior to extrusion. A second option is to blend an additive or pigment (metallic or pearlescent) into an already compounded dry powder to create an aesthetic enhancement. One of the more unique finishes relies upon a third technique that infuses materials into a fully formed surface of a cured powder coating.

Formulation techniques

Examples of effects that can be created through formulation conventions include a pantheon of surface profiles, ranging from a light sand texture to a dramatic anti-skid finish. This range of textures has traditionally been achieved by the addition of low levels of PTFE (poly tetra fluoroethylene). Recent regulations have restricted the use of PTFE, however, leading to a number of PTFE-free alternatives.

Wrinkle finishes are commonly achieved by pairing specific curing agent/catalyst combinations into epoxy or hydroxyl-functional polyester formulations. Still other additives can impart a controlled amount of incompatibility to produce a vein or hammertone texture.

Post-blend additives

The most common post-extrusion technique used to create special effects is the addition of special-effect pigments to already processed powders. These include aluminum flakes and pearlescent micas, which otherwise would lose their sparkle if incorporated during the extrusion process. Specialty metallic flakes and micas are blended with the finished powder coating either through low-intensity mixing or by a process known as bonding.

A range of textures and finishes can be achieved through formulation techniques.

Special-effect pigments such as aluminum flakes are a common post-extrusion technique.

© The ChemQuest Group

© The ChemQuest Group

During bonding, flake pigments are introduced to powder particles that have been softened using the heat from an innovative mixing process.

Speckle finishes can also be developed by blending dry powders. Achieving such an appearance requires blending two or more differently colored powders. During the melt and cure phase, this blend of discrete powder particles produces a consistent varicolored appearance.

Imprinted textures and dye sublimation

Another type of special-effect powder coating involves creating a unique surface profile after the powder has been applied and fused to the substrate. Processes have been developed that use textured plates or rollers to imprint a pattern into the surface (e.g., a carbon fiber effect).

Another post-application visual effect can be created using dye sublimation. With this process, a specially formulated coating is applied and fused to a substrate, and then a printed ink pattern is transferred into the film. These coatings typically have a higher-thanaverage level of crosslink density to resist errant dye diffusion and hence poor image resolution.

Formulas are typically based on either epoxy chemistry (for interior applications) or polyester/urethane technology (for exterior durable end uses). They may be formulated with a lower total colorant pigment content than normal so that the ink is not obscured. Exterior grades also may include a UV absorber package to protect the inks, which may have less resistance to UV exposure than the coating formulation.

INNOVATIVE RESINS FOR COIL, CAN & GENERAL INDUSTRY COATINGS

For over 50 years, Galstaff Multiresine has been developing high-performance resins designed to meet the evolving needs of Coil Coating, Can Coating and General Industrial applications, combining formulation versatility with longlasting durability.

FTALON 9075/75 X BB

Bio-balanced short-oil alkyd resin for high-gloss 2K polyurethane finishes with excellent yellowing resistance, suitable for wood and metal coatings

DP-ITALESTER MR 957-EC

Branched saturated polyester acting as an adhesion promoter, improving film elasticity in oven-cured can and coil coating systems.

DP-ITALESTER 222

Oil-free hydroxylated saturated polyester offering high flexibility and excellent adhesion to metal substrates for coil coating, general industry and appliance applications.

DP-ITALESTER H 36

Oil-free modified isophthalic saturated polyester with mediumhigh Tg, combining hardness and flexibility for waterborne primer and topcoat formulations in can and coil coating

DP-ITALESTER 950/70 X

High-solid branched saturated polyester providing excellent flexibility, chemical resistance and low yellowing for coil coating, automotive and appliance coatings

DP-FTALON F.A. 62 60 X

Short-oil modified isophthalic alkyd resin for primers, sandable surfacers and anti-corrosion coatings for general industry and automotive applications

Grounded in ESG values and certified according to ISO 9001 and ISO 14001, GMR invests in tailor-made sustainable solutions for the coil coating industry of tomorrow!

Blending two or more differently colored powders can create a speckle finish.

The process of dye sublimation requires that the initial coating is fully cured. Next, a heat-transfer film with the desired print pattern is wrapped onto the object and vacuum sealed to ensure intimate contact with the surface. Heat and pressure are applied in an oven, and the specially formulated ink sublimates into the coating to leave a decorative pattern. The most common types of patterns are wood grain, stone, or marble appearances that can allow a metal fabrication to approximate the appearance of natural materials. The design can be anything from a camouflage pattern to a corporate or team logo, or whatever the designer’s imagination can think of.

Producing expressive surfaces

Powder coatings are not limited to smooth, monotone surfaces. A wide variety of appearances can be achieved either by raw material selection, post-manufacturing additions, embossing patterns, or embedding inks post-cure. With the right chemistry and processes, these functional and eco-friendly coatings can produce exciting and expressive surfaces without sacrificing the high performance that powder is known for.

Textured plates or rollers can be used to imprint a pattern into a surface.

In the dye sublimation process, a specially formulated coating is applied and fused to a substrate. A printed ink pattern is then transferred into the film.

© The ChemQuest Group

© The ChemQuest Group

SINCE 1950

EVERY SURFACE

A TECHNOLOGICAL MASTERPIECE

INNOVATION THAT STANDS THE TEST OF TIME, PRECISION BEYOND BOUNDARIES. We do not merely treat surfaces: we transform them into symbols of efficiency and beauty. For more than 75 years, Tecnofirma has been a global partner, enhancing your products with customized solutions and state-of-the-art technologies in the fields of washing, coating, and impregnation. From Italy to the world, we shape excellence with the meticulous craftsmanship of the past and the technological precision of the future.

“Tecnofirma: where technology meets beauty and performance”

Function, form, and space perception: the evolution of pergolas according to BT

Giulia Gentile ipcm®

The evolution of contemporary architecture has expanded the role of traditionally ancillary elements, turning them into features that define the identity and quality of a built environment. Pergolas are a prime example of this trend: they are no longer purely functional structures but design elements that interact with the building and landscape. BT manufactures pergolas that reflect this vision through customised solutions, with particular attention to surface finishes serving as aesthetic and design levers. Its partnership with powder coating manufacturer TIGER Coatings allows it to combine functionality, colour variety, and visual appeal while integrating function, form, and the aesthetic perception of space in a truly contemporary way.

During the 20th century, architecture gradually refined the relationship between function and formal expression, overcoming the traditional hierarchy that clearly separated structural elements, technical components, and decorative features. With modernism, the idea that every part of a building contributes to its overall identity became central. Figures like Le Corbusier, an architect, urban planner, and theorist who was one of the most prominent names in the Modern Movement, championed a more integrated approach to architecture,

The CODE pergola in a ‘seaside’ setting.

viewing it as a union of shape, space, and visual perception. In his work, surfaces, volumes, and colours were not just details, but tools for shaping spatial organisation and the way the built environment is experienced. Over the years, these concepts have been developed to their fullest potential, and today, even elements traditionally seen as peripheral, such as sunshades and pergolas, have gained an increasingly important role in defining architectural styles. From purely functional devices designed to offer protection and environmental comfort, they have evolved into elements meant to interact with the building and the surrounding landscape. Colour, in particular, has become a vital tool for such integration and characterisation, ensuring visual harmony, enhancing materials, and catering to the rising demand for personalisation in modern architecture.

A leading player in this market sector is BT (Lesmo, Monza e Brianza, Italy), which specialises in the design and production of pergolas with a high technological and aesthetic value. In its view, surface finishes are not mere final touches but a valuable design resource that can shape identity, material perception, and architectural coherence. Using powder coatings developed by TIGER Coatings is therefore a strategic choice: these polyester powders certified for outdoor use offer a broader

range of colours and textures, guarantee stability over time, and meet the customisation requirements of architects and other players on international markets.

Through a combination of bespoke design, construction technology, and high-quality finishes, BT thus translates the modernist principle of integration between form and function into contemporary products, with the pergola seen no longer as just a technical structure but as a design element that interacts with the space and landscape in which it is placed.

BT: from Brianza to the world

Founded by Ambrogio Radaelli in Monza in 1954, BT began as a small workshop and, through vision and perseverance, gradually grew into an international industrial firm. In 1975, it launched Brianzatende, specialising in sun protection, whose workshop turned into a shop and showroom. Its expansion continued with the opening of a facility in Lesmo in 1983, the purchase of land, and the construction of new factories, reaching 20,000 square metres of production space by 2009 and offering a product range from awnings to integrated outdoor solutions.

The CODE pergola in a ‘mountaint’ setting.

FOCUS

“The company subsequently evolved into BT and strengthened its presence with BT Sud (Bari, Italy), BT Iberica (Spain), BT Belux (Belgium), and BT Australia, as well as the acquisition of a Canadian firm in 2025 to serve the North American market. Our philosophy is based on a key principle: personalisation. Each product is designed to blend with the surrounding architecture and meet the customer’s aesthetic and functional needs,” says Barbara Mandelli, senior marketing manager at BT. BT currently employs over 260 people in its production department and has three horizontal coating plants, along with advanced aluminium processing and metalworking areas. It offers rapid production, high quality, and extreme customisation, with competitive lead times even for single orders.

CODE: the flagship product and the essence of customisation

At the heart of BT’s product range is CODE, the innovative aluminium slat system that has revolutionised the pergola. Traditionally, pergolas require four posts for structural stability.

CODE replaces these with two built-in structural profiles (6×6 L-shaped and 30×6), enabling water to be drained through the integrated gutter while eliminating the need for bulky posts.

“CODE is the emblem of our Custom Outdoor Design Experience (C.O.D.E.) philosophy, aimed at transforming every pergola into a unique project: architects can design customised models – semi-circular, slender, or modular – and integrate glass enclosures, vertical cable blinds, or drapes, creating their bespoke solutions. In other words, CODE combines industrialisation and customisation, offering practical and flexible resources for planners and designers to craft their own signature style,” explains Barbara Mandelli of BT.

In this context, colour plays a central role: each hue can give the product a different identity, transforming the pergola into an expressive piece that adds value to the architecture, the environment, and the landscape. Colour selection becomes an aesthetic and personal exploration, a way to infuse every project with soul and character. CODE is therefore about not just structural technology but also forward-looking outdoor design capable of interpreting each designer’s vision.

The CODE pergola in a ‘countryside’ setting.

Personalisation and production flexibility

BT has developed an extremely flexible production approach: all pergolas are made to measure, with customised dimensions, shapes, materials, and colours. It has 62 standard colours in its catalogue and can produce specific hues on request, ensuring fast delivery times thanks to its three coating plants and high-precision equipment for aluminium machining and metalworking.

Customisation also extends to integrated technology: pergolas and awnings can be controlled via smartphone, connecting with home automation systems and offering a modern user experience. Attention to detail and a focus on the needs of architects make BT a key player in the sector, capable of combining personalisation, speed, and high quality standards.

Coating plants: precision, flexibility, and production control

“BT operates three horizontal coating systems. This reflects a strategic choice driven by the evolution of our products and our dedication to ensuring maximum customisation and quality. In recent years, the reduction in small parts needing coating – due to our transition from coated to stainless steel internal components –has improved the management of these systems, as they are now used to finish visible parts that are crucial to the overall aesthetic appeal of pergolas.

“The three plants enable us to handle even single, highly personalised orders and respond to any specific requests from architects and clients regarding size and colour, with over 62 standard hues available and the option to develop bespoke colours. Our production process is thus optimised: every element is checked meticulously, and quality remains paramount, since scratches or imperfections are unacceptable,” says purchasing manager Alessandro Citterio.

Additionally, BT not only uses these plants for treating its own pergolas but also to support other companies in the Group, such as BT Glass for glass panes, Form for the business’s own foundry, and BT Sud, ensuring consistent production standards across all business lines. The flexibility of these systems and their ability to also handle individual components allow for a rapid response to market demands while continuing to embrace the concept of extreme customisation, which is at the heart of BT’s philosophy.

The choice of TIGER as the powder coating supplier

To meet the increasing demand for customisation while still delivering high-performance finishes, BT has partnered with TIGER Coatings, an international manufacturer of certified powder coatings.

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

E-COAT SYSTEMS

LIQUID PAINTING SYSTEMS

POWDER COATING SYSTEMS

SELF-LEARNING ROBOTS FOR AUTOMATED PAINTING

SYSTEMS FOR THE TREATMENT OF VOCs EMISSIONS

This partnership arose from a clear strategic vision: to collaborate with a supplier strongly established in the European markets that the Group is currently exploring – particularly Austria and Germany, where TIGER is a well-known provider of architectural powder coatings – but also capable of supporting the company’s international expansion. It is also closely linked to a technical consideration that is particularly significant in Italy: the high exposure of outdoor structures to marine environments. In a country with thousands of kilometres of coastline, protection in such conditions cannot rely solely on the quality of powders but requires an integrated system that includes appropriate pre-treatment cycles, proper

surface preparation, and finishes that ensure corrosion resistance, colour stability, and durability over time.

That is why BT has launched a comprehensive project involving both powder selection and treatment cycle optimisation to guarantee consistent performance even in highly aggressive climatic conditions, and has also begun investing in raising technical awareness among architects and designers. Understanding of pre-treatment, certification, and finish performance remains limited within the industry, despite their substantial influence on project durability.

Through the BT Academy, meetings with key clients, and events

The CODE pergola in a ‘city’ setting.

accredited by local architects’ associations, BT promotes technical culture and knowledge of surface treatments, specifically targeting professionals who guide market choices and increasingly shape the preferences of private clients.

Another key factor in choosing TIGER relates to BT’s expansion into the North American market. US regulations on coatings differ considerably from European ones, and the market still heavily relies on liquid products, especially PVDF coatings. TIGER is one of the few companies that offers powders with AMAA certification, which is a fundamental requirement for operating in that environment. This collaboration, therefore, aligns BT with overseas standards while preserving its identity as a powder technology user, thereby enhancing its competitiveness in global markets.

“Technically and aesthetically speaking, Qualicoat polyester powders intended for outdoor use are central to how we customise our pergolas. Designed to withstand atmospheric conditions, UV rays, and mechanical wear, they guarantee stability and consistent performance even in

severe climates. We mainly use wrinkled textures characterised by three-dimensional and matte effects, which are especially popular in contemporary architecture" says Mandelli.

"These finishes provide two key benefits: they improve the aesthetics of pergolas because they are less ‘invasive’ than glossy surfaces, and they help conceal any imperfections in the substrates, reducing the risk of scratches during handling and leading to less rework and more efficient production,” says Marzia Brambilla, operations director at TIGER Coatings. The wide selection of powders also enables the creation of colour contrasts between roofs and slats, supporting BT’s customisation philosophy and allowing architects to establish a design identity that suits each building and its surrounding landscape.

“Colour control is supported by TIGERator, a digital tool that enables 3D visualisation of coated surfaces, offering architects and clients a realistic simulation of hues, opacity levels, and textures before production begins, thereby reducing the margin of error in final choices,” notes Marzia Brambilla.

From left to right: Barbara Mandelli, senior marketing manager at BT, Alessandro Citterio, purchasing manager at BT, and Marzia Brambilla, operations manager at TIGER Coatings.

This partnership also demonstrates a commitment to sustainability. For a company with products featuring many different finishes, the TIGER Eco-Pack system minimises paint waste, inventory, and disposal costs by providing customised refills ranging from 1 to 19 kg. The choice of powders is therefore not only based on aesthetics but also forms a key part of an industrial strategy that blends customisation, durability, production efficiency, and environmental responsibility.

TIGER’s wrinkled powders are more than just surface finishes: they serve as a technical and design tool through which BT embodies the concept of tailor-made products capable of meeting the most sophisticated requirements of architects, designers, and international markets.

BT at Salone del Mobile: colour at the heart of the experience

BT is going to be present at Salone del Mobile in Milan (Italy) with a 300-square-metre stand located at the front of Hall 7, designed as an experiential space where colour is a central design element. The exhibition will not be limited to displaying products, but it will also highlight the role of finishing in transforming the pergola from a functional structure into an architectural element with its own expressive personality. Through a combination of technology, customisation, and colour research, surfaces gain character and can interact with the built environment and the compositional choices of contemporary architecture.

The contribution of TIGER Coatings’ powders is therefore decisive: their quality, colour stability, and texture variety mean that colour is no longer an accessory element but a full-fledged design material capable of defining visual perceptions, enhancing volumes, and strengthening the coherence among products, architecture, and landscapes. The exhibition will thus confirm the evolution outlined above: surfaces, volumes, and colours have indeed become essential compositional elements in defining space.

The BT showroom in Lesmo (Monza Brianza, Italy).

FOCUS ON TECHNOLOGY

From galvanising to coil coating: UNICOIL’s chrome-free strategy to compete in Europe

The elimination of hexavalent chromium under the REACH regulation has been transforming the coil-coating sector. The case of UNICOIL illustrates how investing in trivalentchromium-based passivation for galvanising and in chromefree nanotechnology pre-treatment for painting has promoted sustainability, regulatory compliance, and access to the European market, thanks largely to a partnership with Condoroil Chemical that dates back more than ten years.

The gradual elimination of hexavalent chromium from surface treatment plants was a turning point for the industry: it was driven mainly by European REACH regulations, but it had repercussions across all countries that export their products to Europe. This change has given a strong impetus to research and development of more sustainable technologies, mainly based on trivalent chromium or, as an alternative, chromium-free solutions based on zirconium, titanium, or organic matrix salts, which offer corrosion resistance often comparable to the old method.

Alessia Venturi ipcm®

UNICOIL is a Saudi Arabian manufacturer of galvanised and pre-painted steel coils for both industrial applications and metal architecture.

This has radically transformed the sector’s operations, safety, and environmental impact. In the production of galvanised and pre-painted steel coils, in particular, the elimination of hexavalent chromium has affected two fundamental processes: hot-dip galvanising and pretreatment prior to painting. The transition has required investments in plant upgrades, new technical skills, and in some cases, the reformulation of pre-treatment cycles to ensure the same adhesion and corrosion resistance performance as that guaranteed by hexavalent chromiumbased solutions.

Once again, this process of updating and adapting plants and processes has affected not only European businesses but also all companies that export their finished products to this market.

UNICOIL, a Saudi Arabian manufacturer of galvanised and pre-painted steel coils for both industrial applications and metal architecture, is one such company. In 2013, to remain competitive in a market heavily influenced by products from the Far East and to enter the European market, it began collaborating with Condoroil Chemical (Casale Litta, Varese, Italy), a supplier of chemicals for galvanising, pre-treatment, and coil-coating lines. The aim was to gradually eliminate hexavalent

chromium across all production phases, replacing it with trivalent chromium-based systems for galvanising, nanotechnology for pretreatment, and latest-generation lead-free polyester and PVDF products for pre-painting processes.

UNICOIL: vertical integration, international expansion, and green transition

Founded in 1997 as the first company in the Middle East specialising in the production of pre-painted steel and aluminium coils, with an initial production capacity of 120,000 tonnes per year, UNICOIL (Universal Metal Coating Company) is now one of the leading players in the coil-coating and hot-dip galvanising sector in the MENA region. Headquartered in Jubail, a strategic industrial and port city in the Eastern Province of Saudi Arabia, it was established as a joint venture between two Saudi industrial groups, Zamil Group Holding Company and Rashed AlRashed Group, and the Australian giant BHP, a global leader in the pre-painted steel industry. In 2004, UNICOIL became a fully Saudi-owned company and made a key strategic move: installing a continuous-flow hot-dip galvanising system as a part of cold rolling.

Among the innovative products adopted by UNICOIL to enter the European market there is the titanium-based nanotechnology pre-treatment Condorcoat EC 956 supplied by Condoroil Chemical (Casale Litta, Varese).

This vertical integration has enabled it to control the entire production chain, improving quality, flexibility, and competitiveness. In 2007, following the acquisition of a second coil coating line in Jeddah, its total production capacity for pre-painted galvanised coils (PPGI) rose to 210,000 tonnes per year.

At the same time, UNICOIL adopted best industry practices, earning numerous national and international accreditations in the areas of quality, environmental and occupational safety, information security, laboratory accreditation, business continuity, and Great Place to Work® certification. This structured approach consolidated its leadership position in local and international markets. Its product portfolio has evolved over the years in response to market and customer demands. Currently, galvanised steel (GI) and prepainted galvanised steel (PPGI) coils are its core products.

Between 1997 and 2005, PPGI production relied on externally purchased galvanised substrates, mostly imported, with a limited range in terms of widths and thicknesses. The coating system applied was mainly standard polyester. The turning point came in 2005 with the commissioning of the hot-dip galvanising line and cold rolling mill, which integrated advanced heat recovery and water saving systems to support sustainability, and with a zinc bath operating within a safe lead limit of 90 ppm.

At this stage, with production mainly for local and regional markets and exports the portfolio of finishes was diversified to include premium polyester and PVDF coatings. However, pre-treatment operations were still based on hexavalent chromium.

On the other hand, the dimensional range expanded as follow:

 PPGI: from 0.30-1.20 mm to 0.23-1.20 mm

 GI: from 0.25-1.50 mm to 0.20-3.00 mm.

This new market focus has prompted Unicoil to invest in the gradual elimination of hexavalent chromium from all its processes to

Pre-painted and galvanised steel (GI) coils ready to ship.

Details of UNICOIL’s coil coating line.

© Unicoil

© Unicoil

© Unicoil

comply with European and American regulations. The transition has required investments in plant upgrades, new technical skills, and in some cases, the reformulation of pre-treatment cycles to ensure equivalent adhesion and corrosion resistance performances.

Change management:

the elimination of hexavalent chromium

Cooperation with Condoroil Chemical began at this stage. Its formulations initially supported UNICOIL’s transition to trivalent chromium in galvanising and, subsequently, the adoption of nanotechnology-based passivation products in pre-painting operations.

This led to the creation of an advanced product portfolio that includes:

 RoHS-compliant chrome-free PPGI;

 RoHS-compliant “TriChrome” galvanised steel;

 galvanised steel with an antibacterial coating for the HVAC sector;

 thin galvanised products with a coloured organic coating;

The drying oven.

© Unicoil

Hardness (Pencil)

Adhesion -T bend

Flexibility

Adhesion – Reverse impact

Cross Hatch

Gloss 60˚ (%)

Chemical, mechanical and weathering performances of UNICOIL’S pre-painted metal.

ASTM D 3363

ASTM D 4145

ASTM D 4145

ASTM D 2794

ASTM D 3359

ASTM D 523

Pencil F or harder

T-bend

T-bend

3T or less (No Pickoff)

3T or less (no cracking)

Reverse impact > 9 joules

Cross hatch > No paint removal

PROPERTY

Resistance to UV (QUV-A)

ASTM G53

Natural well washed exposure

ASTM G7

Exposure Hours

ASTM D2244

ASTM D4214

Color Change

Chalking

1500 Hrs

DE Hunter lab:

Light color ≤4

Int. Color ≤6

Dark color ≤8

ASTM Rating 4 – 2

ASTM D523 % Gloss Retention ≥ 40

Exposure Hours

ASTM D2244

ASTM D4214

Color Change (non-vertical)

Chalking

7 Yrs

DE Hunter lab:

Light color ≤6

Int. Color ≤9

Dark color ≤12

ASTM Rating 4 – 2

ASTM D523 % Gloss Retention ≥ 30

Exposure Hours

Resistance to corrosion (Salt Spray)

ASTM B117

Resistance to humidity at 38± 1°C

ASTM D 2247

Resistance to Abrasion

Resistance to Heat

EN 13523-13

Resistance to Fire

ASTM D714 & ASTM D1654

Exposure Hours

ASTM D714

ASTM D 968

ASTM D 4060

ISO 1518

ASTM D2244

BS 476 Part 7

Blister Density, Size & Corrosion Creep

Blister Density & Size

1000 Hrs

Blister density- Few, Blister size rating ≥8 Undercut from scribe ≤2mm

1000 Hrs

Blister density- Few, Blister size rating ≥8

Falling sand test -

Taber abraser 1000g CS10 wheels -

Scratch

90°C – 700 hours or 60°C – 1000 Hours

Fire rating

≥ 2000gms

ΔE ≤ 5, Gloss ≤ 7%

Class M1

 antibacterial systems for clean rooms;

 energy-saving “cool roof” solutions (Thermo Cool);

 high abrasion-resistance products;

 silicon modified polyester;

 high-durability polyester;

 multi-layer PVDF systems;

 Hi-Build PUPA systems.

Since 2013, in line with its quality principles, UNICOIL has also been using completely lead-free paints for 100% of its production, in compliance with RoHS regulations. Here too, the partnership with Condoroil continues, supplying last-generation primers, top coats, and back coats. UNICOIL’s production mix gradually rebalanced: polyester systems decreased from 95% to around 80%, creating more space for high-performance systems. The performance required of these coating systems includes:

 high durability and weather resistance;

 advanced corrosion protection;

 consistent aesthetic quality;

 compliance with international standards.

From a commercial standpoint, since 2013, the market share of GI (Galvanised Iron), initially almost entirely local and regional has shifted to 75%, with the remaining 25% exported to Europe and North America, confirming the soundness of UNICOIL’s investments in eliminating hexavalent chromium.

The partnership with Condoroil: a technical and strategic choice

Among the innovative products adopted is a low-temperature degreasing system and, in particular, the titanium-based nanotechnology

Reshaping coatings

Addressing the evolving needs of health- and sustainability-conscious consumers and brands.

Sustainability Performance

The layout of the high-speed coil coating line.

pre-treatment Condorcoat EC 956, which can be applied on high-speed lines up to 180 m/min via chemcoater, spray, or dip-and-squeegee systems.

“The choice of Condoroil Chemical as our preferred supplier of pre-treatment and coating products is based on a series of technical, qualitative, and strategic considerations that UNICOIL has been making since 2013, when we converted all our lines to hexavalent chromium equivalent products,” says Sanjay Roychoudhury, the CEO of UNICOIL. “First of all, Condoroil offers a product range consistent with our plant capability and fully compatible with our process parameters. Their consolidated experience in similar sectors and solid track record, as well as the compliance of their products with European regulations, have facilitated UNICOIL’s demand for the EU market, strengthening its competitive position in Europe.”

“From an operational perspective, Condoroil’s products offer flexibility to accommodate process variations and customised formulations based on UNICOIL parameters. The speed at which feedback and formulation adjustments are provided contributes to process optimisation and performance stability,” adds Luca Targa, Technical and Commercial Director at Condoroil Chemical.

“Despite the geographical distance, pre- and post-sales support remains continuous and efficient. In over ten years of use no claims have been recorded, confirming compatibility with technical reliability and strength of the partnership,” Sanjay Roychoudhury concludes.

Pre-painted coils ready to be shipped.

View from the above of the last section of the coil coating line.

© Unicoil

© Unicoil

New

coating line, new standards: superior quality, production continuity, operational safety, and streamlined maintenance

for Cantoni & C.

Monica Fumagalli ipcm®

Cantoni & C. S.p.A., a long-established manufacturer of tippers, has installed a new integrated shot blasting and water-based coating line designed to ensure not only application flexibility and colour customisation but also operator safety and simplified maintenance.

Since the early 2000s, the industrial vehicle bodywork sector has seen a gradual rise in coating quality requirements, transforming a product previously defined by its operational and functional value into one that also appeals to customers’ aesthetic taste – especially in the Italian market.

“Whereas in the past the focus was mainly on the structural strength of the tipper body, today its aesthetic impact and colour customisation, together with its structural characteristics, have become decisive factors in product selection,” observes Andrea Cantoni, sales director and son of the founder of Cantoni & C. Spa (Marcallo con Casone, Milan, Italy). “The increase in customer demands has had a direct effect on the required level of coating quality and, as a result, on the production organisation of companies in the industry, which must adapt their plants and processes to higher and higher standards.”

In the case of Cantoni, this adaptation has been part of a broader development plan launched in 2004 and due to be completed this year. “Our headquarters have always been in Boffalora sopra Ticino (Milan), where our company started. Over time, we grew to such an extent that in 2004 we purchased a new 46,500 m² plot in Marcallo con Casone, in a more convenient location for logistics, and began transferring production. In 2022, we built three new industrial buildings and are currently finalizing

a fourth facility, which will house the offices and the assembly department for a few specific products.

In one of these buildings, we installed a new water-based liquid coating line. This project was led by Eurotherm (Volpiano, Turin, Italy) as the main contractor, with the participation of Wagner Spa which provided the application system and Estalia for the supply of the water-based paints. The initial shot blasting stage was designed and implemented in collaboration with Tosca, which supplied the system, and Ervin Germany GmbH for the supply of the media.”

Key requirements for the new coating line included seamless integration of the shot blasting system, maximum operational safety during the handling and treatment of large parts, and streamlined maintenance. Eurotherm was entrusted with delivering these features alongside high process reliability. “It designed and installed a plant that fully meets the standards we set ourselves,” Cantoni emphasises, “ensuring a level of production continuity that is now one of our main hallmarks of quality.”

From left to right:

Cantoni & C. S.p.A. has been specialising in the production of tipper bodies since 1953.

Eurotherm’s design for the new coating line incorporates an automatic shot blasting system.

The automated shuttle designed by Eurotherm to move the bodies from the shot blasting system to the coating one.

blasting media supplied by Ervin Germany.

The

Ervin Germany

When an idea turns into a business

The history of Cantoni exemplifies how the Italian industry has often turned critical times into real opportunities. In the post-war period, in a country focused on reconstruction after the devastation of war, demand for construction equipment was high, while resources were limited. These constraints sparked the idea that led to the company’s development: in 1953, Marco Cantoni and two partners began converting and refurbishing military vehicles left behind by American troops after the Liberation, laying the foundations for what is now a family-run business in its third generation.

“My father and his partners specialised in the production of tipper bodies,” says Andrea Cantoni. “They soon recognised the importance of consolidating an international presence by establishing production facilities abroad.” In 1965, a factory was inaugurated in Tripoli, Libya; it was subsequently closed following the political events that affected the country. However, that experience made them even more aware of the importance of going global, a point now confirmed by Cantoni’s export rate, which has ranged from 70% to 85% at different times. “Our foreign strategy involves selecting local representatives and technicians to whom we send our products in kits to be assembled on site: we are mainly present in Eastern European countries and the former Soviet bloc.” At the same time, the company continued to expand across Italy, leading

it to acquire F.lli Cordero in 2001 to broaden its range with new tipping bodies, cranes, fixed bodies, vehicle conversion services, interchangeable superstructure systems, and other special solutions. “Our portfolio currently spans from light vehicles starting at 3.5 tonnes, with a production capacity of approximately 2,200 units per year, to heavier vehicles designed for construction sites, which can reach 63 tonnes, for which we have a production capacity of around 1,000 units per year. Both types are manufactured fully assembled or in kits, in a 70% to 30% ratio. We also have a special range dedicated to mining, i.e. vehicles with tippers for mining applications, which accounts for a smaller share of our production.”

“Everything in its place, a place for everything”

The three new buildings in Marcallo con Casone house, respectively, machining (cutting, bending, and robotic welding of bodies and subframes), shot blasting and water-based coating, and the assembly of finished products on vehicles. “The new factory has been designed to integrate state-of-the-art technologies in metalworking, coating, and assembly according to Industry 4.0 parameters,” says Antonio Cantoni, production manager and one of the owners of Cantoni Spa, together with his brother Andrea and sister Bruna. “We have various types of plants in our metalworking department, but our flagship is the laser cutting system, which produces any shape with such a high level of precision that it

The 3 identical, pressurised coating booths at the heart of Cantoni’s new coating system.

eliminates the need for subsequent machining operations such as drilling or slotting. This is complemented by a high-definition plasma cutting system for the anti-abrasion steel sheets we use to line the inside of bodies to ensure greater wear resistance.” The factory is organised into work islands, each equipped with all the necessary tools. This configuration reflects the company’s evolution and management vision, as captured in its founder’s motto: “Everything in its place, a place for everything”. The bodies are assembled and completed in the order of requests, then transported to the building housing the shot blasting and coating lines.

Like one interconnected system

Shot blasting is the mechanical pre-treatment phase that removes oxidation and surface contamination, levels the sheet metal, and creates the correct roughness profile to promote paint adhesion. “The entire line was developed in collaboration with Eurotherm. This also included careful consideration of the positioning of the automatic shot blasting machine, equipped with 16 turbines and sized to accommodate our bodies, in order to integrate it perfectly with the coating system into a single interconnected line. We have also defined specific recipes for each product, which activate or deactivate the turbines according to application requirements.” Shot blasting acts on the surface roughness of metal sheets in a controlled manner, to the order of microns, without altering their thickness. “The degree of preparation must be adjusted precisely: excessive shot blasting would mean thicker layers of paint are needed without properly covering critical areas, whereas too little would not ensure adequate cleaning, possibly causing visible oxidation,” Antonio Cantoni points out.

The inside of one of the 3 booths: the lift is designed to enable the operator to paint from below in complete safety.

An effective abrasive mix

To achieve a SA 2½ preparation grade, Cantoni uses a spherical and angular abrasive mix supplied by Ervin. This combination is the result of a long testing and optimisation phase. “After numerous trials, we identified the most suitable mix for our entire range of products. Exclusively spherical abrasives would tend to mark the surfaces without providing sufficient impact, while angular abrasives would be too aggressive. The mix was defined jointly with the shot blasting machine supplier and the abrasive supplier to obtain a perfectly balanced solution,” adds Antonio Cantoni.

“Following the installation and testing of the system,” says Pietro Turrin, the sales manager of Ervin’s Italian division, “we carried out the necessary technical checks by analysing the required mix, the waste generated, and the degree of surface preparation of the treated products. We then selected our AMASTEEL abrasive, adjusted for size

and hardness, which ensures the ideal blasting action.” Ervin also supplied the AMAPURE degreasing additive, developed to prevent the build-up of oily contaminants left by previous machining operations. “The use of the additive also benefited the external filtration system: condensation, generated by low temperatures and humidity in combination with the hot air from the process, can reduce the filtering efficiency and service life of the elements. AMAPURE helps limit the risk of damage to the cartridges and potential dust emissions.” After determining the most suitable type of abrasive, Ervin’s staff also trained the personnel involved in these operations.

A monitored process

Process control is continuous: Ervin carries out periodic checks, supported by technical reports that certify the plant’s status and recommend any corrective actions. “We carry out a complete check every three or four

The handling area outside the 3 booths.

months: the grit wears, fragments, and becomes more angular, so it must be replenished to maintain the required degree of roughness,” says Cantoni. To ensure operational continuity, a manual shot blasting chamber has also been installed alongside the automatic plant for touch-ups or extraordinary circumstances. “To date, however, we have never had to use it, which demonstrates the reliability of this system.” At the end of the cycle, the tipping body is tilted to recover the accumulated abrasive, which is recirculated to optimise consumption.

The coating plant: prioritising safety and streamlined maintenance

The coating line comprises 3 identical pressurised booths. “Using an automated shuttle,” explains Rocco D’Aloia, project manager at Eurotherm, “the body leaving the shot blasting machine reaches the lower part of the coating plant, where a lifting station picks it up and hooks it onto the overhead crane, which transfers it to its assigned booth according to a

pre-set programme. 80,000 m³/h of air is circulated within each booth, with a constant temperature of 20 °C during the coating phase and 80 °C during the baking phase. The air-handling units (AHUs) are installed outside, where air recirculation also takes place.” “The line we had in mind turned out to be particularly complex,” notes Cantoni. “With support from Eurotherm’s team, we adopted several technical measures that optimised the entire system for both safety and maintenance. We set up a system with hydraulic lifts, designed by the plant engineering company and capable of lifting up to 10 tonnes, ensuring the safety of components during coating from below. In addition, removable trestles allow the parts to be coated from any position without risk. To facilitate maintenance operations, we have also created an easily accessible utility room that houses all filtering systems and enables operators to work in an upright position. This may seem like a minor detail, but it is actually quite significant: plant maintenance always involves heavy work, and together with Eurotherm, we created the ideal conditions to make it easier.”

The storage buffer where the parts are placed before being sent for assembly.

© ipcm

© Estalia

The paint management unit designed and installed by Wagner.

The water-based coating cycle

The coating cycle comprises a two-layer application, a primer and a top coat, supplied by Estalia Performance Coatings Group under its Damiani brand: a two-component epoxy primer from the 0212 WATERPOXGrey RAL 7035 series and a two-component polyacrylic finish from the 0218 WATERPUR Glossy TF series, available in various colours. Again, several preliminary tests were carried out to identify the most suitable solution. The tests showed excellent results in terms of aesthetic quality, application uniformity, adhesion, resistance, and overall reliability, fully meeting the company’s technical and production requirements. In particular, this coating system provides high chemical and physical resistance (salt spray according to ISO 9227 and humidity according to ISO 6270) and weather resistance according to ISO 11507.

“For components, we mainly use RAL 7021, whereas for the bodies, the colour choice is determined by multiple variables, including customer requirements: it can reflect the brand’s corporate colours, which are

usually two, follow specific aesthetic guidelines, or be chosen to ensure a perfect colour match with the cab. To meet the latter requirement, Estalia provided us with a latest-generation portable sphere spectrophotometer, operated via a formulation app that instantly detects the booth colour and transmits it directly to Estalia’s tinting department, enabling us to access an extremely wide range of hues with rapid production times,” indicates Cantoni.

A highly controlled application system

Each of the 3 twin booths installed by Eurotherm is equipped with a mixing system designed specifically for applying the epoxy primers and polyurethane top coats used by Cantoni. The technological heart of the plant is a Wagner Intellimix Touch Plus mixing system, which manages two completely independent fluid sections via a single control panel: each section can operate with products of different chemical natures, maintaining separate mixing, control, and monitoring parameters. This

The application system operates at high pressure using Wagner Leopard 35-70 pumps.

The external AHUs, where air recirculation also takes place.

DSF (Double Fluid Section) solution is particularly suitable for production contexts where different coating systems need to be applied, as in this case, where epoxy primers and polyurethane finishes coexist, ensuring maximum operational flexibility without duplicating control panels. “This enables us to control the entire mixing and parameter management (catalysis ratios, product service life, diagnostics, and traceability) process from a single centralised interface, with clear advantages in terms of plant efficiency, space optimisation, and simplified maintenance,” says Cantoni. The use of water-soluble coatings also requires specific measures for viscosity management, mixing-ratio control, and fluid circuit protection. “The entire system operates at high pressure using Wagner Leopard 35-70 pumps, ensuring constant flow, pressure stability, and reliability even under intensive use. Application is carried out manually using AirCoat technology and GM 4700 guns, a solution that delivers high-quality finishing, excellent atomisation, and minimised overspray.” From a functional perspective, the

© ipcm

Some tippers ready to be shipped to the customers.

adoption of 3 Intellimix systems, one for each booth, ensures full operational autonomy between stations, providing production continuity and reducing the risk of system downtime.

Ensuring technological continuity

Antonio Cantoni emphasises that his company’s longstanding partnership with Wagner was instrumental in smoothing the way for a project that initially appeared particularly complex: “We have been familiar with Wagner’s technology for many years, as we have implemented several of their solutions over time. In addition, we are supported by their certified partner, FG SERVICE, for service activities and the supply of spare parts. This has been a decisive added value, enabling us to integrate this new plant into an already established technical context and to be supported through continuity of service, rapid intervention, and indepth knowledge of our production needs.” Overall, the project was highly technological and geared towards maximum application flexibility, precise control of process parameters, and optimisation of quality and production performance, in line with the most advanced requirements of the water-based industrial coating sector.

Towards extreme colour customisation

“Today, thanks to the system installed, the products we use, from abrasives to water-based paints, and our advanced application system, our coating department not only makes us proud but also enables us to position ourselves at an extremely highquality standard, while maintaining the application consistency,” concludes Andrea Cantoni. “Customers’ quality expectations have grown significantly – as already mentioned, especially in the Italian market –and are set to increase further: this investment was our concrete response to this trend. The project has reinforced our family-run company’s vision and laid solid foundations for its future development, secure in the knowledge that we have chosen the most suitable technology partners for our growth objectives.”

Perfect colour matching between the cab and the body is one of the factors that place Cantoni at the top of the market in terms of coating quality.

The colour of the tipper bodies can reflect the brands’ corporate colours, usually two, or adhere to specific aesthetic guidelines set by customers. © Cantoni

Powder from Nature

The strength of Europolveri powder coatings comes not from the carefully selected blend of raw materials alone, but from the people who study, shape and formulate these products thanks to more than 40 years of experience, and provide customers with a range with more than 1 000 products available in stock and over 40 000 already formulated

New Color, where revamping and digitalising a line made technology more universally accessible

Adopting an innovative approach to business development, powder coating contractor New Color recently completed a full overhaul of its line. The project involved collaboration with Avin, which, in addition to acting as the prime contractor and coordinating the work, reviewed the plant layout, revamped the curing oven, and fully re-certified the plant; Futura, which replaced the existing monorail conveyor with a power & free system complete with two loading and unloading elevators; and Gema, which installed a new, state-of-the-art powder coating booth alongside the existing one. The resulting plant’s high level of technological sophistication now ensures precision, full traceability, and optimised cycle times.

Technological progress is increasingly vital in making the world of work more accessible and inclusive. The digitalisation of production processes optimises workflows, supply chains, and product lifecycles within increasingly integrated environments and, at the same time, also creates a shared operational language that supports learning and training for the next generation in manufacturing companies. This point is emphasised by Massimo De Gianni, owner of New Color Srl (San Donà di Piave, Venice, Italy), a company specialising in powder coating components for various sectors, such as furniture, earth-moving machinery, white goods, construction, and metalworking.

Since 1995, New Color has specialised in powder coating components across various sectors, from furniture to earth-moving machinery, from the white goods industry to the construction and metalworking fields.

Monica Fumagalli ipcm®

“We are currently observing a generational shift: young people joining companies today are naturally more comfortable with digital technologies, even those used in production facilities, as they are part of their daily lives. Compared to previous generations, these operators often have an advantage, since new technologies can be more challenging for those who learned their trade in less digitalised settings. Machine functions are increasingly intuitive, which helps in both transferring know-how and applying it correctly. If our sector had remained solely reliant on traditional skills and manual processes, many companies like ours would have faced closure. Technological innovation, therefore, is crucial for maintaining operational continuity and supporting generational change.”

Already committed to a robust strategy focused on automation and environmental sustainability – the subject of a previous article published after our visit to report on the company’s new chemical-physical water treatment plant1 – New Color has recently undertaken another innovationdriven project, revamping its coating line and integrating it into an environment that was already technologically advanced and characterised by a workforce prepared to adopt new digital technologies.

1 https://www.ipcm.it/en/open/ipcm/2022/76/46-54.aspx

This included an update of the plant layout by Avin Srl (San Martino al Tagliamento, Pordenone, Italy), the conversion of the monorail conveyor into a power & free system by Futura Srl (Robecco Pavese, Pavia, Italy), the integration of a new Gema Europe coating booth alongside the existing one from the same supplier, and the optimisation of the parts traceability system developed by Avin in collaboration with Elettrica Srl (Padua, Italy), which was responsible for software development. Overall, the project’s industrial approach was aimed at maximising the line’s efficiency and ensuring the full operational and digital integration of all its components.

From a monorail to a power & free conveyor: a necessary choice for New Color

When upgrading a coating line, the conveyor system is the crucial element that determines the overall workflow: “Power & free solutions are becoming an inevitable choice for companies facing increased market demand, particularly for firms like New Color, which handles workpieces of varying sizes that can reach dimensions of up to 6000 × 2400 × 950 mm,” emphasises Massimo. “Last but not least, our new system can handle over 500 kg per load bar, a value previously unthinkable with our monorail conveyor.”

The loading and unloading area, featuring an elevator installed by Futura.

Futura oversaw the design of the conveyor, converting it from a monorail to a power & free system.

© Futura

New Color was established in 1995 as a powder coating contractor and has grown steadily since then. “Thanks to our strong focus on the quality of products and processes, we have obtained Qualisteelcoat certification, ISO 9001 certification, and the Environmental Product Declaration (EPD). We also operate in compliance with REACH and RoHS regulations,” says Massimo. “We strongly believe in ongoing development and investment in new technologies, although never losing sight of our commitment to the environment. We currently specialise in powder coating various metals and alloys, particularly Sendzimir hot-dip galvanised steel. Thanks to our certified processes, we have become a partner to some of the largest and most established multinationals operating in a variety of sectors.” These partnerships involve managing increasingly large batches, often with large-sized components that require flexible handling methods and increased production throughput.

“In a monorail system, the line speed remains steady throughout the plant, and any misalignment during loading and unloading can alter the dwell times of parts in different treatment zones, which can negatively affect

production timelines. Conversely, a power & free system allows for the creation of sections with varying speeds and provides control over the dwell time of components across different process stages. The switch to the power & free system designed by Futura was, therefore, a necessary choice for us, aligned with a strategy aimed at boosting plant efficiency, reducing production downtime, and optimising paint application: installing a new coating booth, which we had already planned, would have been pointless without the additional overhaul of the conveyor system.” As a result, the project carried out by Futura entailed the transition from a 236-metre to a 1-kilometre loop.

The power & free conveyor ensures predictable dwell times

During the design phase of this line revamping project, New Color identified some specific market requirements, including strictly controlled surface conditions in both the pre-treatment and curing stages. “In accordance with Qualisteelcoat guidelines, dwell times must be strictly

The storage buffer for workpieces waiting to enter the pre-treatment tunnel.

The new Gema's booth equipped with 18 guns and new-generation AP02 dense-phase pumps.

defined, which is difficult to achieve with a monorail system. Thanks to our power & free conveyor, divided into four operational zones with different speeds, we can now ensure controlled dwell times in the pretreatment, coating, and curing stations, thus fully complying with technical specifications in terms of drying, application, and above all, curing times and minimising the risks of over-curing and energy wastage. The clear goal is not only to ensure maximum operational flexibility – as expected of any coating contractor – but also to enhance energy efficiency and process sustainability.”

The redesign of the plant layout, carried out by Avin in collaboration with the other three suppliers involved in the revamp and made necessary by the integration of the additional state-of-the-art coating booth, also included fitting automatic access doors to the curing oven to maintain constant operating temperatures and a post-chamber to prevent heat loss.

The combination of Futura’s power & free system with the second Gema booth led to a significant increase in production capacity and a marked improvement in energy efficiency, further enhanced by the replacement of the oven’s burner with an air stream unit. This investment was indeed part

of a broader sustainability-focused initiative undertaken by the company, following the previous project concerning waste water treatment.

The new booth with dense-phase pumps

In fact, Gema Europe collaborated on the line’s layout upgrade, working closely with all the other companies involved in the revamping project.

“We adapted our equipment to the line’s new design,” explains area manager Marco Peduzzi. “We repositioned the existing booth within the same foundation pit, moving it 30 cm to optimise the available space, and transferred the cyclone and filtration system to the opposite side compared with the previous configuration. We also collaborated actively with Futura and Avin, which handled the structural aspects of the revamp, to help define the most suitable setup for New Color’s workflow.”

The integration of the new Gema booth marked a decisive step in the development of the paint application area: “Alongside the existing booth, which was suitably upgraded with Venturi injectors, we installed a new cutting-edge booth equipped with 18 spray guns, AP02 pumps (the latest generation of dense-phase pumps available on the market), and a new OptiCenter All-in-One OC10 powder centre.”

A comparison of two application technologies

Massimo De Gianni compares the Venturi application technology implemented in the existing booth with the dense-phase pumps used in the new one: “With Venturi nozzles, experienced operators are essential to ensure accuracy in the application process, so the end results depend on the workforce’s expertise. The dense-phase technology has largely solved this problem, as the last-generation pump system installed offers much more precise powder management and is also easier to maintain.”

“The new-generation OptiSpray AP02 pumps for dense-phase application open up new horizons in terms of coating quality and consistency,” confirms Peduzzi. “A further advantage lies in their long service life and ease of replacement. Whereas the pumps in the old booth had an average lifespan of around 1,000 hours, these exceed 2,000 hours. In practice, whereas previously a booth operating continuously on a single shift

required servicing every six months, now maintenance is needed only once a year and can be performed in just a few minutes and without the use of any tools.”

Another point highlighted by Massimo concerns the management of colour changes, which in the past were among the most critical process aspects. “Working with two booths makes production much more flexible: while one booth is in operation, we can carry out the colour change operation in the other, avoiding line stoppages. This enables us to plan our activities more effectively, manage touch-ups on parts more efficiently, and optimise our overall lead times.”

Dynamic scanning and optimised application

The application equipment was complemented with a Dynamic Contour Detection system, a technology based on laser scanners designed

The increase to 18 guns in the new booth supports the optimization of the 3D scanning system, improving coating coverage and precision.

Avin’s reorganisation of the plant’s layout included installing automatic access doors in the curing oven to keep temperatures steady.

A fully traceable process

to precisely identify products with complex or delicate geometries. Positioned at the entrance to the booth, the scanners capture twodimensional images, which are combined with line speed tracking data to reconstruct the three-dimensional contour of each workpiece. The control system thus automatically manages the positioning and activation of the spray guns, which move along independent axes, accurately following the parts’ outline. Multi-angle technology ensures that even the most complex shapes are coated evenly, reducing the need for post-finishing, which is especially useful when treating large-sized components.

The adoption of this three-dimensional scanning system was also aided by the increase in the number of spray guns, from 12 in the first booth to 18: “In a 3D system, the greater the number of guns available, the easier it is to follow the contours of workpieces. The movement of the lower units, in particular, promotes better penetration and precision. At the same time, a greater number of guns helps to increase the overall electrostatic effect, improving powder transfer efficiency.”

The revamp of this line has also enabled mapping the entire process, creating a ‘road map’ for each component’s journey along the line, complete with all relevant process parameters. A further upgrade involved the pre-treatment tunnel: in every tank, including the rinsing ones, Avin has installed sensors to monitor key parameters, from pH to conductivity and temperature. A control system with a dedicated countdown timer for each bar has also been implemented in the drying and curing oven. “We have designed this tracking system so that every barcode associated with a part is matched with its specific batch’s recipe,” explains Massimo. “In practice, each component is given a sort of ‘identity card’ that makes it traceable at any stage of the coating process and even afterwards, at the customer’s request.

“The storage buffer within the oven ensures we do not waste a single minute: even the longest curing times, which can range from 40 to 60 minutes depending on paint thickness, are managed with the utmost precision. Finally, once the cycle is complete, a report is generated on request, which can be delivered to the customer or kept on file for any future checks.”

The new post-chamber installed by Avin at the oven outlet to prevent heat loss.

© Avin

Conclusions

New Color’s aim is to maximise automation to optimise batch management as effectively as possible. “Working with major clients means we must handle orders with a higher number of batches, less fragmentation, and increased productivity: ‘flexibility’ is the watchword for any contract coater, and if this is supported by advanced digital technologies, the coating process can make great strides,” emphasises Massimo. The switch from a monorail handling system to a power & free conveyor has proved particularly strategic: “Previously, much of the control rested with the operator, which inevitably led to inconsistencies in processing times. Today, thanks to the solutions implemented, manual expertise has been transformed into automated processes. In practical terms, the operator now contributes around 30%, and 70% of the work is handled by the machine, ensuring reliable and consistent results without any risk of over-coating.”

Massimo also emphasises the importance of collaboration with suppliers: “This revamp was made possible through teamwork with companies that shared our vision and customised their designs to our needs. I must therefore thank Futura, Avin, Gema, and Elettrica, which did not restrict themselves to a simple supplier-customer relationship but embraced this project’s objectives with an innovative outlook. Digital industrialisation would not be achievable without such an advanced approach aimed to make technology more universal, standardising complex processes and making them more accessible to the new generations entering the manufacturing world today.”

View of the Futura conveyor in the storage buffer area.

ENGINEERED CHEMICAL PAINT STRIPPING

Accelerate Innovation

Accelerate Innovation

JUNE 9-11, 2026 | TORONTO, ON

JUNE 9-11, 2026 | TORONTO, ON

Join us for FABTECH Canada and experience the latest in metal forming, fabricating, welding, and finishing—all in one place. Discover breakthrough products, test next-generation technologies, and connect with thousands of industry leaders who are accelerating innovation. Learn, explore, and gain the insights you need to stay ahead in a fast-moving industry.

Don’t just watch innovation happe n — be part of it!

Join us for FABTECH Canada and experience the latest in metal forming, fabricating, welding, and finishing—all in one place. Discover breakthrough products, test next-generation technologies, and connect with thousands of industry leaders who are accelerating innovation. Learn, explore, and gain the insights you need to stay ahead in a fast-moving industry.

Don’t just watch innovation happe n — be part of it!

Event Partners

Event Partners

WHERE WE HAVE BEEN

PaintExpo brings innovations and hottest trends to the international stage

Christina Siebenhüner

Leipziger Messe GmbH – Leipzig, Germany c.siebenhuener@leipziger-messe.de

The world’s leading trade fair for industrial painting technology will showcase the full spectrum of sustainability, energy efficiency and intelligent automation from 14 to 17 April 2026 in Karlsruhe, Germany.

From 14 to 17 April 2026, the international paint industry will meet in Karlsruhe to experience the latest solutions and world premieres. Innovations range from sustainable coating systems and energyefficient solutions to AI and automation-driven process optimisations. “PaintExpo is at the heart of industrial painting technology – in Germany, Europe and worldwide. It brings together leading companies, innovative technologies and global decision-makers on one platform and sets standards for the industry’s future,” explains project director Carmen Bender, looking ahead to the event in four weeks’ time. The 2026 edition of PaintExpo is distinguished by an exceptionally high level of participation

from international exhibitors—not only from Europe, where nearly all countries are represented (with Italy leading, followed by France, Poland, the Benelux countries, Switzerland, and Sweden, to name just the most numerous), but also from the rest of the world, including China, India, Turkey, the United Kingdom, the United States, Egypt, and Tunisia.

As of March 13, 424 exhibitors have registered, 216 of which are from outside Germany, occupying nearly 14,000 square meters of exhibition space. PaintExpo once again confirms its position as the world’s leading trade fair for industrial coating technologies, products, and processes.

Sustainable coating systems and material innovations

Resource conservation and sustainability are shaping developments in painting technology. By way of example, this is demonstrated by the following exhibitors with their new developments:

 Venjakob will be presenting robotics for delicate and complex shapes as well as a mobile coating system for columns weighing up to 2,000 metric tonnes.

© Leipziger Messe GmbH / Tom Schulze

© Leipziger Messe GmbH / Tom Schulze

 With its German premiere, Gema Switzerland will be demonstrating how perfect coating results can be achieved with even the most complex application requirements and tricky geometries.

 J. Wagner will once again be demonstrating live solutions that make life easier for coating specialists – through intuitive operation, resource-saving use of materials, optimised processes and greater automation.

 Jürgen Emptmeyer will be focusing on the increasing demands on product safety, verification and quality with CE-compliant hooks and racks.

 Additional sustainable innovations will also be on display. Vulkan Inox will be presenting stainless steel blasting media for corrosion protection, and TOPO

Powder Coating will be launching robust anti-graffiti powder coatings.

Automation, robotics and digital process intelligence

The digitalisation of coating processes and the use of artificial intelligence will be more in focus than ever before for many exhibitors. Highlights include:

 FerRobotics automating the time-consuming masking process prior to painting and repairing paint defects on plastic parts.

 Walther Trowal will be unveiling the Rotamat R 60 for the insulation coating of particularly small components for electronics, plus the new R 100 for large flat sealing elements in e-mobility.

 REITER GmbH & Co. KG’s RoboTwin, which enables intuitive teaching of painting robots, allowing even less experienced personnel to achieve precise results.

 Micro-Epsilon Messtechnik will be bringing a trade fair premiere in the form of fully automated surface inspection of raw car bodies.

In addition, innovations in robotics and automation from other leading providers will shine a light on the future of smart manufacturing: SURFIN Technology with its intuitive robot programming and Fraunhofer ITWM with its measuring systems for simultaneous layer thickness and process analysis.

Process reliability and quality

Consistent quality and stable processes are crucial for cost-effective production processes. At PaintExpo, companies from around the world will be demonstrating how innovative systems increase process reliability.

For example:

 Dürr will be presenting overspray-free painting and a modular paint supply system including material

Hooks & CE Hooks

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

© Leipziger Messe GmbH / Tom Schulze

recovery, fast colour changes and low consumption of flushing agents.

 With its new hybrid E-Gripper Wheel, Eisenmann will be presenting a precise and gentle wheel handling solution that is both flexible and energyefficient, designed to increase and sustainably secure efficiency in its customers’ production processes.

 Krautzberger will be presenting two new automatic spray devices, which ensure greater efficiency on abrasive media and offer advantages in terms of performance, ease of maintenance and cost-effectiveness.

 Sherwin-Williams will be showcasing an innovative portfolio of coatings specifically designed for the everchanging demands of energy infrastructure worldwide.

 Blastman will be presenting a world first for sandblasting small parts in confined spaces.

Energy efficiency, resilience and resource conservation

The optimisation of energy and material use is a core issue for sustainable production. At this leading international trade fair, exhibitors will demonstrate how efficiency gains can be put into practice:

 Feige Lackieranlagen has developed the first new ventilation system architecture for industrial paint booths that combines high-level heat recovery with almost total separation of paint-laden particles.

 For the first time at a trade fair, NoxorSokem from Italy will be presenting an automatic process that removes paint from wheels without manual intervention and with consistent quality.

 Maston Oy has a world premiere: one of the fastest and most efficient portable filling machines, which can fill up to six 400 ml aerosol cans per minute with its 5-litre paint cone.

 Alvarez Schaer will be presenting a new compact anodising plant for aluminium processors who want high-quality anodising with reduced space requirements with lower resource requirements and operating costs.

Global networking and business potential

From 14 to 17 April, PaintExpo will once again highlight its role as the most important platform for industrial surface technology and painting processes. It will present the entire spectrum of international products and services in industrial painting technology along the entire valueadded chain. This makes it a unique meeting place for manufacturers, suppliers and decision-makers from all over the world. The concentration of innovations, products and industry experts creates the ideal conditions for intensive technical discussions, the exchange of experiences and new collaborations. Visitors can identify specific business opportunities, establish partnerships and initiate or conclude concrete orders.

© Leipziger Messe GmbH / Tom Schulze

© Leipziger Messe GmbH / Tom Schulze

LIVE A NEW FUTURE

FILTRATION QUALITY - CUSTOMIZATION - INNOVATION

HIGHLIGHT OF THE MONTH

Euroimpianti: half a century of innovation in coating systems

From an interview with Gianluca Baruffaldi

Euroimpianti Group (Valeggio sul Mincio, Verona, Italy)

Euroimpianti was founded in 1976 as a company specialising in the design and manufacture of coating systems. Since then, it has come a long way: these fifty years in business have been marked by technological developments, new premises, innovations, and constant growth. 2026, therefore, is a special year, an opportunity to celebrate an important milestone – its fiftieth anniversary – not as a final destination, but as a step along a journey of continuous evolution.

It is 1976. Italy is undergoing a period of change: a decade of remarkable growth, known as the economic boom, has ended, and the industrial system now faces the challenge of redefining its balance – partly due to the 1973 oil crisis – by rethinking production processes and reviewing the technology and efficiency of its plants. Against this backdrop, what will become one of the defining features of northern Italian industry begins to emerge: a widespread network of highly specialised companies characterised by high production flexibility and an increasing focus on international markets. It is a dynamic industrial model, grounded in technical expertise, innovation, and adaptability to change.

Euroimpianti has been designing and manufacturing coating systems since 1976.

© Euroimpianti

This is where Euroimpianti got its start. In 1976, it began designing and manufacturing coating systems from its headquarters in Villafranca di Verona (Verona, Italy). From the outset, the goal was clear: to develop technological solutions that would improve the efficiency and quality of industrial processes. The company’s growth closely followed the evolution of technologies and markets. In 1988, it distinguished itself by adopting computers and the first industrial design software, further strengthening its competitiveness with this pioneering step. In 1992, it opened a new facility in Valeggio sul Mincio, in the province of Verona: increased demand and the start of mass production had made it necessary to expand the spaces dedicated to the processing, assembly, and storage of materials. The years passed, and in 2002, Euroimpianti inaugurated its showroom, designed as a full-fledged testing laboratory, a space where customers could directly assess the quality and performance of its systems.

In the following years, the company consolidated its presence in international markets. In 2012, it established Euroimpianti do Brasil Ltda in Balneário Rincão, in the state of Santa Catarina (Brazil), opening the doors to the South American market. In 2016, it founded Euroimpianti Instalaciones de Pintura in Vallirana, in the province of Barcelona (Spain), a strategic location for the Iberian Peninsula. In 2018, it further strengthened its presence in the Americas with the creation of Euroimpianti USA LLC in Miami.

Euroimpianti’s growth trajectory also advanced at the production level. In 2020, a new factory was added to the main headquarters, and the company acquired several state-of-the-art machines, including an automatic warehouse for spare parts, a laser cutting system, and an automatic bending machine. The following year, it established Euroimpianti Deutschland GmbH in Germany, which became its sales office for the Central European market.

And here we are in 2026: Euroimpianti is celebrating fifty years in business, and we at ipcm® decided to reflect on its history alongside its CEO, Gianluca Baruffaldi, who shared with us the journey of a company that remains an exemplary model of entrepreneurial expertise.

Fifty years of business for Euroimpianti: a long journey marked by numerous significant developments. How was the company founded, and what were the key milestones that have enabled it to celebrate such an important anniversary?

Gianluca Baruffaldi: “Euroimpianti was founded in the late 1970s, at a time of strong industrial development in Northern Italy. During those years, many companies were increasing their production volumes, and there was a growing need to paint large quantities of components using industrial and continuity-based methods. Coating was no longer confined to the bodywork sector, with its small volumes and artisanal approach, but it became a critical production phase in many sectors: from

Throughout its long history, Euroimpianti has consistently focused on developing versatile plants capable of adapting to the diverse needs of its customers.

© Euroimpianti

architecture, with aluminium profiles for windows, doors, and façades, to agriculture, earthmoving machinery, and the civil sector for furniture, tables, chairs, and metal components.

Over the years, several milestones have marked our company’s growth. The first important step was taken in the late 1980s when we designed and built the world’s first vertical coating system for aluminium bars. This was a true innovation for the industry and remains one of our most internationally recognised products, which we continue to manufacture and export worldwide.

The second key phase came in the early 1990s with the launch of Euro 90, the first and still the only mass-produced, fully modular and expandable coating system designed to provide companies with a flexible plant that can grow over time along with production volumes. After more than thirtyfive years, it remains one of our flagship products. The third phase began after the 2000s, when we decided to focus decisively on internationalisation and bring our Italian-made products to

the rest of the world. Today, our systems are installed on virtually every continent: from Australia to Russia, from the United States to Canada, from Brazil to Nigeria, and in many European countries such as Spain. Italian technology has always been highly respected and valued across all these markets.”

What core values have characterised Euroimpianti from its beginnings in 1976 to the present day?

“One of Euroimpianti’s core values has always been to see itself as made up first and foremost of people. That is why from the outset, we have chosen to keep all the most important stages of our work in-house: design, production, assembly, spare parts warehouse management, and technical support. Everything is handled by trained staff with direct experience within our company. This choice gives us a high level of control over the quality and reliability of our plants. Many companies in this sector only deal with design and then outsource most of the production process, but

Euroimpianti was a pioneer in developing the world’s first vertical coating plant for aluminium bars. This technology remains one of the company’s flagship products.

© Euroimpianti

we have always preferred to keep our skills and know-how in-house. Over the years, this approach has allowed us to build relationships of trust with both our customers and our employees, creating a stable and highly skilled team capable of tackling complex projects and providing long-term support for our systems.”

Fifty years is a long time: the industrial landscape has radically transformed over these five decades, driven by new trends and market demands. How have you adapted to these changes, and how has your product range developed to meet new requirements?

“In fifty years, the industrial landscape has changed dramatically. We have weathered economic crises, banking crises, geopolitical changes, and complex situations linked to wars or the closure of markets that were historically key for our sector. Our strength has always been our broad international presence. By working across the world, we have managed to balance our target markets: when one region faced a

Osvaldo Baruffaldi, the founder of Euroimpianti.

© Euroimpianti

tough period, others often experienced strong growth and high demand for plants. This has enabled us to maintain a steady workload and continue to develop our technologies.

At the same time, our product range has also evolved. Over the years, we have invested heavily in the development of increasingly efficient, reliable, and automated systems, with a growing focus on environmental sustainability, energy saving, and operator safety.”

What adjectives would you use to describe Euroimpianti yesterday, today, and tomorrow?

“Yesterday: visionary. Since its inception, Euroimpianti has strived to offer innovative solutions for the industrial coating sector, sometimes anticipating needs that the market would only express in later years.

Today: technological. Currently, we are focusing on technological development, with increasingly automated and efficient systems that integrate seamlessly with our customers’ production processes.

Tomorrow: specialised. In the future, we aim to further strengthen our expertise in the industrial coating sector by developing increasingly targeted, sustainable, and hightech solutions.”

Being an entrepreneur today requires having solid plans, but also the ability to think big and face unprecedented challenges. What are Euroimpianti’s specific short-term projects, and what are its hopes and ambitions for the future?

“One of our concrete short-term objectives is undoubtedly to continue developing systems that ensure increasingly safe, efficient, and environmentally friendly work environments for both our workers and the customers using our plants in their production lines. Another area of focus is offering solutions increasingly geared towards environmental sustainability,

with technologies that reduce energy consumption, optimise paint usage, and reduce the environmental impact of manufacturing processes. We are also working extensively on improving our human-machine interfaces to make our systems increasingly easy to use, operator-friendly, and easy to integrate into modern production systems. Looking ahead, we aim to continue developing technologies that combine productivity, quality, and respect for the environment, helping to build a more sustainable industry for future generations.”

In line with its focus on growth and internationalisation, Euroimpianti will be exhibiting at PaintExpo, the leading trade fair for the surface treatment industry, taking place in Karlsruhe (Germany) from 14 to 17 April. The Euroimpianti team looks forward to welcoming you at Stand 2240, Hall 2.

Gianluca Baruffaldi (left) with his brother Massimo.

© Euroimpianti

Automated application, water-based DTM coatings, and IR drying: DAB Pumps’ technical choices for the efficient, high-quality finishing of

cast iron pumps

DAB Pumps, a company specialising in water pumping solutions, has decided to invest in a new state-of-the-art coating plant for the sustainable, high-quality finishing of its cast iron products. Developed in collaboration with Lesta, Wagner, Sherwin-Williams, and Deteco, the line incorporates the latest technologies in automation, energy efficiency, eco-friendly coating products, corrosion resistance, and quality standards.

Water is life. It is the essential resource that supports natural ecosystems, agriculture, industry, energy, and our daily lives. Its effective management, from collection to distribution, reuse, and control, is currently a global priority. The industry of water pumping, management, conservation, and protection systems has a central role in this, ensuring water is available where and when it is needed, in an efficient, safe, and controlled manner. Pumps are employed to move and regulate water flows in many areas, from agriculture and rainwater drainage to the pressurisation of residential and commercial buildings. Historically, their use has been strongly affected by seasonality, particularly in the agricultural sector, where the cyclical nature

Martina Stucchi ipcm®

of water availability has influenced the design and implementation of pumping systems designed to respond to predictable and relatively stable conditions. In recent years, however, this balance has become increasingly unpredictable. Extended periods of drought have alternated with years characterised by intense and sudden rainfall, changing the demand for water management solutions. In some cases, the need for pumps has decreased, and in others, it has increased suddenly. Seasonality no longer follows regular patterns, and companies specialising in the pump sector are facing new challenges as they adapt to a constantly changing scenario.

DAB Pumps Spa (Mestrino, Padua, Italy) manufactures and develops water pumping solutions for a broad range of applications. For over fifty years, it has been committed to innovating and addressing critical issues in water management while meeting current market demands. Within its production facilities, it researches, designs, engineers, manufactures, and coats a wide range of pumps and components necessary for its water handling systems. A few years ago, it felt the need for a new liquid coating plant devoted to one of its product ranges, which, in line with the strategic direction it had been following for some time, had to be a technologically advanced, efficient, safe, and above all, low environmental impact solution. In particular, DAB Pumps had three main sustainability-related requirements: to increase corrosion resistance by using water-based coatings; to minimise overspray and limit the formation of paint sludge; and to reduce energy consumption.

Thanks to the collaboration of a working group composed of Deteco, Lesta, Sherwin-Williams, and Wagner, the company inaugurated its new plant in 2023, applying two-component water-based DTM coatings and fitted with an automatic mixing and application system, articulated

robots, and energy-efficient infrared lamps for paint drying. The objectives achieved were straightforward and strategic: consistent and repeatable coating quality, higher product standards, minimised environmental impact of finishing operations, and cost containment through reduced energy, raw material, and disposal expenses.

Making water easy

Since its foundation in 1975, DAB Pumps has established itself as a leading manufacturer of water pumping systems, offering a product range that covers residential, commercial, and irrigation applications. “We aim to deliver increasingly customised solutions based on customer needs. We define ourselves as an agile company, capable of recognising market demands as they arise and developing efficient and effective solutions promptly,” says David Chiodo, the Group’s production manager. “We operate in the water sector: 90% of our products are designed for the transportation of potable water, particularly for water boosting systems and for pressurising civil and commercial buildings. Another significant portion of our production pertains to the transportation of non-potable water, especially for irrigation or circulators used in closed-loop systems.” This approach is also reflected in the new corporate payoff: ‘Making water easy’. “The word ‘making’ represents what we do: designing, engineering, and building innovative products and solutions that improve the everyday use of water. ‘Water’ recalls our ambition: to transport and manage this vital resource responsibly to support the communities of today and tomorrow. The word ‘easy’, finally, is the element that most characterises us and sets us apart from competitors. Our goal is to offer customers a seamless experience both during installation and operation, as well as in terms of assistance and interaction with our products.”

DAB Pumps headquarters in Mestrino (Padua, Italy) and Piero Zen (centre) with Graziano Sanvido (left) and Riccardo Bertin (right), operations managers of the coating departments.

© ipcm © DAB Pumps

DAB Pumps also develops advanced interfaces and digital solutions: many products are connectable and manageable via dedicated applications, available to both end users and professional operators for constant and reliable pump monitoring.

The company currently employs approximately 1,650 people worldwide, including over 950 in its operations division. It has fourteen sales offices and six representative offices across four continents. In 2025, it produced 1.9 million pumps at six manufacturing sites: four in Italy, one in Hungary, and one in China. The factory in Castello di Godego (Treviso, Italy) produces internal components for motors, while the other five sites manufacture various types of pumps, depending on product features and target markets.

Coating as a strategic choice

DAB Pumps was originally founded as a manufacturer of cast iron pumps. Over the last twenty-five years, through continuous technological

development, it has complemented them with alternative options, such as plastic and stainless steel solutions, but it has never completely moved away from cast iron. In fact, it has further invested in this long-standing product range, enhancing its quality and technological standards. Indeed, in 2020, the need emerged to innovate the IN LINE cast iron pump range by building a new assembly plant. This opportunity also gave rise to the project for a new liquid coating plant, designed to revolutionise the company’s production process and integrate the most advanced technologies available on the market.

This stemmed from an idea by Piero Zen from DAB Pumps’ industrial engineering department, who was then able to involve and coordinate a pool of industry leaders. The project saw the participation of new suppliers, including Lesta, Deteco, Cester, and Movingfluid, alongside long-standing and well-established partners such as Wagner, Kendell (a Chemetall group company), and Sherwin-Williams.

Thanks to the synergy of its specialist skills and shared strategic vision,

this team succeeded in turning an ambitious plan into tangible technological value.

“We started from the paint product: back in 2020, we asked Sherwin-Williams to collect data and carry out specific tests to meet our need for liquid coatings with greater corrosion resistance, better adhesion to the substrate, and higher ease of application. After intensive research and development, SherwinWilliams’ technicians developed a last-generation water-based, DTM liquid paint with high performance and sustainability characteristics in line with the latest European regulations,” explains Piero Zen. It should be noted that previously, the coating process for this product range was manual but already entailed the application of a water-based paint, though one that was less advanced in terms of formulation and performance.

From left to right:

Pumps coated with the last-generation, water-based, two-component DTM product formulated by Sherwin-Williams.

The LEBOT MVA6 articulated robot during automatic paint application in the water-curtain booth.

The pneumatic paint spraying system.

The Wagner Intellimix mixing unit.

The coating process

The coating plant was built by Deteco (Porcia, Pordenone, Italy), which developed a compact and functional system while also acting as the prime contractor for this project. The line handles the coating of cast iron pumps of various sizes, from about 7 kg to 150 kg, totalling over 400 models and variants. The pumps to be treated reach the loading area on special pallets. Here, an operator rotates them 180°, and with the help of an automatic lifting system, places them on the load bars of the power & free conveyor designed by Conveyors Nord (Inzago, Milan, Italy).

Each load bar is provided with an RFID tag, which allows the software program to monitor and track data for each product and select the corresponding treatment recipe. From the loading station, the load bars reach the water-curtain coating booth, where Sherwin-Williams’ waterbased, direct-to-metal liquid paint is applied by an articulated robot from Lesta, one of DAB Pumps’ new technology partners. “We were not familiar

with Lesta’s products, but after a thorough market analysis, we opted for its automation solutions. It is a young and dynamic company, offering innovative ideas and a well-structured after-sales service programme, which was a decisive factor in our final choice,” says Piero Zen.

Lesta’s LEBOT MVA6 robot features advanced software that automatically detects incoming parts, calls up the corresponding coating sequence, and manages colour changes, as it is constantly connected to Wagner’s Intellimix pumping system. A pneumatic spray gun is mounted on the robot’s wrist. This application configuration reduces overspray by 40-50%.

The system is also designed for automatic colour change operations to ensure high production flexibility. After coating, the pumps dwell in a flashoff area at room temperature to allow the film to settle.

The load bars then enter the drying oven. This process stage has been the focus of extensive research and development aimed at identifying an innovative and sustainable solution to avoid using excessive temperatures

Insulated boxes for paint preparation.

The pump coupling system on the power & free conveyor installed by Conveyors Nord.

and, therefore, save energy and reduce the carbon footprint of the entire finishing process. In collaboration with Deteco, DAB Pumps developed a concept for a fully electric oven fitted with IR lamps, which are activated only when a part passes through, thus avoiding energy waste. The software-controlled infrared radiation system adapts the drying programmes to the characteristics of each product, identified through the RFID tag, and automatically modulates the energy emitted to ensure efficient consumption and flexible treatments. Unlike traditional methane gas ovens with hot air ventilated at 80-85 °C, the IR technology maintains the overall internal temperature at around 25-30 °C. This enables ongoing process monitoring via internal cameras, with benefits in terms of efficiency, safety, and maintenance speed,” illustrates Zen.

The coating plant is also fitted with a booth water treatment, overspray separation, and sludge management system developed by Kendell, which has significantly improved the cleanliness of the work area and reduced water consumption. Through a floating flocculation system, sludge is efficiently removed from overspray and disposed of. Finally, sensors are distributed throughout the plant to ensure safe, controlled, and efficient functioning.

The drying oven with IR lamps designed by Deteco.

A team of professionals for high-quality results

The combined effort of all suppliers ensured high plant performance and the achievement of DAB Pumps’ goals. Every product is now manufactured to high quality standards, with consistent and repeatable results throughout the entire process, from paint application to drying, thanks to the reliable monitoring of each operational phase. Cutting energy consumption and optimising the use of raw materials, such as coatings and water treatment chemicals, also greatly reduced costs. In addition, DAB Pumps now uses less paint than in the past because the new product is much more efficient. This also results in less sludge to be treated and lower disposal costs. Collectively, these technological advances have contributed to a tangible reduction in the environmental impact of the company’s entire production cycle. “Another aspect that should not be underestimated is the evolution of our internal skills: operators who were previously engaged in manual coating operations have been reskilled and can now independently manage and programme the system, particularly the Lesta coating robot,” notes David Chiodo.

“The operational results have been impressive right from the start. In particular, we have seen a significant increase in product quality. This new line is a virtuous example of how technological innovation can improve the work environment, safety, and the overall sustainability of production processes, as well as contributing to the professional growth of all the people involved,” concludes Zen.

Finished pumps are sent to the coating line’s unloading station.

The booth water treatment and overspray separation system supplied by Kendell (a Chemetall group company).

ADVANCEMENTS

ANODIKIT® Zone: from the world’s first compact anodising line to a proven industrial model

Edited by ALSAN - Alvarez Schaer Paterna (Valencia), Spain alsan@alsan.es

ANODIKIT® Zone is a compact system developed by ALSAN to rethink the architecture of anodising plants without compromising process integrity. Reduced volumes, advanced automation, and full QUALANOD compliance position it as a consolidated industrial solution focused on flexibility, control, and operational sustainability.

European anodising is changing. Not abruptly or disruptively, but through a silent evolution driven by structural factors: sustained increases in energy costs, growing environmental regulatory pressure, the progressive reduction of specialized technical labour, and the need to produce shorter series with greater flexibility. For decades, the dominant model was clear: large installations, high bath volumes, infrastructures designed for continuous high-tonnage production, and resource-intensive operational structures. That paradigm responded to a stable industrial context with predictable energy conditions. Today, the scenario is different.

In this new industrial landscape, ALSAN - internationally recognized for its engineering and chemical expertise in surface treatment - has redefined how anodising can be conceived and integrated within modern production environments. ANODIKIT® Zone positions itself not as a compact variation of a traditional line, but as a proposal that rethinks the very architecture of the anodising process.

Resizing without compromising the process

A conventional anodising line may require floor areas well in excess of 800–1,000 m², with pretreatment alone accounting for total tank volumes ranging from 50 to 80 m³. Such dimensioning implies large chemical inventories and more complex effluent management, underlining the importance of developing compact process architectures that preserve final result quality while reducing resource intensity.

ANODIKIT® Zone significantly reduces this structural scale. The complete installation can be integrated within approximately 200–250 m², and pretreatment tanks operate at volumes of around 2 m³. This reduction does not alter the electrochemical sequence of the process, but it substantially modifies its energy and operational impact.

Lower installed volumes reduce energy demand to reach and maintain operating conditions and decrease overall chemical consumption, while also introducing significant advantages from a regulatory standpoint. The total volume of treatment baths installed in the plant - including

anodising, colouring and pretreatment stages - is approximately 24 m³, remaining below the 30 m³ threshold that, under the European Industrial Emissions Directive (formerly IPPC), typically triggers integrated environmental permitting requirements for metal surface treatment facilities. By operating below this regulatory threshold, the installation benefits from a significantly simplified administrative framework and a reduced environmental compliance burden compared to large conventional anodising plants. The result is not simply a smaller plant, but a system with lower structural inertia, reduced water and chemical consumption, and greater operational agility.

Intelligent chemical flow compaction

The differentiating element of ANODIKIT® Zone lies not only in volumetric reduction, but in the functional reorganization of the process. Degreasing, etching, and neutralizing stages are concentrated in a multiprocess spray tank, where the profile remains mounted on a patented rotating rack that ensures homogeneous treatment on all surfaces. This solution eliminates at least six traditional tanks while maintaining full chemical consistency of the treatment. The anodising phase is carried out by immersion, preserving the electrochemical parameters of conventional industrial anodising. When required, the line integrates immersion-based electro-colouring, expanding the aesthetic range to stainless-steel tones,

From left to right:

ANODIKIT® Zone by ALSAN is a compact anodising system designed for seamless integration into modern production environments.

This new anodising system can be installed within 200–250 m², with pretreatment tanks operating at around 2 m³.

Profiles are mounted on a patented rotating rack inside a multi-process spray tank, ensuring uniform degreasing, etching, and neutralization.

complete configuration, the installation incorporates a 60 °C aging bath enabling compliance with QUALANOD standards. In terms of productivity, the line achieves capacities of up to 100 metric tons per month in Class 10 and 75 metric tons in Class 15, clearly positioning itself within the segment of medium-scale specialized production.

While ANODIKIT® Zone had already been implemented in previous projects, the 2022 industrial installation marked the first Zone line operating under full QUALANOD homologation requirements. This milestone confirmed that the compact spray-based architecture could meet the most demanding European anodising standards without compromising productivity or process stability. This full homologation not only certified finish quality but consolidated the model as a technically robust alternative within the European anodising landscape.

Automation as a structural response

One of the current challenges in European anodising is not only energyrelated, but human. The availability of highly specialized technicians is increasingly limited, and process stability depends more than ever on automated control systems.

Final sealing returns to the multi-process spray concept and, in its most

ANODIKIT® Zone operates through a system that continuously monitors more than 200 process variables, including temperatures, processing times, conductivity, water inputs, and chemical dosing. This level of digitalization does not respond to a technological trend; it addresses a structural need for repeatability, traceability, and operational stability in

The technology behind beautiful surfaces

PVD coating systems for decorative applications

Our technologies transform metals into durable, elegant and high-performance surfaces.

From eyewear and watches to faucets, handles and fashion accessories, we help manufacturers bring design and durability together.

PVD: stronger, smarter, greener

increasingly audited industrial environments. The full construction in plastic materials and reinforced fiberglass eliminates structural corrosion issues and reduces maintenance requirements, contributing to longer system lifespan.

In addition, the installation can operate with two operators per shift, optimizing human resources without compromising process control.

Internalising to gain control

In a context marked by logistical volatility and the need to shorten delivery times, more and more companies are evaluating the internalization of anodising as a strategic decision.

Historically, the size and investment required for a conventional plant discouraged this integration. ANODIKIT® Zone modifies that equation by requiring an investment approximately three times lower than a standard anodising line, facilitating the incorporation of the process within the company’s own production structure. The consequence is not merely economic, but also organizational. Anodising ceases to be an outsourced service and becomes a direct instrument for quality control, planning flexibility, and lead-time management.

International expansion and scalability

The concept continues its international deployment, with a new installation currently being commissioned in Mexico, further demonstrating the scalability and adaptability of the compact anodising architecture across different markets and regulatory environments. This expansion confirms that the model is not limited to a specific industrial context but can adapt to diverse regulatory frameworks and heterogeneous production needs.

From innovation to a consolidated industrial model

After several years of industrial operation, the system has demonstrated consistent performance, process repeatability, and stable quality control under real production conditions. What began as a compact innovation has evolved into a reliable industrial model.

Technical validation, homologation under demanding standards, and international expansion have transformed the positioning of ANODIKIT® Zone. It is no longer a singular innovation, but a consolidated industrial architecture within European anodising.

TECHNICAL FEATURES

ANODIKIT® Zone is available in three versions:

 Natural, featuring a compact multi-process spray architecture combined with immersion anodising for efficient natural finishes.

 Premium, which adds immersion electro-colouring to expand the aesthetic range.

 Premium Q+, incorporating a 60 °C aging bath to fully comply with QUALANOD standards.

Naturally, a Natural Q+ configuration is available by integrating an aging tank, enabling certification while maintaining a natural finish.

Understanding the real drivers of coating economics and sustainability: HangOn’s Coating Cost Calculator takes a major leap

HangOn announces a major update to its Coating Cost Calculator (CCC), the most advanced analysis tool available today for understanding, simulating, and optimising coating costs. The CCC can be used to quickly summarise the economic impact of different scenarios through standard cases as well as in specific customer set-ups, calculate the effects of any plant improvements or the introduction of new raw materials, and assist decision-makers with a deeper understanding of the economics of coating processes.

Alessia Venturi ipcm®

It is well known that coating is one of the most energy-intensive phases of any manufacturing process. All stages of a coating cycle, except for paint application, require heat. This is necessary to warm the pretreatment water, dry water residues, cure or dry paint, and air-condition the coating booth. Cost control is therefore crucial for any company that coats its own or third-party components, as operating parameters directly affect production capacity and output.

However, many businesses are not fully aware of the profit potential of their coating lines. Yet, parameters such as hanging density or part handling times can significantly impact productivity, costs, and revenues.

Understanding the real cost of industrial coating – and its environmental impact – remains a challenge for many companies, often tackled with limited tools or rough estimates. Building on this idea, Swedish company HangOn, one of Europe’s leading manufacturers of masking devices, hooks, and engineered hanging systems, developed a data-driven approach a few years ago to show that optimising an often-overlooked factor, namely the hanging density of parts on a coating line, can greatly influence both operating costs and CO₂ emissions.

This resulted in the development of the Coating Cost Calculator, a digital tool launched in 2022 and expanded in 2024 with new environmental parameters to meet the European CRSD directive, which requires companies to report on sustainability using standardised criteria. Currently, this software suite serves as a simulation and analysis toolkit that enables industrial coaters to see how optimising hanging density on a line, along with targeted technological upgrades, can influence both their profitability and their environmental footprint. Over the past four years, HangOn has been committed to educating the liquid and powder coating industry about cost control and how to utilise simulation or predictive models that can guide towards increased profitability and reduced environmental impact. In 2026, at the PaintExpo trade fair in Karlsruhe (Germany), it will present a major update to the CCC.

From the first LCA analyses to the ‘Green Effect’ concept

The roots of the CCC project date back more than twenty years, when HangOn took part in a Life Cycle Assessment (LCA) study carried out by a Swedish research institute to compare the environmental impact of different solutions used in coating departments: reusable hooks, disposable fixtures, and paper masking systems. Although the study did not produce definitive conclusions about individual products, it emphasised a key point: the energy use of coating processes is a major source of environmental impact. This led to a concept that HangOn later called the ‘Green Effect’: the idea that filling the coating line to maximum capacity and making full use of its production potential can greatly cut energy consumption per part. For many years, this principle was applied empirically — until 2022, when the company began developing structured calculation models to measure its economic impact.

The first step: cost calculation models

The initial attempts involved using Excel spreadsheets to estimate how increased hanging density affects production costs. During this process, the company’s team realised that many operators in the sector lack a clear understanding of the actual costs of their coating lines.

Opening photo: Coating line efficiency – and in particular hanging density – is often the single most important driver for reducing cost, energy and CO₂ emissions.

The updated CCC allows users to simulate real parts of different sizes and geometries in their own coating lines using various hanging methods.

© HangOn

With most energy consumption fixed in a coating line, increasing hanging density significantly lowers the energy used per coated part. In this case demonstrated through the “Quick effect”hanging systems that reduce handling time and thus enables higher hanging density.

One of the early assumptions was related to energy consumption: HangOn believed that a large part of the energy used by a line was independent of the number of parts processed. To test this idea, it engaged a consultant firm with extensive experience in design of coating lines, which created a detailed simulation of energy consumption considering numerous factors: mass of the parts handled, surface area of the line, ventilation, volume of the metal structure, and thermal requirements. The findings supported the initial hypothesis: 80% to 90% of a coating line’s energy consumption remains relatively constant, regardless of production levels. In essence, running an almost empty line uses nearly the same amount of energy as a fully loaded one.

The importance of hanging density

This discovery has significant implications for the sustainability and cost-effectiveness of coating processes. If most of the energy consumed is fixed, increasing the number of parts coated per unit of time greatly reduces the energy and CO₂ emissions per part. Hanging density, i.e. the number of parts (and total mass) transported per metre of conveyor or per production cycle, thus becomes the key parameter. HangOn’s CCC enables users to simulate different operating scenarios

by modifying parameters such as:

 hanging density;

 line speed;

 weight and surface area of parts;

 line cost;

 powder cost;

 personnel costs;

 local energy costs.

This makes it possible to calculate the cost per painted part, energy consumption, and CO₂ emissions, comparing different workflow configurations.

A systemic view of the process

One of the CCC’s main objectives is to encourage companies to view the coating process holistically rather than concentrating on individual elements or technologies.

For example, in recent years, powder manufacturers have promoted the development of low-temperature curing coatings, which reduce oven energy consumption. Although these innovations are valuable, their overall impact on line consumption may be limited unless other factors,

such as logistics efficiency or hanging density, are also considered. According to HangOn, improving sustainability requires a cumulative approach, in which every action, from powder formulation to hook design, contributes to the outcome.

The impact of the energy source

The 2024 update introduced the calculation of CO₂ equivalent emissions by linking estimated energy consumption to the local energy mix, as this can generate significant differences between countries. For example, the carbon intensity of electricity can exceed 750 g CO₂/kWh in energy systems heavily based on coal, whereas in countries with a strong presence of hydroelectric power, it can drop to around 12 g CO₂/kWh. As a result, emission reduction strategies can vary considerably depending on the energy context. However, according to HangOn, reducing energy consumption remains one of the most effective levers for decreasing the carbon footprint of coating processes, especially in countries with a more emissions-intensive energy mix.

Towards a new metric: CO₂ per coated part

In the coming years, companies will be increasingly required to provide concrete data on the environmental footprint of their products. The Corporate Sustainability Reporting Directive, in force since January 2023, requires a greater number of businesses to report on sustainability using uniform standards (ESRS). Based on the principle of ‘double materiality’ (i.e. the company’s impact on the environment and society, and vice versa), it aims to transform the sustainability report into a document as detailed as the financial report, requiring disclosure of environmental, social, and governance (ESG) factors.

In the surface treatment industry, a key metric that is likely to become essential is the amount of CO₂ emitted per painted part, which enables an objective comparison of the efficiency of various processes and plants. In addition to offering technical support for process optimisation, therefore, tools such as HangOn’s CCC also become strategic instruments for addressing new regulatory and market challenges related to industrial sustainability.

COLOR

Discover Lechler’s inspirational color collection for the cycling world. From racing speed to off-road adventure, from city life to long-distance touring, our palettes and finishes bring every frame to life.

Solid shades, pearlescent effects, glossy or satin-endless possibilities to match your brand, your bike, your vision.

A major update in 2026

HangOn has recently developed a new version of the Coating Cost Calculator, designed to be even more user-friendly and accessible, which will be presented in April at the international PaintExpo trade fair in Karlsruhe.

Firstly, it enables more detailed cost breakdowns, including actual income statements for coating lines, suitable for both simulations of individual batches and full-year production analyses.

The user experience has also been improved with guided cases, data libraries, line models, various hanging systems, support for local currencies, and a new feature called Quick Effect, which demonstrates how reducing handling time when hanging parts can lead to significant savings – an effect that is now easy to observe and quantify. The tool is available in two versions: an open version that anyone can use for basic simulations, and a login version that allows users to set specific parameters and analyse their production lines more precisely.

At PaintExpo 2026 (Hall 3, Stand 3238), visitors will be able to explore the CCC through use cases based on real-world examples or simulate their own coating process in just three simple steps, obtaining a detailed, datadriven analysis.

Small components, big effects

For HangOn, the CCC is also a means of demonstrating how seemingly simple factors can have a significant impact on the efficiency of an entire process. In fact, its entire corporate philosophy is founded on the idea that small details can generate big changes, especially when analysed in the context of a complete production system.

At the same time, when considering the bigger picture, the value of the CCC is even greater: it guides companies in the highly fragmented coating industry towards more informed, analytical, and conscious management of their activities, with positive effects not only on profitability in the strict sense but also on the overall well-being of their business and people. That is what sustainability is all about.

GET READY PFAS-FREE

Visit us at

SurfaceTechnology GERMANY

05–07 May 2026, Stuttgart Hall 001 - Booth C42

As the world‘s leading manufacturer of high-performance corrosion protection systems DÖRKEN consistently focuses on sustainability and environmental protection. In line with the current developments around the possible PFAS ban, we already offer our main products completely PFAS-free.

You can rely on innovative solutions that combine maximum performance and ecological responsibility.

Contact us.

Dörken Coatings GmbH & Co. KG . Wetterstrasse 58 D-58313 Herdecke . Telephone +492330 63243 www.doerken.com

From an interview with Sebastien Pellissier (SP), Sales Manager Industrial Products at Dürr Margaux Goerlinger (MG), Business Developer Europe & Americas at ERMA Concept

The EcoBell2 is used in glass bottle painting.

Dürr Systems AG, part of the Dürr Group, operates globally in the automotive industry and other markets, specializing in painting technology, final assembly, dispensing technology, and consulting. As a market leader, Dürr designs and implements turnkey systems and manufactures high-quality machines and robotic technology as well as production lines for battery electrodes. In the Industrial Products (INP) division, Dürr works with integrators/business partners. This enables system provider to consistently meet the individual industry requirements of its customers and allow end customers to get the best of both worlds: high-quality coating products that are optimally tailored to specific coating processes.

We asked Sebastien Pellissier (SP), Sales Manager Industrial Products at Dürr, and Margaux Goerlinger (MG), Business Developer Europe & Americas at ERMA Concept, to describe the nature and advantages of this collaboration, presenting the successful case of the paint shop installed at the Cypriot company Kassatly Chtaura.

Why has Dürr chosen to work with integrators and business partners within its Industrial Products (INP) division, and how does this collaboration model help address the increasingly specific requirements of different industrial sectors?

SP: The key reasons are the strong expertise and quick response times provided by our integrator network. This enables us to meet end-users’ highly specific requirements across different applications. Today’s industrial markets demand highquality products, fast and flexible support, and competitive pricing. Working closely with integrators allows us to respond efficiently to these expectations and deliver tailored solutions.

From a technical and operational perspective, how does the cooperation between Dürr and local partners such as ERMA Concept enhance the adaptation of coating technologies to local market needs and customer-specific processes?

SP: For a global company like Dürr, managing local certifications and addressing the diverse requirements of industrial markets can be complex. This is why our strategy of collaborating with local partners is so valuable. Partners like ERMA Concept bring indepth knowledge of regional regulations, market expectations, and customer processes.

ERMA Concept receives the highest level in the Dürr Integrator Excellence Program.

A strong example is the glass bottle sector, where ERMA developed its own spindle line conveyor. This type of local innovation enables us to adapt our coating technologies precisely to customer-specific workflows and ensure optimal performance in each market.

MG: Even though ERMA is well-versed in spraying technology, Dürr’s broad portfolio of advanced solutions perfectly complements our expertise. Their highlevel technologies for dosing, mixing, dispensing, and spraying enable us to offer customers even more efficient and tailored solutions.

The painting line implemented at the glass bottle manufacturer Kassatly is a concrete example of this approach: which were the key technical challenges of the project, and how were responsibilities and competencies shared between Dürr and ERMA Concept during engineering, installation, and commissioning?

SP: ERMA Concept installed seven painting lines at the Kassatly facilities eight years ago. After joint discussions, we identified that Dürr’s EcoBell2 with external charge HD technology— especially its small spray pattern—could deliver

significant improvements to these existing lines. Together, ERMA, Dürr, and Kassatly decided to conduct a pilot test on one of the painting lines in Cyprus. As expected, the results were excellent, leading the customer to equip all four of their lines with this technology.

ERMA managed all phases of the project independently, including engineering, installation, and commissioning. Dürr supported the project specifically during the onsite testing and in defining the optimal product configuration.

Focusing on the plant design: what key features characterize the coating line supplied to Kassalty in terms of layout, process integration, and flexibility for future production requirements?

SP: Key characteristics of these lines include their high production speed of 18 m/min, which currently makes them the fastest in this segment. Another special requirement was the integration of the painting lines into an existing food and beverage facility.

The new coating technology, which reduces paint consumption by 30–40%, delivers significant benefits under these conditions. It not only lowers operating costs but also minimizes overspray and improves overall process efficiency, making the line well equipped for current and future production needs.

MG: This project is a perfect example of how an already efficient ERMA machine can be significantly upgraded with Dürr technology.

The improvement in performance, particularly the substantial paint savings, resulted in an exceptionally fast payback. The efficiency gains were so convincing that it was easy to secure the CEO’s approval for the investment.

From an automation standpoint, how do control systems, data management and process monitoring contribute to ensuring coating quality, repeatability, and efficiency in a project like this?

SP: Thanks to our ready2integrate portfolio, we can ensure seamless automation integration within the line. With our autonomous control

ERMA Concept is a Platinum Business Partner of Dürr.

© Dürr

system, EcoAUC, the new applicator is fully controlled while maintaining continuous communication with ERMA’s main PLC. All relevant paint process parameters are monitored, managed, and recorded. This allows the end user to store, track, and analyze the data to ensure consistent coating quality, high repeatability, and overall process efficiency.

MG: For us, the initial integration of the EcoAUC system was an important step, as we needed to align it with our own standards and processes. Now that the integration is complete, our team is fully familiar with all aspects of the EcoAUC and can manage it with confidence. We are already looking forward to the next release.

For end customers, what are the tangible advantages of the “best of both worlds” approach—combining Dürr’s global coating expertise with the local process knowledge of its business partners—in terms of performance, reliability, and project execution?

SP: End customers benefit from combining Dürr’s leading painting technology with the local expertise and onsite support of our trained partners. This approach brings together high-performance, reliable equipment and the ability to adapt processes quickly to local requirements.

MG: ERMA clearly benefits from Dürr’s extensive experience in the automotive sector, as we can transfer this high-level know-how into our own machines and applications.

Looking ahead to PaintExpo 2026, how do you see Dürr’s business partner program evolving, and what role will integrators and local partners play in supporting customers as coating processes become more complex and application-specific?

SP: Today, with increasing environmental regulations and rising costs in coating processes, many companies are showing strong interest in our highly efficient technologies such as EcoPaintJet, EcoSupplyP Core, EcoAUC2, and EcoBell.

Our partner program is therefore much more than an award; it is a clear sign of trust in our partners’ capabilities. It demonstrates to end users that these companies are well trained, certified, and fully supported by Dürr.

MG: As an integrator, we have high expectations for our collaboration with Dürr in 2026. Our partnership is becoming increasingly important for our market positioning, and over the past years we have gained extensive knowledge about Dürr products and how to adapt them to

THE POWER OF PARTNERSHIP WITH A SYSTEM SUPPLIER

our customers’ specific needs. This expertise has contributed to us winning the Top Collaborator 2025 Award and we are confident and motivated to win it again.

PaintExpo is a key international platform for industrial coating technologies: why do you consider this trade fair strategically important, and what do you expect from your participation in PaintExpo 2026 in terms of customer dialogue, partnerships, and technological positioning?

SP: PaintExpo is the only trade fair fully dedicated to the world of industrial painting, which makes it a strategically important platform for us. Many European companies are currently hesitant to start automation projects in their coating processes. With our latest technologies, we aim to demonstrate the tangible benefits and help them take the next step toward more efficient, sustainable, and reliable production. By participating in PaintExpo 2026, we expect to engage in meaningful dialogue with customers, strengthen partnerships, and further position Dürr as a technology leader in highefficiency coating solutions.

MG: For a smaller company like ours, an event like PaintExpo is a major opportunity to strengthen our market position and communicate the right messages. It allows us to demonstrate our capabilities, meet potential customers, and highlight the success of our collaboration with Dürr.

The new EcoAUC2 control unit will be demonstrated for the first time at PaintExpo. © Dürr

Efficient paint mist separation with edrizzi® Cube in Cube at LEICHT Küchen

In 2025, LEICHT Küchen AG, a premium kitchen manufacturer, fitted one of its spray booths with the new “Cube in Cube” system component from edrizzi®. The edrizzi® dry separation system is tailor-made to meet the requirements of high-quality paint finishing systems. It significantly reduces the energy consumption of the exhaust air system, protects system components, and ensures consistently high paint finishing quality.

Since July 2025, LEICHT has been painting in one of three identical clean room cabins with the latest edrizzi® system component Cube in Cube. Back in 2019, the premium kitchen manufacturer converted its wet separation to the edrizzi® dry separation system. Slotted paper filters were used in the meantime for particularly dry surface materials. With the conversion in summer 2025 to the new Cube in Cube filter, which was developed by brainflash specifically for dry surface materials and low initial pressure differences, LEICHT is now relying on a sustainable, economical and maintenance-friendly system. Cube in Cube is tailor-made for the requirements of high-quality painting systems – from automotive manufacturing to furniture construction, as here at LEICHT.

The edrizzi® Cube in Cube system component was specially developed for applications with fast-drying or dusty overspray.

Consistently high quality with minimal maintenance thanks to edrizzi® system components

The extraction area of the paint booths at LEICHT measures 4,000 mm × 2,000 mm with an exhaust air capacity of 16,000 m³/h. A total of 32 Cube in Cube filters is used in the converted system, covering a total filter area of 8 m². Thanks to the innovative design of the edrizzi® Cube in Cube, the brainflash development team was able to triple the filter area per square metre compared to conventional cardboard filters. With the Cube in Cube, brainflash GmbH has developed a new component for dry separation that combines efficiency, ergonomics and sustainability. The cube-shaped filter is made of sturdy cardboard and is lined on five sides with the innovative naffi® filter fleece.

This glass fibre-free filter material is made of 100% recycled polyester and is harmless to health. The naffi® filter medium impresses with its high dust storage capacity and durable structure. It enables longer service life, clean handling without protective clothing and a significant reduction in maintenance costs – ideal for use in painting systems with dry paint dust, such as those found in furniture and industrial production.

Stable

system operation thanks to low initial pressure difference of the edrizzi® Cube in Cube

With an initial pressure difference of only around 10 Pa, the edrizzi® system with Cube in Cube is extremely energy-efficient. The low flow resistance ensures an even air flow throughout the entire cabin and

| Karlsruhe | April 14-17, 2026 | Hall 2 Booth 2318

IT‘S THE PROCESS THAT BECOMES YOUR SOLUTION.

The paint booths at LEICHT Küchen measure 4,000 mm × 2,000 mm with an exhaust air capacity of 16,000 m³/h. This picture shows the system before conversion to edrizzi® Cube in Cube.

The paint booth after conversion to the edrizzi® system with the innovative Cube in Cube filter.

significantly reduces the energy consumption of the exhaust air system. At the same time, the pressure curve remains stable throughout the entire service life, which ensures consistently high paint quality and protects the system components.

Delivered folded flat, assembled in just a few simple steps and easy to maintain

The paints used at LEICHT Küchen are dusty and dry as soon as they hit the partition wall. This is where the edrizzi® system with Cube in Cube shows its strengths: it ensures stable pressure differences (initial pressure approx. 10 Pa), clean exhaust air flow and a filter change interval of 4–6 weeks. Maintenance and filter replacement are simple, quick and safe. Like all edrizzi® system components, the Cube in Cube filter boxes are delivered and stored folded flat and unassembled to save space. Thanks to the prefabricated and fitted filter media, the filter boxes can be assembled quickly and intuitively.

The Cube in Cube from edrizzi® stands for sustainable technology in the furniture industry

In the fourth quarter of 2025, another paint booth in the clean room painting area at LEICHT Küchen was converted to the edrizzi® system with Cube in Cube system components. The conversion to dry separation eliminates water consumption, paint sludge and costly disposal. The compact, cardboard-based filter cubes are easy to handle and can often be recycled for energy after use. The naffi® filter medium is one of the most sustainable filter mats in the industry. This enables LEICHT Küchen to support its own sustainability goals while reducing operating costs and downtime.

“We already relied on the edrizzi® system when converting from wet to dry separation in 2019. With the new Cube in Cube system component, we have now been able to increase efficiency and service life many times over and even dispense with a separate post-filter stage”, states Wolfgang Oberle, Head of Plant 5 at LEICHT Küchen AG.

New products at PaintExpo

In addition to this new Cube in Cube system component, brainflash GmbH will be presenting another revolutionary trade fair innovation at PaintExpo (Hall 3, Stand 3213) that is specifically aimed at applications in the automotive industry.

Technical data of the system

• Location: LEICHT Küchen AG, Germany

• Conversion: May 2019

• System manufacturer: Förster Helmut / LINOCEM

• Conversion area: W 4,000 mm × H 2,000 mm

• Exhaust air capacity: 16,000 m³/h

• edrizzi® system: 32 Cube in Cube paint mist separators (8 m² filter area)

• Paint: Solvent-based paint, dry and dusty

• Filter change interval: 4–6 weeks

• Initial pressure difference: 10 Pa

LEICHT Küchen AG specialises in the development and manufacture of high-quality kitchen solutions.

© brainflash GmbH

& Spray Scan

Dynamic Contour Detection

Programming-free coating of any shape!

The second generation of Dynamic Contour Detection detects the object contour fully automatic and positions the guns individually even for thin objects and at high conveyor speeds. In combination with the NEW Vertical Module ZA17 targeted positioning of the gun on the coating object was never that efficient and will complete your high level of automation. So you can achieve perfect coating results even with complex application requirements and difficult part geometries.

Gema Europe Srl | Via Goldoni, 29 20090 Trezzano s/N | Italy T +39 02 48 400 486

GSB International at Paint Expo 2026

Paint Expo is considered the leading trade fair in the paint and coating industry, which is precisely why GSB is represented there as a quality association for the coating of aluminum, steel, and galvanized steel.

The focus of GSB is on outdoor applications in the architectural sector, and has always been since the association was founded in 1977.

GSB ensures the quality of the entire coating process chain, from pre-treatment and the coating materials used to the coating companies themselves, which are audited twice a year. All audits and tests are carried out by independent accredited testing institutes. The GSB quality assurance system and the associated close-knit factory production control enable potential sources of error to be identified at an early stage. This minimises

rework and complaints. GSB certification is therefore not only a powerful tool for ensuring high and consistent coating quality, but also an important step towards efficient and sustainable resource-saving process management.

Visitors can experience GSB’s quality assurance system firsthand at the GSB booth, where they can dive into real-life test scenarios and get an impression of GSB’s outstanding quality assurance. Leading experts will be on site to provide practical and professional advice. This will give anyone interested in architectural coatings the opportunity to find

out about the GSB System and the related certifications.

One thing is certain: the GSB system is always at the cutting edge. Specialists in the industry respond dynamically to ongoing developments. The Quality Guidelines are regularly reviewed and revised, so they are kept practical and applicable daily business.

To ensure proper implementation of these quality standards, GSB offers training courses to it´s members and external parties. Since demand for those trainings has grown considerably, GSB has added a feature on its website that allows users to express their interest in a specific online training course. This feature will be launched at Paint Expo. Once enough people have registered, the online training will be offered.

In this way, the GSB is responding proactively to market demand and thus always has its finger on the pulse.

The GSB team looks forward to welcoming all interested parties in hall 1, booth 1118.

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

Left: Guido Rohloff, Head of Technology of GSB; right: Philipp Mader, Managing Director of GSB.

Sustainable rinse-water treatment with VACUDEST by H2O: quality, cost-efficiency and closed-loop water reuse in focus

In industrial coating technology, large volumes of rinse water are generated every day. Disposing of it is not only costly, but also environmentally challenging. H2O GmbH will be presenting its proven solution at PaintExpo 2026: the VACUDEST vacuum distillation system – enabling zero liquid discharge production.

Sustainability meets cost-efficiency

With VACUDEST, companies significantly reduce their wastewater volumes and permanently lower disposal costs. Thanks to efficient energy recycling and the option to reuse the treated process water, businesses not only save money, but also make an important contribution to environmental protection.

Highest water quality enables closed-loop reuse

The water treated with VACUDEST delivers excellent quality. It is ideally suited for closed-loop reuse in production – a key advantage for companies looking to conserve resources and optimize their processes.

Benefits at a glance

 Significant cost savings on disposal and freshwater consumption

 Sustainable production through zero liquid discharge processes

 High-quality water for a closed-loop system.

For further information: www.h2o-de.com

✔ Up to 2,000 mm wide ✔ Thickness from 0.6 to 4 mm ✔ Wide range of colors suitable for bending/folding

✔ Perfect color matching with other metallic elements

✔ Fast leveling and cutting service With Decoral Coil, high-definition consistency is guaranteed. We provide powder-coated aluminum and steel with impeccable results.

Coating solutions in all dimensions

For Venjakob, the system supplier of automatic surface coating lines, no challenge is too big or too small. The same applies to the workpieces to be coated.

On the occasion of PaintExpo 2026, Venjakob is strengthening its position in already well-established customer segments. “We aim to further intensify our presence in the renewable energy, mobility, glass, and metals sectors”, says Gert Große Deters, Head of the General Industry and Automotive Business Unit. Using current lighthouse projects as examples, Venjakob demonstrates the wide range of workpiece dimensions that can be handled in automated coating. The company also showcases its solution expertise in serving each customer individually along the entire process chain.

New development: mobile coating line “Ven Spray Monopile by Rodopi”

A particularly outstanding example is a new development by Venjakob for coating heavy-duty components such as monopiles. These are columns weighing up to 2,000 tonnes and measuring up to twelve meters in diameter, forming the foundations for offshore wind turbines at sea. For this purpose, an automatic mobile coating line was developed and brought to series maturity and market launch together with the customer Rodopi.

“This mobile line, which can be transported by forklift, demonstrates what we are capable of in customer-oriented development, drawing on our cross-industry expertise. In addition, this line can be used for the automatic coating of heavy-duty projects of all kinds,” says Große Deters.

Robotics for delicate and complex shapes

A completely different challenge in coating involves delicate and visually sensitive glass packaging, such as that used in cosmetics—for example, lipstick cases, perfume bottles, and more. In a current project involving the automatic coating of hollow glass in high volumes, Venjakob is using robotics for precise handling. Depending on customer requirements, Venjakob integrates its robotic solutions for various tasks: material handling, drying, and coating.

Venjakob will present suitable application examples for different coating solutions to interested industry representatives at PaintExpo in Hall 2, Booth 2318.

For further information: www.venjakob.de

© Venjakob

Why in-process temperature measurement matters in coating operations

At PaintExpo 2026, PhoenixTM will showcase its innovative temperature monitoring solutions, designed to prevent coating defects, optimise oven settings, and improve energy efficiency.

Recently, several surveys have been published in coating magazines and online regarding temperature measurement technologies. One of the findings was that some people consider the costs of testing equipment, maintenance, and calibration to be rather high. Naturally, purchasing such equipment involves costs, but significant costs are also incurred when batches have to be reworked, customer complaints need to be handled, or when the process does not operate effectively.

These points are not always immediately apparent. Energy costs are spread throughout the year, while other expenses are not recorded separately but are included in the overall production costs. By contrast, a single, higher investment for a measuring system tends to stand out more clearly. When such costs also require approval, their usefulness is often called into question.

The advantages of temperature measurement technology across the entire process

In coating processes in particular, there are numerous factors that can compromise the optimal result. If the coating is not cured correctly, the necessary chemical reactions do not occur or remain incomplete. This can lead to several quality issues, such as:

 Brittle coating

 Adhesion problems

 Reduced gloss level

 Spalling

 Colour deviation.

All these problems can certainly be detected using commonly applied testing methods. For example, coating adhesion can be assessed by means of a cross-cut test, while the appearance of the coating can be evaluated through gloss measurements and other standard tests.

However, these testing methods are used after the coating process has been completed; by that point, it is already too late. The objective should instead be to prevent coating defects in advance, thereby avoiding non-conforming products or the need for rework.

This can be achieved by carrying out checks throughout the entire heat treatment process, using a system that runs through the oven and measures the actual temperatures at the relevant points on the product. In this way, oven settings, heating systems, and fans can be optimised to achieve the desired and specified results.

An additional positive effect is the more energyefficient operation of the oven, resulting in reduced energy costs, more sustainable use of resources, and lower CO₂ emissions.

PhoenixTM will present its temperature measurement solutions at PaintExpo 2026, Hall 2, Booth 2238.

For further information: www.phoenixtm.com

• Without tooling costs

• Perfect for fitting tests

• No minimum order quantities

WAGNER at PaintExpo 2026: sustainable and smart solutions for the coating process

WAGNER will be showcasing its latest technologies at Hall 3, Stand 3330, during PaintExpo 2026.

WAGNER will once again be impossible to miss at PaintExpo 2026, the world’s leading trade fair covering all aspects of industrial coating, with its stand spanning 200 m². The company will showcase the latest innovations in liquid and powder coating, alongside a comprehensive range of services and digital solutions. Under the motto “Better for you”, WAGNER will highlight solutions designed to make coaters’ work simpler – through intuitive operation, resource-efficient material use, optimised processes, and greater automation for increased productivity. In the liquid sector, one standout is the TOPFINISH Bell 2 system. With the new generation of high-speed rotation atomisers combined with the modular WACON Spray control system, high-speed rotation technology has never been easier. Visitors will also be able to experience the innovative Activeflush flushing process, among other highlights. Individual industry solutions in collaboration with Walther Pilot will be featured, as will enamel coating.

For powder coating, the emphasis will be on highly efficient solutions and digital features – spanning manual applications to advanced automation. Flowsense, the automatic control of powder quantity, has already proven its effectiveness in practice. Visitors can interactively discover how this technology significantly boosts the efficiency of powder coating systems. The Sprint 2 manual system will also introduce exciting innovations that make daily work easier for manual users. Enamel coating will again play a role. Beyond liquid and powder coating, WAGNER will present new features of the COATIFY IoT platform, which keeps users informed about the current status of their coating system anytime and from anywhere. As an extra highlight, visitors will also be treated to a special magical surprise – “it’s really worth stopping by!”

For further information: www.wagner-group.com/en/industry/paintexpo/

Magnify your efficiency with our automation solutions

Since it was founded in 1988, HUBO Automation has always focused the attention to the market needs and to the technological evolution. This allowed the company to establish itself as a leader for the industrial automation and painting. Thanks to the experience of the technical staff and to the continuous investment in new technologies, HUBO is able to satisfy dynamically the requests of a wide range of industries.

HUBO core business is the painting division. The wide range of automation solutions fully meets any need of automatic painting; in addition, the combination of special systems can satisfy particular requests and can guarantee a flexible and reliable painting system from all points of view.

Berizzi Srl will present its all-Italian technology for paint

spraying

and fluid transfer at PaintExpo 2026

The company, based in the province of Bergamo (Italy), will once again participate in the international PaintExpo trade fair this year to showcase its extensive range of all-Italian products.

Berizzi Srl (Cisano Bergamasco, Italy) specialises in the manufacture of pumps and accessories for spray technology and fluid transfer. With thirty years’ experience in the sector, it will be exhibiting at the international PaintExpo 2026 trade fair to showcase its range of all-Italian products. It manufactures all its solutions in-house, starting directly from raw materials, including steel, stainless steel, aluminium, and brass, as well as plastics in the form of polymer granules. Its technologically advanced, state-of-the-art machinery ensures high quality standards and reliable performance, also enabling the company to export its know-how worldwide.

Berizzi offers a wide and diverse portfolio of products, beginning with pumps for paint spraying and fluid handling for various sectors (woodworking, metalworking, shipbuilding, construction, heavy engineering, and automotive), all conceived, developed, and manufactured in-house with a unique and modern design. The range also includes many other components and accessories for paint spraying and fluid handling, such as high-pressure manual and automatic spray guns, low-pressure spray guns, manual nozzles, pipe coating systems, paint spraying filters, spray gun nozzles, filter holders, in-line filters, gravity tanks, spare parts for pumps and spray guns, fluid regulators, pressure tanks, hoses, fittings and sandblasting equipment. All Berizzi’s accessories are compatible with the leading brands in the sector available on the global market. The complete product range includes:

 Apollo pumps: pneumatic piston pumps for medium or high-pressure

paint spraying, using airless or air-assisted airless technology. All components of the pumping section are made of stainless steel and tungsten carbide, ensuring high wear resistance and a long service life. The pneumatic air motor is equipped with an instantaneous volumetric reversal system that allows the equipment to be used without lubrication, thus eliminating the need for antifreeze solutions. The Apollo pneumatic coating units are suitable for spraying both solvent-based and waterbased paints.

 Low and high pressure manual spray guns: Berizzi’s manual spray guns are designed for airless or air-assisted airless spraying applications and are suitable for a wide range of materials and processes. They guarantee high transfer efficiency, excellent finishing quality and impressive production speeds and they are particularly well-suited for treating large surfaces requiring high coating thicknesses.

 Low and high pressure automatic spray guns: Berizzi designs and manufactures automatic spray guns for professional coating operations, intended for integration into automated systems, booths, and plants where they play a key role in the automation of painting processes. Berizzi’s automatic spray guns ensure high performance and are ideal for applications requiring high quality standards, including gloss value, application consistency and colour accuracy.

 Fluid regulators: the company manufactures and supplies high- and low-pressure fluid regulators designed to maintain a constant flow of paints, sealants, liquids and other fluids. These devices help to increase

application productivity and prevent material build-up. They ensure precise product control, allowing operators to adjust the flow rate to specific requirements and making the coating system more efficient and reliable.

 Nozzles for spray guns: Berizzi manufactures nozzles designed to meet any application requirement and suitable for use with both airless and air-assisted airless spray guns. Nozzles are fundamental components in the coating process, as they determine the type of spray pattern and the quality of application results. Berizzi uses special, extremely durable and compact materials and high-precision machining technologies to ensure optimal atomisation and a long service life. Choosing the correct nozzle has a direct impact on the quality and efficiency of the coating process.

 Spray filters: filters are essential components in spray systems, as they ensure a uniform, high-quality coating while protecting the equipment from any residues. Berizzi’s high-quality spray filters are compatible with all the leading brands available on the market. Its range includes filters for manual and automatic spray guns, pumps and suction systems, as well as high- and low-pressure in-line filters. Berizzi’s units are manufactured in-house from various metal alloys and plastics, with a variety of filter mesh types and sizes tailored to every application requirement and product.

Berizzi Srl will be exhibiting at PaintExpo 2026 in Hall 3, Stand 3111.

For further information: www.berizzi.it

COLORING YOUR WORLD

CE-compliant hooks and racks for safe coating processes

At PaintExpo 2026, Jürgen Emptmeyer will present its CE-certified hooks and suspension systems designed to ensure safety, traceability, and efficiency in industrial painting and powder coating processes.

Jürgen Emptmeyer, a company specialising in the development and manufacturing of suspension solutions, will present its CE-certified hooks and rack systems for safe and efficient painting and powder coating processes at PaintExpo 2026. As a specialist in hanging solutions for surface technology, the company demonstrates how productivity and occupational safety can be effectively combined in modern coating operations.

With its portfolio of CE-tested hooks, racks and crossbars, Emptmeyer addresses the growing requirements for product safety, traceability and quality in industrial coating lines. “Our aim is to support customers in making their processes future-proof and compliant with increasing safety standards,” explains Frank Brünnig, Managing Director of Jürgen Emptmeyer GmbH.

As safety-relevant load handling devices, hooks and racks must meet specific requirements regarding design, load capacity and intended use. CE certification makes these requirements transparent and documents that a product has been tested according to applicable standards and approved for its intended application.

For painting hooks with a wire thickness of 4 mm and above, Emptmeyer offers CE-marked solutions. Each product undergoes documented load testing, is permanently marked and supplied with detailed operating instructions. These include information on load capacities, permitted load types, approved paint stripping processes, intended use and requirements for periodic inspections.

For painting hooks with a wire thickness below 4 mm, Emptmeyer provides a manufacturer’s declaration in accordance with the Machinery Directive. These products are manufactured under the same quality assurance processes and meet the same technical safety requirements as CE-marked hooks. Since direct marking on such thin wire is technically not feasible, identification is ensured through accompanying documentation and packaging labels. This approach guarantees full traceability and verifiability.

Visitors can learn more about these solutions at PaintExpo 2026, Hall 2, Booth 2320.

For further information: www.emptmeyer.de

Load capacity test of a painting hook from Emptmeyer and permanent marking of a CE-compliant painting hook.

© Emptmeyer

© Emptmeyer

AkzoNobel unveils next-generation powder innovations at PaintExpo 2026

AkzoNobel showcases advanced powder coating technologies at PaintExpo 2026 in Karlsruhe, highlighting energy efficiency, durability and design innovation.

AkzoNobel Powder Coatings will present its latest advances in powder technology at PaintExpo 2026, demonstrating how innovation is driving smarter performance, reduced energy demand and long-lasting design impact.

PaintExpo 2026 takes place from 14–17 April in Karlsruhe (Germany). Visitors can explore the latest powder coating innovations from AkzoNobel at Booth #3420: the company will spotlight developments from its Interpon and Resicoat portfolios – thus reflecting evolving expectations across architecture, mobility and sustainable manufacturing.

In collaboration with IPG Photonics, AkzoNobel will showcase laser-based curing technology that selectively applies laser energy to enable faster curing cycles, enhanced process control and lower overall energy consumption. A live powder coating and laser curing demonstration will take place hourly at the stand, offering visitors first-hand insight into the technology’s potential to increase efficiency and flexibility within powder coating operations.

Architectural powder coatings are increasingly required to balance bold creative vision with long-term durability. A key feature of the stand will be the Futura Collection 2026–2029, a fouryear architectural colour trends programme developed to reflect emerging global design directions.

The company will also present Interpon Précis Ultra Matt, delivering ultra-matt finishes with a subtle glint and luminosity that allow light to animate façades. In addition, an extended Interpon D2525 Anodic range offers the refined appearance of anodised aluminium combined with superdurable performance.

High performance remains critical in mobility applications, where coated components

must withstand extreme mechanical and environmental stress. Interpon powder coatings are widely applied to wheels, springs and underbody components to ensure corrosion resistance and long-term durability.

As vehicle electrification gathers pace, the Resicoat portfolio provides high-performance electrical insulation powder coatings engineered for batteries, motors and associated components, supporting safety, reliability and sustained performance in electric vehicles. Through its Eco+ portfolio, AkzoNobel will also highlight solutions designed to reduce

curing energy, minimise material consumption and streamline application processes without compromising durability. From single-layer corrosion systems to optimised low-energy curing and thin-film technologies, the emphasis is on delivering measurable environmental benefits alongside improved operational efficiency. Together, these innovations demonstrate how powder coatings continue to support both aesthetic ambition and lasting exterior protection.

For further information: www.interpon.com

© AkzoNobel

HIGHLIGHT OF THE MONTH

Decoral Coil will present the new frontier of colour matching at PaintExpo

Interview with Andrea Piva

Viv Decoral Srl – Arcole (Verona, Italy) info@vivdecoral.it

By installing one of the world’s largest plants for coil powder coating, Decoral Coil has opened up a wealth of new applicative and colour options. At PaintExpo, it will showcase the capabilities of this line, with a particular focus on colour matching for architectural components and new finishes designed for industry professionals.

The coil coating market is currently valued at over $6 billion and continues to grow at an annual rate of 4%-6%, driven primarily by the construction and architectural façade sectors, which account for the majority of pre-painted metal applications1

Decoral Coil (Arcole, Verona, Italy), the division of the Decoral® Group that specialises in this technology, has been expanding its production activities in recent years, also opening one of the world’s largest powder coating plants for sheet metal coils2

Although this new system was installed only recently, the company already has a broad portfolio of clients, particularly in the architectural sector, where the perfect colour matching guaranteed by the fact that all processing operations are performed in-house within the Group ensures a consistent colour scheme across all the components that make up a building.

Backed by the success achieved in just a few months, it will attend PaintExpo, the international trade fair dedicated to surface treatment, which will take place in Karlsruhe (Germany) from 14 to 17 April, to present its wide range of colour options. We spoke with Andrea Piva, the owner and a member of the Board of Directors of Decoral® System Srl, the Group’s parent company, to explore the advantages of this new process and how the company plans to promote it to the market during the trade fair.

1 https://www.fortunebusinessinsights.com/coil-coatings-market-108289

2 https://www.ipcm.it/en/open/ipcm/2025/92/140-146.aspx

© Arcangelo Piai

What are the main features of the new coil coating line you have installed at your premises?

Andrea Piva: “Our plant is organised over three floors and begins with a decoiling section featuring a storage buffer and two decoilers. This is followed by a nine-stage pre-treatment tunnel that includes acid degreasing, pickling, and chrome-free passivation. After drying, the coil is coated in two Gema booths using dense-phase technology with bottom-up application. The coil is then cured in an oven with catalytic panels on the upper floor. The process continues with a cooling phase, during which we recover the heat generated. Afterwards, the coil passes through the automatic centring unit and the outlet section, where coiling, quality control, and the application of a protective film take place before any final processing. The unique feature of this system lies in its ability to coat both sides of the coil, making it possible to apply two different colours and even combine different aesthetic and functional benefits, for example, by applying a coating to the reverse side that improves corrosion resistance or sliding properties. This technology has unlocked new possibilities for production and customisation, also encouraging the Group’s companies specialising in powder production, such as Gi Color and Decoral® System, to experiment with new formulations for market release. We can now offer innovative coating solutions that go beyond traditional standards, and it is precisely this aspect that we aim to showcase at PaintExpo.”

Your customers especially value that the powders used in your coil coating plant are produced in-house, as this ensures perfect colour matching across all project components. How significant is this factor for the market?

“The interest shown by architects and designers in this concept has surprised even us. The ability to harmonise hues across different structures, surfaces, furnishings, and architectural components allows us to achieve exactly the colour effect envisioned during the design phase. Colour matching also plays a central role in our manufacturing processes: our in-house powder production and the availability of multiple sites and plants within our Group enable us to guarantee colour consistency across elements produced in different locations but intended for the same architectural project.”

How did the market react to the launch of this new coil powder coating concept?

“Right from the start, we have been able to count on the trust of the companies that were already working with us before we installed this new plant. These established relationships provided a solid foundation from which we could attract more customers. In particular, architects and designers appreciate the higher application flexibility and wider colour range offered by our coil coating line compared with traditional horizontal coating plants. The application principle remains unchanged, but our new line allows for much

© Arcangelo Piai

© Arcangelo Piai

more controlled and uniform thicknesses, as well as greater efficiency and more competitive costs. Added to this is the possibility to apply two different colours to the front and back of the coil, which is hardly feasible on traditional lines. Together, these factors have enabled us to significantly expand our target markets.”

How are you further developing this technology?

“We are expanding our range of available materials to offer an even broader selection of alloys, thicknesses, and formats. This allows us to cover all the application variables that our line can handle and enables our customers to select the most suitable combination based on each specific end use. Our coil powder coating system can currently coat coils up to 2 metres in width and with thicknesses from 0.6 to 4 mm, further making this plant one of a kind. At the same time, we are working to further expand the process’s scope, aiming to gain approval for even thinner thicknesses in the future.”

What can visitors expect to see at your stand at PaintExpo?

“At PaintExpo, we aim to show that coil powder coating can open up new possibilities in terms of colour matching across building components and architectural structures. Thanks to our in-house powder production, we can supply coated coils or sheets that are perfectly coordinated with other components, such as profiles. Alternatively, customers can directly source the powders developed by our Group and independently coat the various elements required with the guarantee of perfect colour matching. In both cases, such high flexibility is a clear advantage for them. At our stand, visitors will also find a colour palette that differs from those typically associated with coil coating. Alongside sublimation effects, such as wood, stone, or marble, we will be presenting a selection of innovative finishes that are in high demand in architecture, including ultra-metallic, super-matt, textured, and tactile-effect ones. In particular, wrinkled and tactile-effect coatings are emerging among the most promising trends in modern architectural design.”

What other technological advancements are you working on, and what new features do you intend to introduce during the year?

For 2026, we are primarily focusing on developing new solutions for coil powder coating, aiming to further improve durability. We are especially researching formulations that offer greater resistance to light and weathering, making these materials suitable even for highly exposed architectural applications, such as façades or structures designed for environments characterised by high levels of UV radiation. Simultaneously, we strive to maintain high post-coating bendability, which is a fundamental requirement for subsequent metalworking processes. We are also continuing to invest in certifications, which we regard as another essential factor. In particular, we are observing a growing market focus on fire resistance and sustainability, through the use of recyclable materials and supply chains geared towards renewable sources.

2026 will be a very busy year for us in terms of trade fairs, with several opportunities to connect with the international market. PaintExpo is a particularly important event for showcasing our solutions, especially the innovation of coil powder coating. At our stand, visitors will be able to discover a wide range of finishes and examine numerous application examples up close: we will have an entire wall dedicated to decorative sheet metal, designed to enable professionals to view and touch the solutions developed by our Group. For a glimpse into this new world, we look forward to seeing you in Hall 2, Stand 2330.”

The powder coil coating plant installed at Decoral Coil.

© Arcangelo Piai

The colour chart of the Decoral Group.

© ipcm

The growth strategy of Vernici Caldart

Edited by ipcm®

As it prepares to debut at PaintExpo, Vernici Caldart recounts its growth journey through technology, sustainability, and internationalisation.

In recent years, Vernici Caldart has embarked on a significant path of industrial growth, supported by investments in production and a strategy aimed at strengthening its operational capacity. This Italian producer of liquid paints has two manufacturing plants located in Bellusco (Monza e Brianza) and Pojana Maggiore (Vicenza), each specialising in different application sectors and production technologies. The former has traditionally focused on eyewear and cosmetic packaging, whereas the latter serves the car refinishing and general industry sectors. Over time, the two plants have also developed complementary know-how and skills: the first is mainly focused on mixing processes for the production of clear coats, catalysts, and thinners, and the second specialises in grinding, which is key for creating formulations that contain pigments and other solid components.

The increase in production volumes and steady growth in turnover have led Vernici Caldart to launch a major industrial expansion project at its Pojana Maggiore site, aimed at increasing its overall production capacity.

“With the growth in our turnover, it became clear that we needed to strengthen our production capacity. That is why we decided to expand this factory, upgrade its grinding department, and create a new, fully automated production unit that would replicate some processes that until then, had only been carried out at the Bellusco plant,” explains Cristian Sala, the managing director of Vernici Caldart.

The project led to the creation of approximately 2,000 m² of new production space, housing a new manufacturing department equipped with 4.0 plants and automated systems, new warehouses, a new office building, a training area, and a technical application centre designed to welcome customers, showcase the company’s products, and provide coating-related education.

Alongside the expansion of its production facilities, Vernici Caldart recently acquired Atlantic Industria Vernici, a company located a few kilometres from the Pojana Maggiore plant and also active in the production of liquid paints for industrial use. “This operation is part of a development strategy aimed at integrating complementary skills and expanding our portfolio of solutions by diversifying our commercial offering and covering additional application segments, such as precious metals and railways with approved coatings,” states Gianluca Zanardo, Export Sales Director at Vernici Caldart.

© Vernici Caldart

The technical centre: process development and training

“One of the aspects we value most is providing technical support to our customers. That is why, when we designed our new site, we created a state-of-the-art technical centre designed to reproduce and simulate our customers’ application cycles in conditions that are as close as possible to industrial ones,” explains Zanardo. The centre is equipped with systems for traditional and airless applications, as well as paint drying and curing ovens. In addition to developing and testing application cycles, the centre plays a key role in providing education, with both theoretical and practical sessions. “We use it as a training space for distributors, agents, and end customers, with the aim of transferring our technical know-how and ensuring optimal utilisation of our products,” adds Zanardo.

PVD

and PFAS-free products: the green future of coatings

From a technological point of view, Vernici Caldart is working to expand its portfolio of sustainable coatings in line with the latest regulations.

“We have created a space dedicated to simulating application processes, which is also equipped with a PVD sputtering chamber. Here we can test metallising and PVD cycles in conditions that are as close as possible to real-world industrial ones. This technology deposits thin metal films on plastic and metal surfaces, producing decorative and functional finishes with high aesthetic and technical performance –

Verona Impianti designs, manufactures, and installs tailor-made coating plants, pretreatment lines, and drying systems.

Reliability, competence, and experience: these are the three nouns that best describe the team of VERONA IMPIANTI 2002.

Vernici Caldart’s new plant in Pojana Maggiore. (Vicenza, Italy).

© Vernici Caldart

making them ideal for sectors ranging from cosmetics to automotive and household appliances – and more sustainable compared with traditional electroplating,” says Sala.

Another key area in the company’s innovation strategy is the development of entirely PFAS-free coating systems, since per- and polyfluoroalkyl substances are increasingly regulated at the industrial level. “We are still in the early stages, but we expect the process to be similar to the one that led to the elimination of lead,” notes Gianluca Zanardo. To stay ahead of regulatory and market developments, Vernici Caldart is taking action directly upstream of the production process, avoiding the use of raw materials containing PFAS as early as the procurement stage to reduce the risk of contamination and ensure product compliance. The first fields of application of these coatings are the sectors of fashion accessories – such as buttons, buckles, and decorative components – and cosmetic packaging, which are seeing a rapid increase in demand for PFAS-free products.

Alongside the development of new formulations, Vernici Caldart is exploring the use of artificial intelligence tools to support business processes, research and development, and procurement activities. The goal is to accelerate the development of formulations, optimise the performance of coating systems, and streamline processes, making daily work more efficient for its staff.

Towards new international markets and events

This path of industrial and technological evolution will be presented to the international public on the occasion of Vernici Caldart’s first participation in PaintExpo, the leading international trade fair dedicated to industrial coating technologies. The innovations developed in recent years, from PFAS-free coatings to PVD systems, will offer a strategic opportunity to strengthen ties with European and international customers.

“European markets are now a strategic priority, particularly countries such as Poland, France, and Spain, whose industrial supply chains are relevant to our sectors of application. At the same time, we continue to maintain a presence in non-European markets such as Turkey, China, India, and various countries in the Americas,” explains Zanardo. “In recent years, our growth has been steady and organic, thanks in part to the diversification of application fields and technologies. That is why we are investing heavily in new markets and development opportunities.”

Attending this trade fair thus marks a key step in Vernici Caldart’s international expansion strategy and consolidates its position as a technological and sustainable partner for the industrial coating sector. “We look forward to seeing you at PaintExpo (Stand 2237, Hall 2) to showcase our latest innovations,” concludes Zanardo.

The new production department is equipped with Industry 4.0 machines and automated systems.

Overview of the warehouse.

© Vernici Caldart

© Vernici Caldart

A conveyor designed to overcome the bottleneck in Decor Glass’ painting process

Ilaria Paolomelo ipcm®

Decor Glass, which specialises in coating, metallising, and screen printing for the perfumery, cosmetics, tableware, and beverage industries, has recently installed a new automatic liquid painting system. The core of this system is an inverted conveyor developed by SE.PO., and integrated into the line by FP Alfema, which has enabled the Italian company to boost productivity by utilising the limited space within its factory more effectively.

In the consumer goods sector, packaging is no longer just about containers but has become a strategic tool for communication and positioning. It forms an essential part of the product experience, serving as the first point of contact with consumers and a means to convey values, identity, perceived quality, and to strengthen brand recognition. Colours, special effects, and finishes play a crucial role: every detail helps build the corporate image and distinguish the product on the shelf or in stores.

As also emphasised by Decor Glass (Scorzè, Venice, Italy), a company with over forty years of experience in glass painting and metallising for various sectors, ‘appearances matter’. Aesthetics are no longer an accessory element but a competitive factor that can influence product perception and market choices. That is why packaging becomes a real strategic lever for enhancement and differentiation.

In the perfumery industry, trends closely align with the fashion world: vibrant and bold hues, colour gradients, transparencies, and metallic effects that make a strong visual impact. The choice of colours is never arbitrary but reflects the brand’s identity and the expectations of consumers, who are increasingly attentive to the aesthetic appeal and recognisability of products. “Over the last year, for example, there has been a strong comeback for burgundy and wine-coloured shades, in line with the colour palettes featured in fashion collections. Incidentally, the demand for personalisation is constantly growing in the wine sector, too: wineries are increasingly turning to screen printing and direct decoration on glass, either replacing or complementing traditional labels to transform each bottle into a distinctive element that reflects the brand and narrates the story of its region of origin,” says Lara Michielan, the CEO of Decor Glass.

This aesthetic evolution would not have been possible without ongoing research and technological innovation. Recently, this company has invested in several new plant solutions, including a state-of-the-art painting line developed in collaboration with FP Alfema (Treviglio, Bergamo, Italy) and SE.PO. (Olginate, Lecco, Italy) to paint bottles with two different colours simultaneously, handle products with complex shapes and undercuts, and ensure uniform and controlled finishes.

Between family tradition and technological innovation

“Decor Glass is a family-run business built on the decades of experience of my father, Lucio Michielan, who has been working in this sector for over forty years,” illustrates Lara Michielan. “He started out as a sole trader focusing on glass engraving and satin finishing. Over time, he specialised in painting until he decided to establish a structured business capable of offering a more comprehensive service.”

Founded in 2003, Decor Glass initially operated in the contract decoration of blown, flat, and centrifuged glass, mainly serving the lighting and, to a lesser extent, household industries. A significant transition occurred in 2010, when it launched a new project involving a few experienced employees and shifted its focus towards industrial glass painting, also expanding its skills and technologies with the entry of the family’s new generation. “We diversified our services by adding screen printing, pad printing, and later, metallising. As for our painting processes, we initially had a small manual plant, but as our business grew, we made some targeted investments and decided to also install two automated painting lines.”

This enabled Decor Glass to broaden its target markets and establish a presence in the mid-to-high-end segments. Today, it can decorate a wide variety of glass products, including bottles, glasses, dispensers, and cosmetic containers. At the same time, it maintains strong ties with the Veneto region and its renowned winemaking sector, particularly the Prosecco segment. “We collaborate with numerous local wineries, especially for painted and metallised bottles. Many of our customers export abroad, including to Korea, China, Japan, Spain, and the United States. Knowing that our products travel the world is a source of great pride for us.”

Decor Glass’ growth has been matched by continuous technological upgrades, which are essential for responding to a dynamic and increasingly demanding market. “This is precisely why we have chosen to take a further step forward with the installation of a new painting plant,” states Michielan.

The coating process phases

“The decision to install the new system arose from our need to optimise production performance and, at the same time, improve energy efficiency,” explains Lucio Michielan. “We wanted a plant capable of achieving greater operational capacity with a lower environmental impact.” The line begins with a manual loading area, where an operator places the products on load bars installed on an inverted conveyor. From this point onwards, the handling system supplied by SE.PO. transports the products through all stages of the process, making it the real heart of the plant.

The first step is flame hardening, which removes dust and surface impurities and activates the glass surfaces, opening their pores and improving paint adhesion. The products then move into the painting booth, where two two-axis positioners equipped with Graco spray guns apply exclusively water-based liquid paints – a choice that further demonstrates Decor Glass’ commitment to reducing the environmental impact of its processes and meeting increasing sustainability demands. “The positioners automatically detect a product’s presence, manage its fastening, and position it correctly for the painting process, during which it spins around its axis, with the positioners following it by moving horizontally and vertically to achieve uniform coverage across its entire surface. This also enables painting items with complex shapes and undercuts in one step, working from both above and below, without the need for subsequent reworking,” says Luca Ferrari, the owner of FP Alfema.

The painting plant also stands out for its high operational flexibility. It can use a single colour across the entire surface of the product to maximise efficiency or apply two-colour finishes and systems that combine transparencies with other effects, all in a single step. “We can even apply

different solutions on the same bottle and incorporate multiple treatments within the same process cycle. Management via the positioner’s PLC enables us to quickly adjust process parameters and achieve exceptional design freedom. Flexibility is one of our key strengths, and we strive to translate this into increasingly customised solutions,” states Lucio Michielan. After painting, the products pass through a long flash-off area, which is necessary to stabilise the paint, and then enter the drying oven, where they dwell at about 200 °C for 20 minutes. Subsequently, the bottles pass through a cooling circuit equipped with deflectors that direct air along their axis, ensuring uniform cooling and overcoming the limitations of conventional top-down blow-off operations, which fail to cover all surfaces evenly. Finally, the products are unloaded manually for the quality control and packaging stages.

Technical challenges and the key role of the conveyor

From the outset, one of the main difficulties was the limited space available within Decor Glass’ factory, which made it necessary to develop a customised plant. Particular attention was paid to the conveyor, a

strategic element in ensuring optimal performance, especially since it was the actual bottleneck of the previous line.

“One of the main problems was related to the conveyor’s chain, which experienced frequent wear and required constant maintenance. To tackle this critical issue, FP Alfema turned to SE.PO., which designed a new conveyor fitted with a CRT 37 monorail chain, built to withstand heavy use, reduce maintenance, and optimise workflows,” says Michielan. The new inverted conveyor has also removed one of the line’s main limitations: its speed. “In the past, the line’s speed was about 1 metre per minute, resulting in inevitably low productivity,” notes Ferrari.

Inside the painting booth, two two-axis positioners equipped with spray guns are in operation.

In the flash-off area, the conveyor makes very tight curves to make full use of the available space.

From left to right:

The “inverted” conveyor designed by SE.PO.

“Thanks to very tight curves and optimised load management, we have managed to triple the speed without sacrificing precision and quality.” Particular attention was also paid to the flash-off area, located just before the baking oven, and to the route inside the oven itself. Space constraints posed the main challenge: both these phases require time and room to ensure high finishing quality. To make the most of the available space, the conveyor makes very tight turns in the flash-off area, while two additional branches inside the oven – bringing the total length of the chain to almost 95 metres, 60 m of which are within the oven – allow the treated products to stay in place long enough for proper paint drying. This is vital to ensuring the formation of a uniform film without surface defects, colour alterations, or loss of mechanical performance in terms of adhesion and resistance.

“The conveyor made all the difference: tight curves, more space, and optimised management enabled us to triple production without ever compromising on finishing precision and quality,” confirms Michielan.

Added value for glass

The new plant fully met Decor Glass’ expectations regarding productivity, quality, sustainability, and safety. Replacing the previous gas-fired oven with an electric one eliminated harmful emissions, optimising the production process in terms of energy efficiency and environmental impact. Safety-wise, in line with Industry 4.0 standards, the system is equipped with advanced monitoring devices that constantly oversee speed, oven temperature, and positioner settings, all manageable from the operator panel and viewable in 3D.

This enables quick adjustments and complete oversight of the entire production process. The system is integrated within the company’s workflow, exchanging data with the office and allowing real-time order monitoring. Additionally, operator safety has been significantly improved: the entire line features integrated emergency shutdown systems that activate automatically when necessary, ensuring worker protection and process continuity.

“We are extremely satisfied with the technologies installed, as well as with the relationships formed with our suppliers. Their prompt and dependable support is always crucial when it comes to making any changes to improve the process. Additionally, they carefully trained our staff to enable us to get the best out of our line,” summarises Lucio Michelan. “All this translates directly into added value for the packaging industry, as we can offer bottles and containers with perfect aesthetic finishes, highly customisable, capable of enhancing the brand identity, and providing a distinctive aesthetic and sensory experience for consumers.”

The PLC of the painting system.

ipcm

From left to right: Luca Ferrari of FP Alfema with Lara, Lucio and Martina Michielan of Decor Glass.

CHEMICAL MAKING SOLUTIONS

TRATTAMENTO ACQUE

WATER TREATMENTS

PREVERNICIATURA

E NANOTECNOLOGIE

COATING PRETREATMENT AND NANOTECHNOLOGIES

SGRASSANTI INDUSTRIALI DEGREASERS

SVERNICIANTI

PAINT STRIPPERS

A century of colour, progress and family spirit

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

FreiLacke looks back on 100 years of company history – shaped by customer focus, technological development, ideas and people.

When companies celebrate their roots, they often commemorate courageous founders, decisive turning points and people who take responsibility for generations to come. At FreiLacke in Döggingen (Germany), all this is part of a story that has now been written for 100 years - and which shows how closely regional cohesion and international innovation can be combined.

A start in difficult times

In 1926, Emil Frei senior laid the foundation stone for what is now one of the most influential industrial companies in the Black Forest. Despite the economic turbulence of the interwar period, he dared to take the step into self-employment and first built up a wholesale business for paints and varnishes. His formula for success: his feeling for customer needs, his proximity to people and his will to develop

solutions for challenges and applications were the cornerstone for an extraordinary success story. Even 100 years after the company was founded, this philosophy is still deeply anchored in the company’s DNA and is lived in the daily work of the now more than 650 employees.

As early as 1927, he began his own production in Döggingen – a courageous step that accelerated growth.

Even the Second World War cannot stop the development. In 1947, his three sons joined the company, and the company grew rapidly during the years of the economic miracle. New halls were built, the workforce grew, and in the 1960s, the second generation relied on new technologies such as powder coatings, electrodeposition coatings and glass-fibre reinforced plastics.

From the Black Forest to the world

The company grew continuously until the 1990s. The third generation took over in 2003 and set clear priorities: international orientation, sustainable production and a culture of togetherness. Subsidiaries in Sweden, England, Russia and China followed, and later also a location in Mexico. Disciplined investments – for example in modern production halls, a new administration building or the expansion of powder coating production – make FreiLacke a globally sought-after supplier.

At the same time, the company remains deeply rooted in the region: with stable jobs, a training

© FreiLacke

rate of around ten percent, social commitment through the Emil Frei Foundation and a lived corporate culture that has received several awards from “Great Place to Work”.

Challenges of the present

The years since 2016 have presented FreiLacke, like many mediumsized companies, with unexpected tests. The Corona pandemic is hitting the family business hard: slumps in demand, raw material shortages and global supply chain disruptions require maximum flexibility. A crisis team keeps the business running with a great deal of improvisation and close cooperation. Digitization steps such as home office, virtual training days and online communication are accelerating.

No sooner has the pandemic been overcome than the Ukraine war and geopolitical uncertainties are bringing new burdens. However, FreiLacke demonstrates stability – thanks to short decision-making paths, a loyal workforce and reliable customer relationships.

Emil Frei senior laid the foundation stone of the company in 1926.

© FreiLacke

2026: a medium-sized company with roots and wings

Today, the company generates a turnover of around 180 million euros, more than half of which is generated abroad. More than 650 employees work at the headquarters in Döggingen and at international locations. In particular, the system coating solutions that make FreiLacke one of the few manufacturers that develops all relevant coating technologies under one roof and that has significantly shaped the term as a pioneer are in demand.

A new Product Technology Center (PTC) is currently being built, which will bundle development, application technology and training. FreiLacke is thus setting the course for the coming decades.

Looking ahead: tradition meets innovation

The next 100 years cannot be planned – but FreiLacke has a reliable basis. These include innovative strength, sustainable action, a broad international network and the family spirit that is deeply rooted in the Black Forest. Many employees have been working for the company for decades, some in the second or third generation.

The managing directors Dr. Rainer Frei and Hans-Peter Frei emphasize that it is precisely this mix that makes the future viable: “In the end, it’s not about technologies or key figures. It’s about the people. They are the core of our formula for success – then as now.”

Thus, just in time for the company’s 100th anniversary, the next chapter of this Black Forest success story begins and with the new long-term positioning 2032, the strategic course for the next few years has been set. And once again, it is clear that the best ideas and solutions are created where experience, courage and people come together.

In the anniversary year, FreiLacke is planning a wide variety of activities to support social institutions in the region and celebrations for its staff, their families and customers.

The business from which the company’s development originated was wholesale trade in paints and varnishes.

Despite the challenges of the Second World War, the company expanded rapidly after 1947, when Emil Frei’s three sons joined during the years of the economic miracle.

© FreiLacke © FreiLacke

New self-learning robots with VR Tracking technology: the next level of coating at Pentax Industries

Federico Melideo ipcm®

Pentax Industries S.p.A. has decided to insource and keep its coating operations in-house as a strategic move to guarantee quality, durability, and process control. In 2025, it upgraded its lines by installing three GR 680 six-axis articulated robots with VR Tracking technology, supplied by CMA Robotics.

Pentax Industries S.p.A. (Veronella, Verona, Italy) is a leading global manufacturer of electric water pumps. Established through the merger of Elettromac and Zetabase in 1990, it has consolidated its international presence in over one hundred markets, with a particularly solid position in Latin America and the Middle East. Its technological offering is wide and varied, with pumps for domestic and industrial applications, firefighting systems, and large hydroelectric plants. In recent years, it has also strengthened its submersible electric pump division through the acquisition of a specialist firm in the province of Como (Italy). Currently, the company has over 150 employees: 140 work at the headquarters in Veronella, the heart of the assembly and finishing operations, and 15 operate in Albinea (Reggio Emilia, Italy), where large pumps for hydroelectric plants are manufactured.

“We outsource 90% of our machining operations. In-house, we mainly deal with assembly and coating,” explains Gianluca Cengia, systems and general affairs manager at Pentax Industries. “As for the latter, this has always been a strategic choice to meet the high aesthetic and, above all, functional requirements of our international customers.” For over twenty years, the company has been using coating robots supplied by CMA Robotics. Recently, it has renewed this collaboration by installing three new selflearning GR 680 robots with VR Tracking technology.

Complex geometries and maximum customisation

“Our range includes products with very different designs and intended uses. Managing such a varied production is challenging. Moreover, given the geographical distance that separates us from most of our suppliers, having full control over the main processes, including finishing, is essential to minimise errors and avoid waste at the customers’ end,” continues Cengia. After arriving at the plant, the components undergo the cleaning process in the pre-treatment system supplied by Tecnofirma (Monza, Monza and Brianza, Italy) to remove processing oils, shavings, and impurities. The entire production is then assembled and tested in-house before being sent to the coating process. “We have five automatic coating lines built over the years by SAVIM Europe (Arbizzano, Verona) and a manual system treating larger and heavier parts that cannot be handled on chain systems.”

The configuration of the lines is similar, but each one is devoted to specific types of products:

At Pentax, the coating phase is critical to maintaining full process control and meeting the high quality and functional performance standards required internationally.

 one for large-sized components;

 one for complete pumps and accessories;

 one for smaller pumps;

 one for medium-sized components;

 one for very heavy parts weighing up to 35 kg, suspended using hoists.

The new GR 680 robots have been installed on the first three lines, while the fourth and fifth lines are equipped with previous-generation robots, also supplied by CMA Robotics.

On each line, the operators manually load the components onto a monorail conveyor supplied by CM Automazione (Giussano, Monza e Brianza, Italy), which takes them to the automatic, water-curtain coating booths by SAVIM Europe, where robots apply the paint using mixing systems supplied by WAGNER (Valmadrera, Lecco, Italy). “We use exclusively water-based paints. Years ago, we were among the first to adopt this type of coating product, in line with our commitment to environmental sustainability,” emphasizes the owner, Knight of the Order of Merit of the Italian Republic Gianluigi Pedrollo. After paint application, the parts are transferred to the drying oven, then unloaded manually and sent to the finishing line.

“With a view to sustainability, the plants operate in a closed loop: they are equipped with filtration systems that separate paint overspray and filter presses that extract solid sludge, allowing the purified water to be recovered and recirculated into the booths’ water curtains,” explains Cengia.

Technical features of the self-learning robots

The three GR 680 robots supplied by CMA Robotics are six-axis articulated machines designed for maximum freedom of movement and access to even the most complex geometries. “The previous robots were five-axis models. Moving to six axes means adding a 360° wrist articulation that helps reach every surface area on the coated component, ensuring uniform and complete coverage,” explains Marco Zanor.

The main innovation introduced is VR Tracking, an advanced self-learning technology where an operator uses a special lightweight joystick equipped with a spray gun to manually coat the first workpiece. Sensors monitor the trajectory and store it so it can be replicated by the robot, streamlining programming compared with traditional methods. “On the previous models, programming was done using an older generation self-learning system,” explains Gianluca Cengia. “The improvement has been significant, especially in terms of ergonomics: our operators no longer have to physically drag the robot structure to teach it new trajectories but can use a lightweight, easy-to-handle device instead.”

The new robots are also equipped with software that enables real-time adjustments to existing programmes for corrections or optimisations without needing to recreate the entire work sequence. Finally, the setup includes a new motor with an electronic axis for precise rotation of parts and a CAPV system that electronically manages needle opening, atomisation, and spray pattern width, ensuring high repeatability, control of the applied film, and waste reduction.

Monitor display of the trajectory traced by the operator and stored by the system for subsequent automatic replication by the robot.

“For us, the true technological leap occurred in 2002 with the first switch from reciprocators to CMA robots, which significantly reduced overspray,” notes Cengia. “Over the past twenty years, we have continued to evolve, especially in terms of software, and the VR Tracking system is a clear example of this progress. Maintenance has also become easier: the newgeneration brushless motors have made the robots more reliable and faster, streamlining servicing.

The reasons behind the investment

“In 2025, we decided to make this investment to address a specific need. The first robots installed in 2002 had reached the end of their service life, and the difficulty in sourcing spare parts was beginning to jeopardise production continuity. Additionally, we needed to respond more swiftly to requests from companies importing our products worldwide, which often require product customisation with their own branding (which translates into the need for frequent colour change operations), dedicated labels, and specialised packaging,” explains Giorgio Pedrollo, General Manager of the company.

Choosing CMA as the technology partner was a natural decision. “When we decided to upgrade our systems, turning to CMA Robotics was almost automatic. In addition to the technological upgrade aspects, the real added value for us lies in its excellent service and support. As well as its invaluable geographical proximity, we also benefit from its remote support, which means assistance can be provided in real time, ensuring operational continuity and minimising any plant downtime. Its team’s responsiveness and reliability are critical factors for us in keeping up with the pace demanded by international markets.”

After more than twenty years of collaboration, the installation of the new GR 680 robots strengthened a long-term technical partnership geared towards innovation and ongoing improvement, supporting the high standards of quality, reliability, and production flexibility that set Pentax’s electric pumps apart in the over one hundred global markets in which it operates.

© Pentax

A robot’s operator console.

Coating application via an articulated robot.

© Pentax

TOPFINISH Bell 2 WACON Spray

Next level engineering. High-end system possibilities.

The new, attractive system package: The combination of TOPFINISH Bell 2 high-speed rotation atomizer and WACON Spray control unit. High-end coating has never been easier.

Experience it live now: At your local WAGNER distributor and at PaintExpo in Karlsruhe, Germany.

FOCUS ON TECHNOLOGY

A 5.0 coating plant to support WAMGROUP’s growth and manage its diversified production

Ilaria Paolomelo ipcm®

Visa Impianti has designed and built a new powder coating plant installed at WAMGROUP’s headquarters. Developed in accordance with Industry 5.0 principles, this line incorporates Wagner powder application technology and a Futura power & free conveyor system, enabling increased production capacity and the handling of a very wide range of industrial components.

In recent years, the debate about the future of the manufacturing industry has gradually shifted from the paradigm of digitalisation, typical of Industry 4.0, to a broader and more complex model: Industry 5.0. This is no longer only about adopting advanced technologies but

also about introducing a more balanced view of production systems that combines technological innovation, environmental sustainability, and energy efficiency without losing sight of the central role of people in industrial processes. While the 4th Industrial Revolution emphasised system connectivity, automation, and data management, Industry 5.0 adds a layer of complexity: that of a smart and responsible factory where digitalisation, energy monitoring, and process integration become tools for enhancing competitiveness and reducing the environmental impact of production activities.

Even the most seemingly consolidated manufacturing processes, such as coating, are undergoing a profound transformation. Today, coating lines are becoming smart systems capable of communicating with corporate IT systems, monitoring energy consumption, optimising raw material usage, and maintaining increasingly high quality standards.

The investment made by WAMGROUP, a multinational company headquartered in the province of Modena (Italy) and specialising in technologies for bulk solids handling and water treatment, exemplifies this very trend. With nearly 60 years of history, over 2,500 employees, and a production and sales network spanning more than 50 countries, this Group clearly demonstrates how technological innovation can drive industrial growth yet remain firmly rooted in local communities. Its WAM Industriale site has recently installed a new powder coating system that embodies the principles of Industry 5.0 in tangible terms. This line was designed and built by Visa Impianti (Tregasio di Triuggio, Monza e Brianza, Italy) based on a systematic approach emphasising technological integration, energy management, and operational ergonomics as the project’s core elements. Every component of the system works in harmony to enhance overall performance in terms of both efficiency and sustainability. In particular, the power & free conveyor system developed by Futura (Robecco Pavese, Pavia, Italy) enables the adjustment of production flows and the adaptation of part movements to specific processing requirements, while the application technologies supplied by Wagner (Valmadrera, Lecco, Italy) dynamically adapt to the geometric characteristics of components to optimise powder transfer efficiency and minimise waste while ensuring high quality standards.

Glocalisation as a growth strategy

Founded by Vainer Marchesini in Ganaceto, in the province of Modena, in 1968 as a small mechanical workshop specialising in the custom manufacture of tubular screw conveyors for concrete batching plants,

WAMGROUP has gradually grown into a global leader in technologies for bulk material handling and water treatment. “In the 1970s, the company began to standardise its products, although it still offered the option of customising them to meet specific requirements. With the establishment of WAM S.p.A. in nearby Ponte Motta di Cavezzo in 1978, the foundations were laid for a more structured organisation, ready to look beyond Italy’s borders,” says Matteo Reggiani, marketing & communications director at WAMGROUP.

The 1980s marked the start of the Group’s international expansion, with the opening of its first foreign subsidiaries in France, Germany, and the United States. Simultaneously, WAM invested in research and innovation by establishing the WAM Research Laboratory, which was accredited by the Italian Ministry of Education, University, and Research (MIUR) in 1988, to strengthen the technological approach that would fuel future growth. In the 1990s, the Group took a decisive step towards localising production, opening its first factory in China in 1995 – a pioneering achievement for an Italian company at that time. During this phase, WAM expanded its product range, automated its production processes, entered new industrial sectors, from food to chemicals, and experimented with the use of innovative engineering polymers.

From 2000 onwards, the company has embraced a philosophy of ‘glocalisation’, a blend of localisation and globalisation. “For us, it’s not a question of relocation, it’s a choice of smart localisation. Our subsidiaries and facilities are not merely focus on production, they are there to serve local markets with greater speed, flexibility, and proximity to customers,” explains Reggiani.

Overview of the powder coating plant and, from left to right: Cristian Boem from Wagner, Paolo Massari from Visa Impianti, and Filippo Inversani from WAMGROUP.

This philosophy has guided the Group’s international expansion, with factories and subsidiaries not only in Europe and Latin America, but also in Africa, Australia, and Türkiye. “Today, WAMGROUP operates in more than 50 industrial sectors, including construction materials, food and feed, chemicals, lithium battery production, materials recycling, and civil and industrial water treatment. Our product range is equally comprehensive and includes screw and chain conveyors, bucket elevators, industrial mixers, shut-off and feeder valves, rotary valves, dust filtation systems, and machines for solids-liquid separation and waste water treatment,” illustrates Nicola Manzali, the general manager of WAM Industriale.

A complex production process and the importance of coating

Such a broad range of products intended for a variety of industrial sectors inevitably translates into complex production processes. “Our production

cycle begins with a series of machining operations on sheet metal, including laser cutting, panelling, and bending, followed by welding and metalworking to produce the structures and components required for our different product lines. Afterwards, the components, made from carbon steel or stainless steel, move on to the next stages. In particular, all carbon steel parts undergo a powder coating process before final assembly,” explains Manzali. “Coating not only protects their surfaces against corrosion and harsh environmental conditions but also ensures aesthetic uniformity and quality, meeting high standards across an extremely diverse range of products, from small mechanical components to large panels and structures.”

To support production growth and the development of new product lines, WAM has recently installed a new, more adaptable coating line that can handle larger components and operate alongside the existing plant, which remains in service. The new system, designed and installed

by Visa Impianti, will therefore not only increase the company’s production capacity but also ensure operational continuity and reduce the risk of bottlenecks throughout the entire process. “Our Group’s filter division alone produces 12,000 units a year at this site, and its goal is to reach 30,000 filters, so we definitely needed both a backup for the existing plant and a system capable of meeting our new production requirements,” indicates Manzali.

The coating cycle and the new plant’s technical characteristics

“The process begins in the loading area, where the operators place the components, which can measure up to 5,000 x 1,000 x 1,600 mm, on the load bars, each with

a maximum load capacity of 500 kg. Given the size of the treated workpieces, both the loading and unloading stations are equipped with automatic elevators that lower the load bars, easing the operators’ work and reducing ergonomic risks. This solution aligns with the principles of Industry 5.0, where a focus on ergonomics and safety helps to improve not only working conditions but also overall process efficiency,” says Filippo Inversani, production technologist at WAM Industriale. The components are then transported by Futura’s power & free conveyor to the pre-treatment tunnel, where they undergo a pickling stage, a rinse with mains water, phospho-degreasing, a second rinse with mains water, and a final rinse with demineralised water. “Finally, each component undergoes nanotechnology From left to right:

Both the loading and unloading stations are equipped with automatic elevators that lower the load bars, easing the operators’ work and reducing ergonomic risks.

Components at the entrance to the pre-treatment tunnel. The tunnel’s nozzles.

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

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

Just contact our Experts!

passivation using a process developed by Chemetall (Giussano, Monza e Brianza, Italy), which improves corrosion resistance, salt spray performance, and durability even in particularly harsh environmental conditions,” indicates Inversani.

“Before entering the pre-treatment tunnel, dedicated sensors measure and verify the incoming parts’ dimensions to prevent any damage to the equipment or the workpieces themselves,” adds Paolo Massari, sales manager at Visa Impianti.

After pretreatment, the components pass through the drying oven powered by a direct-flame burner and are then conveyed first to the powder coating booth supplied by Wagner and subsequently into the curing oven, where they dwell for about 1 hour at a temperature of 180190 °C. This is followed by a cooling phase and automatic unloading via elevators. “To improve productivity and meet our operational requirements, we asked Futura to design a conveyor that splits at the oven’s exit: if the treatment cycle is complete, the component moves to the cooling area before unloading; if a second coat is needed, it is sent directly back to the booth for this additional stage,” explains Inversani.

“Together with Futura, we have also placed strategic storage buffers to better manage the end of the cycle. The purpose was to prevent oxidation,

which can occur when parts remain inside the pre-treatment tunnel at the end of a working day. With the new plant configuration, the operators can empty the line at the end of each shift, transferring the load bars to the storage buffers so the components do not remain in the plant and are not exposed to the risk of oxidation,” adds Visa Impianti’s sales manager.

“All recipes and process parameters, such as pre-treatment times, curing temperatures, and spray gun settings, are integrated into our MES system. This enables us to automatically manage the entire production cycle, tailoring each stage to the specific characteristics of every component and paint product while achieving high quality standards, full traceability, and maximum operational efficiency,” states Inversani.

Powder application and management technologies

“10 automatic spray guns are installed inside the booth, 5 on each side. Due to the wide variety of dimensions and shapes of the parts being treated, the plant has been designed to adapt dynamically to the specific characteristics of each component. At the entrance to the booth, a contour detection system using photocells identifies the size and position of the incoming part and activates only the necessary guns, positioning them accordingly. This enhances application uniformity and minimises paint

From left to right:

The application booth features 10 automatic spray guns, 5 on each side, which are activated only when needed, depending on the size and shape of the part to be coated.

Overview of the technologies supplied by Wagner.

Components exiting the curing oven.

waste,” explains Cristian Boem, area manager at Wagner. “One of WAM’s main objectives at the start of the project was specifically to decrease powder consumption, which is why the spray guns operate in this manner. Furthermore, the application technology used is state-of-the-art in terms of electrostatic efficiency: around 80% of the powder dispensed by the guns is actually deposited on the workpiece, while the remainder, known as overspray, is recovered and fed back into the production cycle.”

At the core of the application system is the SuperCenter Evo powder centre, which ensures high repeatability and consistency in powder quality through the continuous blending of virgin and recovered powders. All powder coating flows are consistently monitored using load cells that precisely measure the quantities used and track consumption by batch or colour, providing reliable data for cost control and process optimisation. “The colour change system is also highly efficient: thanks to Wagner’s patented solutions for cleaning the booth and its internal surfaces, the entire process is completed in around 10 minutes. Since WAM carries out an average of 8 colour changes per day, this speed is crucial for maintaining high productivity levels and reducing line downtime,” concludes Boem.

At the oven’s exit, the conveyor splits: if the treatment cycle is complete, the component moves to the cooling area before unloading; if a second coat is needed, it is sent directly back to the booth for this additional stage.

During the loading and unloading phases, automatic elevators facilitate the hanging of parts.

A

plant designed in accordance with the principles of Industry 5.0

One of the most significant aspects of the project concerns the plant’s compliance with the Industry 5.0 paradigm. “The line is fully connected to our company’s digital systems and enables real-time monitoring of production data, process parameters, and energy consumption. Compared to earlier solutions based on the Industry 4.0 framework, the implementation of a plant meeting the Industry 5.0 requirements entailed a particular focus on its integration with the company’s IT systems. However, such a high level of complexity has paid off, as we now have access to advanced tools for controlling and optimising our production processes and reducing our energy consumption,” says Caterina Cau, buyer at WAM Industriale.

“Another interesting feature of this system is its readiness for future energy developments, since it has been designed to be converted from gas to electricity without requiring any significant structural changes, enabling further improvements in energy efficiency over time,” notes Massari.

“The construction of our new plant was made possible through the collaboration of several technology partners. We entrusted Visa Impianti with the design and installation tasks, recognising its high standards of quality and its experience in building highly automated industrial coating systems, and we worked closely with the technical teams of Wagner, our long-standing partner in coating application technologies, Futura, which developed a conveyor tailored to our production needs, and Ecoteam for the demineralised water production system. The result is a highly customised line that is perfectly calibrated to our specific requirements,” concludes Manzali.

FOCUS ON TECHNOLOGY

At Metalprogetti, preventive maintenance ensures high-quality, effective pre-treatment

According to a recent study, the average cost of downtime due to unplanned plant stoppages in the manufacturing sector is approximately €220,000 per hour. That is why preventive maintenance is essential. A company that understands this well is Metalprogetti, which specialises in the design and manufacture of automated systems for handling and storing hanging or folded garments and various types of lightweight products. After insourcing powder coating, it now performs regular maintenance on its pre-treatment system in collaboration with Chemtec, the supplier of the chemicals used in this pre-coating phase.

Maintenance is most commonly defined as ‘keeping something intact and efficient’. Industrial maintenance enables manufacturing companies to ensure that plants, machinery, equipment, and production infrastructure function correctly and without interruption, helping to improve operational efficiency, reduce downtime, extend the service life of equipment, and promote worker safety. Failures, whether in an individual machine or an entire production line, can have a significant impact not only on downtime but also on productivity losses, repair costs, and safety risks.

According to one of the most recent reports1 on preventive (or scheduled) maintenance aimed at radically reducing costs and downtime across all sectors, the average cost of unplanned downtime in the manufacturing sector is $260,000 per hour (approximately €220,000 per hour). 80%

1 https://zipdo.co/maintenance-industry-statistics/

Monica Fumagalli ipcm®

Metalprogetti specialises in the design and manufacture of automated systems for handling and storing hanging or folded garments: in this photo, the sculpture located outside its production area, depicting a conveyor belt, the heart of its systems.

of industrial plants adopt preventive maintenance to avoid unexpected breakdowns, and 65% of companies report a 30% reduction in downtime after implementing such programmes. Although the average lifespan of industrial equipment is 10 years, around 40% of machinery breaks down prematurely due to inadequate maintenance.

“This is the reason why the maintenance of plants and systems, including pre-treatment ones, is so important,” emphasises Carlo De Alessandri, Business Developer at Chemtec Srl, a company specialising in the formulation, production, and marketing of chemical products and equipment for the industrial finishing sector, from surface treatment to industrial water purification. “As formulators and suppliers of chemical compounds, we always provide precise instructions on the controls and actions necessary to keep a plant clean. Not all users adhere to the recommended timings. Yet to ensure a high coating quality, it is essential to combine process control with thorough routine maintenance. One of the virtuous exceptions is Metalprogetti (Perugia, Italy).”

The revolutionary idea behind this company

We have often featured stories in our magazine about businesses that started from an insightful idea transformed into an industrial vision. In

the case of Metalprogetti, a company founded by Augusto Santicchi in the late 1970s, that insight marked a true paradigm shift in the hanging garment handling sector. During a trade fair dedicated to the laundry industry, Santicchi observed escalators, early automatic handling systems, and the growing focus on store layout, and he realised it was possible to develop a solution that combined automation, space optimisation, and aesthetic design. The aim was to improve picking management and streamline operator work. Building on his experience as a machine maintenance technician at Perugia’s renowned chocolate company, where he had also developed an automatic solution for recovering chocolate, and supported by his family and colleagues, he designed an innovative system for managing hanging garments in dry cleaners. 60 units were produced in the first year. “Today we produce 700 systems per year, 90% of which are exported to foreign markets,” says Fabrizio Bacchi from the Facility Management-Soft Services office at Metalprogetti.

Plant engineering, automation, and software design are the three key elements that define the company’s identity, with the recent addition of a growing focus on surface treatment, following the creation of a division devoted to powder coating the components of its automation systems intended for the management and storage of hanging or folded garments.

The belt that runs inside the automated systems can take on different configurations, even on multiple levels, depending on the application; One of the automated systems on display in the company’s showroom; A cutting machine for flat sheet metal.

From top left, clockwise:

The outside of the semi-automatic pre-treatment tunnel: the plant is connected to a control PLC used to select the treatment sequences depending on the components to be cleaned.

Components at the entrance to the pre-treatment tunnel.

Chemtec supplies Metalprogetti with its PHOSTRI TTS4 phosphating agent, DNAD NOF surfactant, and PRONORTEC MM-01 nanotechnology product.

“To guarantee high performance, we have always combined our drive for innovation with mechanical precision and product aesthetics: that is why surface treatment has also become an increasingly important aspect for us,” continues Bacchi. “Previously, we relied on external suppliers. However, five years ago, we installed an in-house coating line designed and manufactured by Eurotherm Srl (Volpiano, Turin, Italy), consisting of a pre-treatment tunnel in which we use Chemtec chemicals, a booth for drying the parts after pre-treatment, a coating booth applying polyester powders from Austrian multinational Tiger Coatings, and a curing booth. Our customers are now often supported by architectural firms and, in addition to the most popular colours – primarily white, which brightens indoor spaces, light grey, and dark grey – it is important for us to be able to offer customised colours and effects upon request, thanks to the special formulations developed by Tiger Coatings’ Italian division.”

Metalprogetti, a dynamic company

Metalprogetti’s production plant was built in 1985, the year the company consolidated its presence in the fashion industry. This step marked the beginning of a technological evolution that took it from creating the first storage systems for hanging garments to developing increasingly advanced automation solutions, which were to become the company’s core business in the 1990s.

The fields of applications gradually expanded to the textile maintenance sector, with solutions designed to support and optimise activities in industrial laundries and dry cleaners. However, the turning point occurred in 1996, when the Geneva University Hospital (HUG) requested the adaptation of an automatic garment return system for managing work uniforms. This collaboration led to the creation of the first automated distribution system for professional uniforms, which has since simplified the management of personal and work clothing in many specialised sectors, from healthcare to industry.

The 2000s marked a further phase of growth and international expansion: the company entered the US market, supported by its participation in the Clean trade fair, and then the French market, thanks to a partnership with the large-scale retail group E.Leclerc. This latter experience also led to the creation of Trident, the multi-level horizontal rotating warehouse that introduced the concept of dynamic picking.

Metalprogetti’s technological evolution is now on display in the showroom inaugurated by the company in 2011, where customers and partners can see the company’s systems in operation through real-world application simulations, a testament to a design approach based on research, experimentation, and market listening.

“Starting from the simple system invented by our founder,” emphasises Bacchi, “we have made listening to customer needs the driving force behind the development of new solutions. Our ability to customise products is key to creating those kinds of ‘tailor-made’ solutions that are especially valued in the Italian manufacturing industry. We currently hold 45 patents worldwide for our handling systems.”

This openness to listening to customer feedback is rooted in Metalprogetti’s entrepreneurial vision, and it is also reflected in the attention given to people and spaces. Its factory is designed to accommodate around 100 employees and customers in a comfortable environment, with areas dedicated to meetings and outdoor spaces cared for with the same attention as a home garden.

System reliability and a focus on the manufacturing process

“Efficiency is a delicate balance of mechanical precision, technological innovation, and human ingenuity” is the philosophy of Augusto Santicchi, the founder of Metalprogetti, and the guiding principle behind its complex production processes. “The core of our solutions is the belt that runs through our automated systems and can take on different configurations,

even on multiple levels, depending on the application,” explains Bacchi. “We manufacture all the parts that make up our systems inhouse using different materials, from steel (for the belts) to galvanised steel, aluminium, and plastic, on advanced machines for cutting and processing both sheets and profiles. The precision of mechanical construction enables the mechatronic components that control our systems’ movements to operate with utmost accuracy, seamlessly integrated with automation devices and software suites designed to interface with the management systems already used by our customers. If necessary, we can also create customised IT solutions.”

Metalprogetti’s approach is therefore characterised by constant attention not only to people, but also to the technologies implemented. “The same care we devote to designing our systems is also applied to managing our production lines, such as the coating one we have recently installed, consisting of a pre-treatment tunnel, a drying oven, a powder coating booth, and a curing oven, entirely manufactured by Eurotherm. In our technical language, the concept of care

From top left, clockwise:

Each of the chemicals supplied by Chemtec has been chosen after careful analysis of Metalprogetti’s needs.

The demineraliser with ion exchange resin.

The drying booth where the parts dwell after pre-treatment.

translates into maintenance, which is essential for optimising production: only by servicing our plants regularly and accurately can we ensure operational continuity, reduce machine downtime, and protect the safety of our employees.”

The pre-treatment chemicals

Metalprogetti’s semi-automatic pre-treatment tunnel is designed to accommodate components of various shapes and sizes to meet all its customisation needs. De Alessandri explains: “The process involves an initial phospho-pickling stage carried out with the product PHOSTRI TTS4 combined with the surfactant DNAD NOF, formulated to reduce or eliminate foam formation during the phosphating phase, which was one of the most critical issues encountered by Metalprogetti in the first year of using this plant. This is followed by three rinses, the last of which utilises osmotic water, and a no-rinse nanotechnology-based passivation stage with the PRONORTEC product, which has recently obtained Qualicoat certification, in addition to the Qualisteelcoat certification already obtained,

guaranteeing the high quality of this treatment on steel, galvanised steel, and now also aluminium.”

The primary water treatment plant supplies osmotic water for the final rinsing stage and for addition to the high-pressure sprayed nanotechnology solution, improving paint adhesion to metal and enhancing corrosion resistance. “It is fitted with several types of filters, from the coarsest ones, for larger impurities, to activated carbon filters, capable of removing particles down to one micron. The heart of the system is the ion exchange resin membrane, which transforms mains water, with a conductivity of around 400 μS, into osmotic water with a conductivity of around 10 μS, suitable for both the final rinse stage and the preparation of the nanotechnology-based solution.”

The role of maintenance in the pre-treatment process

“We have optimised our pre-treatment process through ongoing collaboration and mutual exchange with the Chemtec team,” says Bacchi. “We previously used a manual plant, but the search for superior aesthetics

The powder coating booth.

The curing oven.

Components waiting to be sent to the assembly department. Typically, Metalprogetti’s automated systems are subjected to functional tests before the finishing phase.

and durability and the need to speed up finishing times prompted us to opt for a more advanced system. Pre-treatment is one of the most delicate stages of the entire process, and having no direct experience, we had to learn the ropes and gain a thorough understanding of how it works. Chemtec not only assisted us with initial training but continues to support us in optimising and maintaining our system: this includes the management and replacement of products but also the cleaning of the tunnel.”

In addition to checking the pre-treatment chemical parameters twice a week, a key factor to ensure the long service life of a pre-treatment plant is indeed its cleanliness. During the phosphodegreasing stage, sludge accumulates on the tunnel walls. Typically, corrosive acid products are used to remove it, but these can damage the internal metal surfaces. “Our laboratory has formulated Defos AK-01, an effective product for sludge removal, allowing rapid dissolution without altering the metal parts of tunnels,” explains De Alessandri. “Thanks to this innovative formulation, the cleaning phase takes less time than with traditional acidic products and ensures significantly better results.”

The residual sludge that builds up on spray bars, tanks, heat exchangers, and external boilers diminishes plant performance. “Without regular maintenance, we would lose all the benefits gained from process optimisation,” Bacchi highlights. “Once a year, we perform a thorough cleaning of all the tanks, which hold about 6 m³ of liquid. We have learned to handle this work independently, but we always request support from Chemtec staff, taking advantage of the plant shutdown to oversee and review the entire coating process together.”

An all-round partnership

The products used in the pre-treatment tunnels are the same for different materials. “Since, for example, components that have already been pickled are less dirty and require less intensive cleaning, whereas others require more intensive treatment, the storage of pre-set treatment sequences allows for flexible management of different requirements, ensuring faster and more consistent processing times.”

The collaboration with Chemtec has also proved fundamental in terms of waste disposal. “Due to the characteristics of the chemicals used, it was necessary to find a balance in waste management as well. Applying too much product apparently improves cleaning, but actually causes significant problems in the disposal phase. Together, we determined the correct dosage to avoid environmental problems. This is further confirmation that our relationship with Chemtec is not limited to the simple supply of products but is a continuous exchange on any operational challenges,” concludes Bacchi. “Metalprogetti’s management pays equal attention to its products’ quality and the quality of life of its employees. That is why plant maintenance is a key factor, as is waste water management, which we have learned to monitor and optimise thanks to our collaboration with our partner, which has gone beyond the supplier-customer relationship and has itself become a guarantee of our systems’ quality.”

New TIXO Clear and TIXO Filler. Superior quality for carbon fiber surfaces.

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

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

Coating and waterproofing with polyurea

Martha Jungwirth b&m GmbH – Oberteuringen, Germany m.jungwirth@bm-gmbh.com

The waterproofing of flat roofs on bungalows in Sarajevo was successfully completed using polyurea spray systems, with on-site training and equipment provided by b & m GmbH. This project demonstrates the efficiency and technical performance of modern high-pressure spray technology.

Thanks to their resistance, sustainability and fast curing properties, liquid membranes based on polyurea and polyureapolyurethane hybrids are playing an increasingly important role in a wide range of applications, including waterproofing, flooring and anti-corrosion protection on concrete, steel and other substrates.

Fast roof insulation through the effective combination of materials and spray technology

Polyurea coatings are spray-applied liquid membranes characterised by high resistance, waterproofing performance and very fast curing times. These coatings are applied by spraying the two components mixed directly inside the PU spray gun onto the surface, ensuring excellent protection against abrasion, impact loads, chemical agents and corrosion.

These membranes are used on roofs, flooring systems, bridges and concrete and steel structures - particularly in the water and wastewater management sector - as well as on parking decks and underground garages.

The benefits are evident:

 Protection of the substrate from moisture

 Protection of steel from corrosion

 Thermal stability – reliable performance across a wide temperature range

 Mechanical strength – excellent resistance to abrasion and impact

 Seamless, fully bonded layer – monolithic, joint-free

 Very low emission values

 Solvent-free

 Extreme durability – retains waterproofing and protective properties under various environmental stresses

 Elastic and flexible – accommodates substrate movements without cracking or delamination

 Chemical resistance – withstands various chemicals, including acids and oils.

Case study: a challenging construction site in Sarajevo

The project involves the waterproofing of several flat roofs on bungalows in Sarajevo, Bosnia. Local applicators were trained on the correct use of materials and the appropriate spray equipment.

Using professional two-component high-pressure airless pumps, transfer pumps, heated hose assemblies, and a two-component mixing and atomizing spray gun, a coverage rate of 100–150 m² per hour is achieved. The team from b & m GmbH, headquartered in Oberteuringen, Germany, and the supplier of this type of professional spray equipment, travelled to Sarajevo to provide hands-on training under real on-site conditions. The spray unit was installed at ground level. Material supply (components A and B) is provided via two pneumatic transfer pumps drawing directly from 200-liter drums. The pumps feed the material to the pneumatically driven high-pressure pumps of the polyurea spray system. Transfer pumps are pre-assembled on the drum lids. When a drum is empty, a new drum is opened, and the complete lid, including the transfer pump, is placed on top. This setup minimizes changeover time and prevents unnecessary ventilation of the material circuit.

The high-pressure pumps pressurize components A and B, delivering them through separate hoses. From there, the material is conveyed via heated hose assemblies (up to 90 meters) to the spray gun for application. The extended hose length allows the material to be pumped vertically across several floors, while the spray equipment remains safely positioned at ground level.

The perfect mix for blast cleaning

Ervin has been providing customers with the best blasting solutions since 1920. Whatever your needs, we can provide the ideal abrasive and technical support for perfectly clean and prepared surfaces.

Amasteel shot & grit

• High quality martensitic steel abrasives for cleaning, surface preparation and peening

Stainless shot & grit

• Produces high gloss, rust free surfaces

• For cleaning, surface preparation and peening

Amapure

• New mineral degreasing additive

• Improved productivity and coating performance

• Combine with Ervin Amasteel and Stainless abrasive for the ideal blasting solution

Ervin Germany GmbH T +49 30 6780 4940 info@ervin.eu www.ervin.eu

Spray equipment installed at ground level.

At the application area, the operator easily sprays the polyurea using the heated hose assembly and spray gun. This setup optimizes space requirements and significantly reduces time and logistical effort on site. Components A and B are delivered through separate heated hoses to a dedicated two-component spray gun equipped with an internal mixing chamber. Inside the gun, the components mix and discharge at high pressure through the spray nozzle. The mixed material is then applied to the surface in a fine, atomized spray pattern.

Since the reaction time after exiting the spray gun is limited to only a few seconds, the applied coating is ready for subsequent layers or overcoating within minutes.

Electronic control and operating parameters

A key feature of the two-component spray system is its intelligent electronic control unit, equipped with a user-friendly display that provides all relevant operating parameters. The system monitors and displays critical data such as flow rate, material temperature, and mixing ratio tolerances. In the event of a malfunction, the system automatically issues a warning signal.

The recommended ambient air temperature for polyurea application ranges from 5 °C to 40 °C. Relative humidity levels of up to 85% are permissible, making the material suitable even for use in tropical climates.

As an alternative to polyurea, PU foam insulation materials can also be processed using the same equipment. However, this technology is not a doit-yourself solution. Proper training is essential. Operators must be instructed by the equipment supplier on correct handling, commissioning, shutdown procedures, and thorough cleaning of all system components.

Proper training and safety

For appropriate material selection and correct application procedures, additional training provided by the material supplier is strongly recommended. Ideally, both the material and equipment suppliers should be present during the initial on-site training session to ensure optimal system setup and user qualification. Last but not least, the use of appropriate personal protective equipment (PPE) is mandatory.

The roofing project in Sarajevo was successfully completed within a remarkably short timeframe. All stakeholders expressed great satisfaction with both the technical results achieved and the long-term value of this forward-looking investment.

From top to bottom:

Spray unit with dual pumps and integrated control panel.

User-friendly control display.

High-pressure application: the material is mixed inside the spray gun and atomized by airless high pressure, eliminating the need for additional atomizing air.

SAVIM EUROPE DESIGNS AND BUILDS HIGH-VALUE INDUSTRIAL PAINTING SYSTEMS.

Advanced technologies and a highly tailored approach make every project unique - from initial assessment and engineering to post-installation support Built for special applications and complex processes, our plants ensure high performance, consistent quality, and maximum safety, fully compliant with the most rigorous sustainability standards. savimeurope.com

From catalysis to hydrogen: five decades of infrared innovation with Infragas

Alessia Venturi ipcm®

Established in 1971, Infragas (Mappano, Turin, Italy) is celebrating over half a century of activity in the field of gas-fired infrared technologies. Founded by Danilo Fassio and now run by his children Irene and Claudio, it has gained an international reputation through continuous research, technological expertise, and the ability to adapt its solutions to a diverse range of industrial processes.

Energy infrastructure forms the backbone of our cities. Invisible in everyday life, yet essential to the functioning of entire communities. Today, this infrastructure needs to go further: it must actively contribute to reducing emissions and creating a more sustainable energy system. This is exactly the approach adopted by Infragas, a leading supplier of catalytic infrared panels and high-temperature gas-fired IR systems. Over its history, sustainability and safety have remained central to its innovation efforts. By developing new technologies, recently adopting hydrogen as a fuel source for infrared systems, and analysing the carbon footprint of its operations, it has been creating products and solutions that cater to a rapidly evolving world.

“Infragas has built its identity around three core values,” explains Michele di Mauro, Head of Sales and Marketing. “The first is a focus on environmental impact, with research always geared towards technologies capable of reducing emissions and enhancing the energy efficiency of industrial processes. The second pillar is technological innovation: our commitment to research into catalytic materials and new configurations of infrared systems has enabled us to develop unique, high-performance solutions suitable for a wide range of sectors. The third value is our strong connection to the Italian manufacturing tradition: all our products are designed and manufactured entirely in Italy, making us one of the few companies able to guarantee high quality standards and direct control over every production stage. These three elements will also form the heart of our exhibition at PaintExpo in Karlsruhe (Germany) in April: the design of our stand (Stand 1410, Hall 1) will combine our technological expertise and our corporate values for the first time, reflecting our renewed focus on Europe, Italy, and the pursuit of new technological and commercial partnerships.”

Technological advancements to cover the entire infrared spectrum

From the outset, Infragas has focused on gas-fired catalytic infrared technology, which converts the energy of a fuel into infrared radiation without producing a flame. In the early years, its primary applications were in the domestic and industrial sectors, particularly in tanneries, where catalytic panels were employed for drying and heat treatment processes.

© Infragas

Besides infrared heating systems, the company has also gained significant expertise in catalytic converters for treating fumes and odours across various sectors, such as domestic pyrolytic ovens, professional kitchens, and cooking systems for the catering industry.

The turning point for entry into industrial markets occurred in the early 2000s when Infragas began developing new catalytic solutions specifically tailored for production processes. Alongside the Infracat system, a catalytic panel based on a flameless reaction, it launched Boostercat, an improved version with rear ventilation to enhance power density and heat transfer efficiency. With these technologies, catalytic infrared systems have found application in numerous surface treatment processes: liquid paint drying, powder coating gelling and curing, ink drying on paper and glass, and even processes in the MDF and HDF panel industry, which for a time became one of the company’s key markets.

A key strength of Infragas’ technology is its combination of high energy

efficiency with very low emissions of CO, NOx, and unburned fuel. At the same time, these catalytic systems are designed to last: in many industrial installations, these panels can remain in operation for over twenty years, maintaining consistent performance over time. “IR technology also offers significant advantages in terms of production layout for powder curing processes within two-coat finishing applications. The installation of infrared sections between the application of the first and second layer removes the need for major changes to the existing coating systems and allows the treated workpieces to dwell in the oven only once, thus optimising production time and space,” says Francesca Marabotti, business development and marketing manager. A further step in the company’s evolution was the development of the radiant high temperature (RHT) technology.

“Unlike catalytic systems, the RHT units are short-wave infrared panels that produce a micro-flame on the surface of a sintered metal structure composed of iron, chromium, aluminium, and yttrium,” explains Marabotti. “This enables reaching a surface temperature of up to 9501000 °C and a power density of up to 200 kW/m², compared to around 30 kW/m² for catalytic systems. By introducing this technology, Infragas has covered the entire industrial infrared spectrum: long and medium waves with catalytic panels, and short waves with RHT systems. This has opened up new application opportunities in processes characterised by high speeds or significant thermal masses, where previous technologies had proved inadequate.”

Hydrogen as an energy carrier for new catalytic applications

Looking ahead, Infragas is now exploring and developing solutions based on the use of hydrogen as an energy carrier for advanced applications –a technology already presented by ipcm® in 20221 – which shows great potential for reducing the environmental impact of various industrial processes, supporting high-efficiency energy systems, and promoting new models of energy production and consumption. “Infragas’ catalytic panels are designed to switch from natural gas or LPG to mixtures containing hydrogen or to pure hydrogen simply by flipping a switch, without requiring any major plant modifications. This approach enables many customers to gradually convert their existing lines to fuels with a lower environmental impact, anticipating future developments in the energy market,” states Michele di Mauro.

1 A. Venturi, “Hydrogen-powered catalytic IR panels: a technology with a zero carbon footprint” in ipcm® no. 78, Vol. XIII Nov/Dec 2022, pp. 106-108

Right: powder gelling tests with RHT units.

Left: thermal fixing of decal applications on bicycle frames using Boostercat enhanced catalytic infrared panels.

© Infragas

The Test Centre as a competitive advantage

In recent years, one of the cornerstones of Infragas’ strategy has been its in-house Test Centre, an application laboratory designed to showcase the advantages of infrared technology in industrial processes to customers. Fitted with various system configurations, including a vertical line with a speed-adjustable conveyor and Infracat, Boostercat, and RHT modules, it enables the simulation of numerous industrial processes such as powder gelling and curing, liquid paint drying, heat treatments, and dehydration. It is also equipped with a horizontal oven based on the Boostercat technology, used in complex projects for major automotive brands. For example, it was recently employed to test fire-retardant coatings intended to protect electric vehicle batteries.

The Test Centre also facilitates the validation of complex industrial processes. In a project developed for an LGP tank manufacturer based in Montreal (Canada), for instance, a combination of RHT panels for the initial gelling stage and catalytic modules for the final curing stage was used; the quality of the resulting coating was then evaluated using a specific powder adhesion test (cross-cut test). “The ability to carry out real-world application tests is now one of our key competitive advantages,” comments Francesca Marabotti, “because it enables end users and integrators to validate our system’s performance before installation.”

A long-standing brand

Having been deeply rooted in the Italian industrial landscape for over fifty years, the company is currently gathering all the necessary documentation to register the “INFRAGAS” trademark in the Special Register of Historical Trademarks of National Interest established by the Italian Patent and Trademark Office. This is a prestigious distinction awarded to outstanding Italian companies with a long-standing connection to the country, such as Lavazza, Ferrero, Olivetti, Borsalino, and Pirelli.

© Infragas © Infragas

The horizontal oven based on the Boostercat technology. The vertical line featuring a speed-adjustable conveyor and Infracat, Boostercat, and RHT modules at Infragas’ Test Centre in Mappano.

Walther Trowal unveils two new Rotamat coaters at PaintExpo 2026

Walther Trowal will showcase its latest technologies at PaintExpo 2026 in Hall 2, booth 2310.

At PaintExpo 2026, Walther Trowal will present two new Rotamat coating systems: the Rotamat R 60 for the insulation coating of extremely small electronic components, and the Rotamat R 100, designed for large, flat sealing components used primarily in electric vehicles. Both machines were developed specifically to process workpieces that, until now, were unsuitable for mechanical drum coating. For the insulation coating of very small electronic components – such as magnetic cores with volumes as low as one cubic millimetre – Walther Trowal has equipped the Rotamat R 60 with a uniquely shaped rotary drum. Specially designed ribs and deflectors inside the drum ensure that each workpiece receives a perfectly homogeneous coating, which is essential for reliable insulation performance. Despite their extremely small size, the components do not stick together during processing and are discharged individually at the end of the coating cycle.

Walther Trowal will also showcase the Rotamat R 100, developed for coating large, flat sealing components made from elastomers. These sealing elements are widely used in electric vehicles, for example to insulate individual battery cells and cooling systems incorporating heat exchangers. They are also employed in fuel cells and electric motors.

Depending on the application, the coating material may consist of antifriction or coloured lacquers.

The new Rotamat R 100 has a usable volume of 160 litres. In a single batch, it can process around 150 flat sealing components with diameters of up to 350 mm, or approximately 50,000 O-rings – around three times the capacity of its predecessor, the R 85.

“Until now, Rotamat coaters have mainly been used for smaller components such as O-rings. With the new R 100, we have taken a completely different approach. It is the first system of its kind that enables manufacturers of significantly larger sealing components to coat their products fully automatically and with a highly cost-efficient process,” has stated Frank Siegel, Sales Manager for Coating Technology at Walther Trowal. In addition, the Rotamat R 100 is suitable for decorative coating of plastic components made from ABS or polyethylene, as well as thin-walled metal rings with diameters of up to 300 mm. These rings, used as shaft seal rings, are first treated with a bonding agent before the elastomer coating is applied.

For further information: www.walther-trowal.de

quattroClean technology: automated dry cleaning before painting saves costs, resources, and space

With its quattroClean snow-jet technology, acp systems AG (Hall 3, Booth 3521) presents at PaintExpo a modern and sustainable solution for the automated cleaning of entire surfaces or parts of components prior to painting and coating.

The dry cleaning process with recycled liquid carbon dioxide and compressed air not only ensures that components are cleaned as required, but also enables significant savings in costs, resources, and space compared to conventional wet chemical cleaning. By offering different alternatives and sophisticated automation solutions, this efficient process can be optimally adapted to the respective task and various degrees of contamination. With quattroClean snow-jet technology, the liquid carbon dioxide is passed through a wear-free two-component nozzle and expands on exit to form fine snow, which is concentrated by a compressed air jacket jet and directed precisely at the contamination to be removed. This alternative is now state-of-the-art in plastic coating due to its easy integration into fully automated painting lines.

The quattroClean rotation system opens up a new level of quality in the removal of loosely adhering, particulate contaminants.

The quattroClean rotation system removes loosely adhering particulate contaminants fully automated with high surface coverage. It is also suitable as a replacement for manufacturerintegrated snow blasting systems, for example in flatbed painting machines.

The rotation unit can be adapted in terms of wing number, diameter, and jet angle, enabling solutions that are optimally tailored to the application with very high area coverage and optimized resource consumption. In addition, this alternative is also suitable as a replacement for snow-jet systems already integrated into paint lines that no longer meet increased cleanliness requirements. Persistent particulate and filmic contaminants are a task for acp’s powerSnow technology. With this solution, the liquid carbon dioxide is compressed into fine cleaning granules within the system and accelerated with compressed air through an application-specific nozzle, which is then directed at the surface to be cleaned. Since the external pellet production required for conventional dry ice blasting is no longer necessary, fully automated, uninterrupted cleaning processes can be easily implemented.

For further information: www.acp-systems.com

Innova&ve Eco-Friendly Water Treatment

Chemicals Discover cu+ng-edge biopolymer-based and advanced products for efficient water / wastewater treatment and paint coagula;on

ALIT presents the new generation of its industrial paint strippers at PaintExpo

Among the products from the extensive ALIT Technologies portfolio that will be showcased at PaintExpo are industrial paint strippers - innovative solutions for paint removal at low temperatures. These products are designed for a wide range of industrial applications and developed to combine efficiency with sustainability.

For years in the industrial paint stripping sector, cold paint strippers have been considered the most practical and effective solution.

No heating, no thermal management, immediate action at room temperature. Many of these products were formulated with methylene chloride and halogenated hydrocarbons: highly efficient chlorinated solvents capable of rapidly removing even complex coating systems.

From a technical standpoint, the results are unquestionable, but this effectiveness comes at a cost: operator safety and environmental impact. These substances are in fact toxic to humans and harmful to the environment.

Risks to people and the environment

From a health perspective, exposure - especially by inhalation - can affect the central nervous system, leading to reduced visual and motor functions. In poorly ventilated environments, vapours can accumulate, increasing the risk of asphyxiation. In the case of methylene chloride, part of the substance can be metabolized into carbon monoxide, further worsening the risk profile. From an environmental perspective, beyond airborne emissions linked to high volatility, these substances can contaminate soil and water in the event of uncontrolled release, generating impacts that extend far beyond a single production cycle.

Today, these products still exist and in some cases are still used, particularly where regulations are less restrictive. However, the industrial context has changed: safety, sustainability, and regulatory compliance are no longer secondary aspects but an integral part of production processes.

Towards a shift in perspective

Cold paint strippers work, but their effectiveness alone is no longer sufficient to align with a modern and responsible production model.

In recent years, the sector has been moving toward less hazardous alternatives with a more balanced safety profile. In particular, hot paint strippers are taking on a central role: the controlled use of temperature makes it possible to reduce reliance on extremely aggressive substances while maintaining high performance.

“At ALIT Technologies we work every day on this balance: industrial performance and health protection must move in the same direction,” the company states. “The objective is clear: all the formulations we develop are designed to ensure high stripping efficiency while at the same time reducing environmental impact and improving operator safety.”

These and other products from the ALIT Technologies range will be on display at PaintExpo (Karlsruhe, April 14–17, 2026) in Hall 2, Stand 2536.

For further information: www.alit-tech.com

COMMITTED TO INDUSTRIAL PAINTING SINCE MORE THAN 60 YEARS

The ELETTROSPRAY® manual and automatic painting equipment both for liquid and powder paints application are fully designed and made by RAVARINI CASTOLDI & C. S.r.l. and are on the market since 60 years.

ELETTROSPRAY® electrostatic generators in particular represent a “unicum” in the solvent and water based painting equipment market.

The ELETTROSPRAY® are compliant with CEI/CENELEC standards to guarantee the maximum working safety.

Ravarini Castoldi & C. S.r.l. ELETTROSPRAY ®

Officine Minelli: a new 24-metre coating booth for material handlers

This Italian manufacturer of self-propelled, hydraulic material handlers has recently insourced its coating operations by installing a 24-metre booth and oven designed by Savim Europe. This investment marked a significant step forward, improving quality control and increasing production efficiency and speed.

The Brescia area, and in particular the Val Trompia in northern Italy, has been of great importance to the metallurgical industry since the Middle Ages. The availability of iron ore, the abundance of woodland necessary for producing charcoal for the furnaces, and the numerous watercourses that supplied energy to smithies all contributed to the development of the first water-powered forges for ironworking. Thanks to these favourable conditions, Brescia soon became renowned for the production of iron tools, agricultural equipment, and objects. This tradition was firmly ingrained in the centuries that followed, especially during the period of the Republic of Venice (15th-18th centuries), when the region specialised in the manufacture of muskets and gun barrels. With the Industrial Revolution in the 19th century, Brescia further strengthened its position in the metallurgical sector, gradually expanding its production into steel. After the Second World War, the area became one of Italy’s leading steel-producing

Martina Stucchi ipcm®

Officine Minelli’s self-propelled, hydraulic material handlers.

hubs, largely thanks to the widespread adoption of electric furnaces using recycled scrap iron instead of ore.

This manufacturing model established Brescia as one of Europe’s top steel-producing districts, and it was here, in the 1950s, that Officine Minelli was founded in Cazzago San Martino (in the province of Brescia) by four siblings who decided to set up a machinery manufacturing business. Initially, the company focused on the agricultural sector, producing machines for soil cultivation. Later, however, in response to the local market’s needs linked to the expanding steel industry, it developed its first material handler for ferrous materials.

This advancement demonstrated the remarkable entrepreneurial flair of the Minelli brothers, who were able to anticipate market changes and steer their business towards new growth opportunities. In line with this innovative spirit, the company has recently taken another step forward with the installation of a 24-metre-long booth from Savim Europe Srl (Arbizzano, Verona, Italy), aimed at insourcing its machine coating process and enhancing quality control across its entire production.

Officine Minelli’s expertise

“We are a family-run company specialising in the manufacture of hydraulic material handlers designed to operate in harsh and particularly demanding environments,” explains Roberto Fiorini, the director of Officine Minelli.

“Our product range is very diverse and comprises eight core models, from lighter machines weighing around 15 tonnes to larger, heavier ones up to 50 tonnes. Each configuration, however, is tailored to the end customer’s requirements. Our main target market is Italy.” The company manufactures approximately 80 to 90 machines annually. “One of the traits that sets us apart is our production model: we work exclusively on a made-to-order basis, avoiding the need to keep machines in stock and, at the same time, managing to provide highly customised products built to every customer’s specific requirements.”

Officine Minelli’s technical department meticulously designs these machines in every detail. “Once the design phase is complete, we order oxy-cut steel from our qualified and trusted suppliers, which deliver semifinished parts according to our technical specifications. At that point, we can begin machining and assembly. We perform all required machining, welding, and assembly operations on steel sheets in our in-house metalworking department,” says Fiorini.

“Currently, some components are pre-painted before assembly, while the complete machines are coated afterwards.” Until a few years ago, finishes were not considered a key process aspect or a significant machine feature in the scrap metal handling industry. This was due to the work environments where material handlers are used, such as collection and recycling centres, steelworks, foundries, or recycling facilities, which are

Savim Europe’s coating booth, divided into three sections.

An operator preparing an Officine Minelli machine for coating.

characterised by harsh operating conditions that cause rapid bodywork deterioration. In recent years, however, operators have started to pay more attention to this aspect: machines must be functional, durable, and also aesthetically pleasing. “We place great importance on the quality of finishes. We aim to supply machines whose coatings offer high resistance to the elements, preventing colours from fading in sunlight and corrosion from developing due to rain and humidity. At the same time, in line with market demands, we also strive to meet increasingly high aesthetic standards.” This is one of the reasons that led the company to insource the coating process, integrating it into its workflow. The goal was to ensure consistent and controlled quality, speed up the entire process, and give customers the opportunity to further customise their machines.

A new in-house process: coating

“Until recently, we outsourced our coating operations to local body shops. The process was quite time-consuming in terms of logistics and quality control. Additionally, the steps involved in our coating phase are varied and fairly complex. For example, surface preparation depends on the initial condition of the sheet metal: in some cases, filling is necessary, while in others, it is possible to directly paint the workpieces. Handling all these activities inhouse enables us to supervise every stage and determine how best to achieve each finish. We currently apply multiple coating layers to ensure the results meet the high quality standards we have set for our products,” notes Fiorini. “We allocated a hall exclusively for coating at our Cazzago San Martino plant and, at the same time, began searching for a technology partner capable of designing a bespoke solution that would meet our requirements. As we handle large-scale machine components, it was crucial to identify the most suitable configuration. Alongside Savim Europe, we managed to develop a booth with all the required characteristics,” states Fiorini.

The Savim Europe booth in its entirety: it is 24 metres long and 6 metres wide.

A part of a coated handler’s bodywork and the inside of the booth: the largest parts to be treated are lowered from above using an overhead crane.

electrostatic systems for liquid painting

Savim designed and installed a 24-metre-long, 6-metre-wide coating booth, specially built to be divided into three sections that can operate as three adjacent booths. “This layout allows Officine Minelli to use the booth in its entirety or in different configurations, dividing it into two parts of 16 metres and 8 metres or into three 8-metre segments. All sections can perform both coating and flashoff operations independently,” illustrates Francesco Scavini, the managing director of Savim.

Another distinctive feature of this plant is the 1.5-metre-wide and 16-metre-long pneumatic hatch on its ceiling, which allows access for taller components via the overhead crane. We have also installed hydraulic platforms running the entire length of the booth, enabling operators to move around and lift themselves up to reach the highest points of the machines being coated. Doors have been installed to divide the booth into three sections; these can be opened or closed as required to separate the different work chambers. After a thorough analysis of structural aspects, we were able to create a fully customised solution based on Officine Minelli’s requirements,” continues Scavini.

“The application of the two-component liquid paint is carried out manually using pneumatic technology: as these are large machines with particularly complex geometries, operators work both from the ground and on the three-axis aerial platforms installed on both sides of the booth, which can be raised to a height of up to 6 metres. For filtration and overspray abatement, the plant employs a completely dry technology. Hot air for drying is introduced from above via a

electrostatic systems and spraying booths for powder coating

pneumatic systems for high-, medium-, and low-pressure painting

robot and reciprocators IR and UV drying systems

©

The ceiling of the booth, with a filter deck fed by air-stream burners.

filter deck fed by air-stream burners, which also offer advantages in terms of energy efficiency: they burn 100% of the gas used and produce zero emissions of carbon monoxide and nitrogen dioxide.

“Dry filtration does not occur at floor level, so no foundation work was necessary. Instead, the booth is equipped with suction walls and external extraction units also fitted with dry filters, including fibreglass pre-filters with variable density and an additional acrylic filter, thereby ensuring compliance with all regulatory limits. As for the air flow rate, the booth handles a total of 170,000 cubic metres of extracted air compared to 155,000 cubic metres of supplied air. Savim also supplied the liquid paint preparation unit, fitted with ATEX-certified components, as are all the structural elements of the booth itself,” says Scavini.

A step forward in the company’s production process

The solution developed by Savim has enabled Officine Minelli to further improve the quality of its material handlers. The goal was also to speed up lead times and produce around 8 machines a month while maintaining very high quality standards and continually enhancing the entire workflow.

“Thanks to this new process and the technologies we have adopted, our material handlers feature a superior finishing level compared to what we previously achieved. For us, it is crucial to produce machines that meet user expectations, are reliable, stand the test of time, and encourage customers to keep choosing us because they are satisfied with our products. We are very proud of our material handlers, both for the hard work and dedication behind their production and because they carry a well-known reputation in the industry. We will continue to invest to achieve and maintain these results,” Fiorini concludes.

From top to bottom:

The filtration system installed on the booth’s suction walls.

A coated hydraulic material handler.

A material handler with a matt finish.

PIROMAX

Where effectiveness meets gentleness.

With PIROMAX ovens thermal paint-stripping is performed only through heat, paint is incinerated without altering the piece dimensionally or mechanically.

FOCUS ON TECHNOLOGY

Tecno 3FP’s growth continues with a new powder coating plant

Verona Impianti 2002 designed a new powder coating plant for Tecno 3FP, engineered to achieve performance levels aligned with QUALISTEELCOAT standards while optimising space through a compact, smart layout.

Coating quality is assessed based on performance over time. However, durability, corrosion resistance, colour stability, and finish aesthetics depend not only on the application phase but on the entire surface treatment cycle. Process certifications are crucial tools for guaranteeing documented and consistent performance. International quality standards for coated steel, such as QUALISTEELCOAT, are now among the most authoritative references for steel coating, as they certify not only the finished products but also the entire application system, from surface preparation and pre-treatment parameter management to coating application, final checks, and process traceability. Obtaining and maintaining certification at this level requires a substantial structural commitment. This is not merely a matter of formal compliance but a journey that involves investing in suitable equipment, ongoing staff training, documented procedures, periodic inspections, continuous monitoring of process parameters, and regular audits by external bodies. The technical specifications mandated are based on ISO 12944-2, and strict control of steel protection processes and coating operations through periodic inspection visits is also essential. QUALISTEELCOAT thus ensures that coating systems meet minimum performance requirements according to the relevant categories of atmospheric corrosivity, guaranteeing levels of protection aligned with operating conditions. To fulfill all these criteria, Tecno 3FP (Cerea, Verona, Italy) has recently invested in a new powder coating plant designed and installed by Verona Impianti 2002 (Colognola ai Colli, Verona), which has enhanced its capacity to provide a competitive and technologically advanced service.

Ilaria Paolomelo ipcm®

The coating booth is equipped with three spray guns on each side and manual pre- and post-finishing stations.

Industrial growth and vertical integration

Tecno 3FP was established in 2008 as a metalworking business specialising in sheet metal cutting and bending. “At the beginning, there were only four of us, and our work mainly involved laser cutting and bending. Over the years, our company has experienced gradual but steady growth, supported by focused investments in new technologies, the expansion of its equipment fleet, including new laser systems and state-of-the-art presses and bending machines, and the integration of additional machining processes. The goal was not only to increase our production capacity but also to enhance the level of service offered to customers,” says Nicola Scapini, head of purchasing and coating plant certification. “Today, we no longer solely carry out sheet metal processing, but we can assist our customers from the design stage with the drafting of technical drawings, right through to product

industrialisation, manufacturing, and surface treatment. Essentially, we offer a comprehensive, full-service solution.”

This company’s growth has also been driven by the gradual expansion of its production facilities and a strategy of continuous investment. In April last year, Tecno 3FP acquired Finimetal, a company specialising in coating metal sheets and structures, further strengthening its expertise in surface treatment. “In addition to expanding our production areas and lines, the incorporation of Finimetal has enabled us to further improve the organisation of our coating department and streamline our processes,” explains Luca Faccini, head of the coating department. “It was a significant investment, but today we can say that it is yielding concrete results.” Tecno 3FP currently employs over 80 people, has four production sites, and is developing an additional site, reflecting a growth strategy focused on vertical integration and full control of its production workflow.

The loading area.

Parts entering the pre-treatment tunnel.

The pre-treatment phase

“80% of the sheet metal subjected to coating is produced in-house by Tecno 3FP. Our core business is the industrial ventilation sector, but we also coat electrical panels and uninterruptible power supplies, as well as medium-heavy metal components. Part of our production is also destined for another company in the Group that manufactures wood-burning stoves and cookers, which are high-end niche products requiring an excellent aesthetic appeal,” explains Faccini. Materials from customers that Tecno 3FP provides with contract coating services account for the remaining 20%. The variety of parts processed, from functional components to products with a high aesthetic content, called for a flexible system capable of handling parts with different geometries and intended uses.

“Our coating cycle begins with the manual loading of components, which are transported inside the pre-treatment tunnel via a monorail conveyor

developed by SE.PO. (Olginate, Lecco, Italy). Here, the products undergo hot degreasing, phosphodegreasing, two rinses with mains water, and one rinse with demineralised water. The pre-treatment phase ends with the nanotechnology-based conversion phase,” illustrates Faccini.

“A pre-treatment process with two hot degreasing stages is not particularly common, but it was requested directly by this customer to ensure greater paint adhesion, better salt spray resistance, and therefore, superior protection against corrosion,” emphasises Stefano Tamellin, the owner of Verona Impianti. “The pre-treatment tunnel is the heart of our plant and has been designed to achieve maximum performance and meet the requirements of QUALISTEELCOAT certification,” adds Scapini.

The application phase

After pre-treatment, the parts are taken to the drying oven and then to the

The U-shaped pre-treatment tunnel optimises the available space.

Overview of the plant and the entrance to the oven.

coating booth, which has six spray guns (three on each side) supplied by Gema Europe, along with manual pre- and post-finishing stations to ensure consistent finishing and uniform coverage, even on complex shapes.

“Depending on customer requirements, we apply one or more coats of paint,” says Luca Faccini. Once the application process is complete, the components enter the curing oven, where they dwell for approximately 23 minutes at 180 °C, depending on requirements.

The system adheres to Industry 4.0 standards and is fitted with dedicated PLCs and software, enabling real-time monitoring and adjustment of key parameters such as conveyor speed, bath and oven temperatures, and spray gun pressure and flow. Digital control ensures consistent results and full process traceability, which is essential for complying with and maintaining QUALISTEELCOAT certification.

The pre-treatment tunnel’s rinsing tanks.

The plant incorporates Industry 4.0 principles, with dedicated PLCs and software for real-time monitoring and adjustment of the main process parameters to ensure consistent results and full traceability, a fundamental requirement for maintaining QUALISTEELCOAT certification.

A layout designed to maximise space and performance

“One of the main challenges was the limited space available,” explains Pietro Tamellin, co-owner of Verona Impianti with his brother Stefano. “For this reason, we designed a coating system with a compact and functional layout that makes the most of every available area inside and outside the building. The conveyor speed, which determines the plant’s productivity, has been set at 2 m/min in order to meet the high productivity required during the design phase. This results in the extensive layout of the plant line”. Indeed, the curing oven was placed outside the main building, in a dedicated structure with a concrete roof to ensure optimal protection and functionality; it is connected to the inside through specially made openings in the wall.

The pre-treatment tunnel was also designed with space limitations in mind: its U-shape configuration reduces the line’s overall length and utilises some of the building’s load-bearing columns, maximising the use of the available length in the facility without compromising the space needed for loading and unloading operations. “We minimised the plant’s footprint as much as possible, identifying engineering solutions that would comply with structural constraints while ensuring high performance and productivity,” says Tamellin.

“We chose Verona Impianti not only for its technical solutions, which were perfectly tailored to our needs, but also for its prompt and reliable technical assistance and support at every stage. Our new system enables us to offer a more competitive, rapid, and versatile service, meeting the needs of a wide range of customers with different types and volumes of parts.”

On the sides: Stefano Tamellin and Pietro Tamellin, the owners of Verona Impianti. In the centre: Luca Faccini and Nicola Scapini from Tecno 3FP.

QUALITY ECO-FRIENDLY INNOVATION

CHEMTEC’s chemicals are revolutionary, cutting-edge, and environmental friendly.

Our revolutionary technologies are designed to have a very limited environmental impact, to reduce consumption of resources and for a greater operational simplicity.

CHEMTEC develops customized solutions that aim to maximize the customer’s satisfaction.

DISCOVER MORE ON WWW.CHEMTEC.IT

ReBox: the new reusable filters for coating booths, designed for the ‘Sustainable Paintshop’

Alessia Venturi ipcm®

Geico’s Sustainable Paintshop project aims to develop a sustainable automotive paint shop by 2030. The integrated and reusable ReBox filtration system reduces consumption, waste, and costs, representing a circular production model.

The Sustainable Paintshop is strategic initiative by Geico – the company being a global leader in the design and construction of turnkey coating systems for the automotive sector – aimed at developing an energy self-sufficient, CO2-emission-free, and circular paint shop by 2030.

The ReBox dry overspray filtration system was developed three years ago within this sustainability project, which includes energy consumption optimisation and material recirculation – primarily the filter cardboard – with the aim of reducing waste and consumption while promoting the reuse of resources already available within the process.

The technological background

In recent years, dry overspray filtration systems have become common in automotive paint shops and high-volume industrial coating applications. They are designed to capture paint particles from the air in the booth, using either finely pulverised lime or cardboard filters that force the paint-saturated air through filtering elements typically measuring 500 × 500 × 500 mm. Inside these modules, the air follows a winding path that increases the chances of paint particles hitting the filter walls and sticking to them, thus removing as many as possible.

The transition from water-curtain filtration systems to dry systems has been driven primarily by energy considerations. In wet systems, the air passing through the water curtain cools down and becomes saturated with moisture; as a result, it must undergo a reconditioning process to be recirculated into the booth. Dry systems avoid this problem, as air can be recirculated almost indefinitely, with only the need to introduce a minimal amount of fresh air to keep the LEL (Lower Explosion Limit) value under control inside the booth.

These solutions are therefore gaining ground in the market because they reduce energy consumption and are relatively easy to maintain: with cardboard systems, the only upkeep required is the periodic replacement of filters, which does not demand any specialist skills. In addition, compared with limestone-based powder systems, they also involve lower costs and simpler operation, although they present some logistical

challenges related to inventory storage and the handling of spent filters. In limestone-based systems, on the other hand, the material is managed through tanks that are periodically refilled, making logistics less dependent on just-in-time supplies.

Geico offers three solutions within this technology family: Hydrospin Plus, based on wet separation; Dryspin, a dry system using limestone powder; and DryCar, based on inertial filters. The system developed within the ReBox project falls into the latter category but introduces an innovative concept: the possibility of reusing the filter.

ReBox’s technical features

ReBox filters are designed to replace traditional cardboard inertial filters in all overspray recovery applications within medium and large coating booths that apply single-component water-based and solvent-based paints. Structurally, they consist of a series of overlapping layers made from a plastic material similar to polypropylene, specifically formulated to ensure high electrical conductivity and prevent static electricity build-up. The various layers feature different geometric configurations, and once assembled, they create a progressive path along which the air passes through increasingly smaller channels, following a tortuous route that heightens the likelihood of paint particles contacting and adhering to the filter surfaces.

The initial tests of the new ReBox solution were conducted at the Pardis Innovation Centre, Geico’s R&D facility, where the results showed filtration efficiency values comparable to those of traditional systems.

ReBox filters are designed to replace traditional cardboard inertial filters in all overspray recovery applications in medium- and large-sized coating booths using single-component water-based and solvent-based paints.

The ReBox filter is located at the bottom of the booths, where overspray (the excess paint not deposited on the car body) accumulates. The paint is captured by the filter and naturally solidifies during its usage cycle without the need for heating, and can then be easily removed. Downstream of this filtration stage, there are additional levels of fine filtration to ensure that the recirculated air does not contaminate the system’s ducts or equipment.

“The treated air can be recirculated almost entirely within the booth. The air renewal rate, which prevents the build-up of solvents and odours and keeps the LEL value under control, depends on the type of booth: while in manual booths the air is typically fully refreshed for regulatory reasons, in automatic booths with dry filtration systems and robotic operation, it is possible to achieve 80–90% air recirculation, with only 10% fresh air requiring thermal treatment. This results in significant energy savings, as air conditioning is only required for the fresh air portion,” says Paolo Colombaroli, Vice President R&D and IT from Geico.

“As they have the same dimensions and technical characteristics as cardboard filters, replacing the latter with ReBox filters is straightforward and does not require any modifications to the filtration system (fans, ducts, filter housings, and so on). This means that users can install either traditional filters or our new reusable filters without modifying their existing equipment. The main advantage of these new filter models lies is that they can be reused multiple times.”

“Geico is also developing a dedicated maintenance and paint removal system that uses brushes or jets of compressed air to dislodge the material from the filters. The collected paint overspray loses most of its adhesiveness thanks to the booth air passing through it and can be removed without the need for heating.

The entire process thus becomes more sustainable and cost-effective, as it promotes circularity and environmental sustainability by reusing the same filter and thereby reducing the impact associated with the disposal of paint-soaked filters,” Colombaroli adds.

Circular economy

The key feature of the ReBox system lies in the end-of-cycle filter management, which allows the filter to be removed, cleaned, and reused. During maintenance, only the accumulated paint is removed, whereas the filter media stays in use. This significantly reduces the volume and weight of waste requiring disposal, as only the paint collected by the filter is discarded.

“At present, the removed paint is classified as hazardous waste, but Geico is conducting studies in collaboration with the Politecnico di Milano to explore possible alternative uses,” indicates Paolo Colombaroli. “Although the recovered paint has not passed through the drying oven and, therefore, is not fully cross-linked, it cannot be reused as paint because the polymer

© Geico

has partly degraded during the process. However, for example, it could be used as a filler for sealants or other composite materials. If this research study were to confirm its feasibility, this would bring us even closer to a fully circular process.”

Fields of application

The system, suitable only for one-component waterbased or solvent-based paints, was initially designed for the automotive sector but can be applied in various fields of the general industry where standard-size cardboard filter systems are already in use, such as in the coating of agricultural machinery, earth-moving machinery, engines, or industrial components.

“The initial tests were conducted at the Pardis Innovation Centre, Geico’s R&D facility, where the results showed filtration efficiency values comparable to those of traditional systems. The next step is to conduct trials directly at our customers’ premises to verify performance under real operating conditions. In the tests presented to car manufacturers and general industry companies, installation simply involves fitting some experimental filter cells, usually seven or eight units, into existing plants to monitor their behaviour, durability, and maintenance requirements with different coating cycles and product types,” says Colombaroli.

As stated by Daryush Arabnia, the President and CEO of Geico Spa, the launch of the new ReBox paint booth filter is part of the company’s diversification and stability strategy, as it is a standard product that can be used across various industrial sectors.

Sustainable Paintshop: the future of coating

Geico’s Sustainable Paintshop project covers multiple ESG management factors, particularly those related to the environment, which ties in with the concept of circularity, and the social aspect, since it is key to quality and employee well-being. Indeed, for Geico, it has always been crucial to be pioneers in the fullspectrum energy transition, where governance plays a predominant role. The first step towards realising this ambitious project is CO2-Free Day, an initial milestone to assess progress, to be reached by 2027, a full three years ahead of the 2030 target.

Scan the Qr Code to see how ReBox works.

Geico’s headquarters, located in Cinisello Balsamo (province of Milan).

Evonik extends strategic VISIOMER® methacrylates partnership with IMCD into the U.S.

Building on their established partnership in Brazil and Canada, IMCD will now distribute Evonik’s VISIOMER® Specialty Methacrylates across the U.S., providing customers with greater access to the full portfolio of advanced solutions.

Evonik has announced the expansion of its successful collaboration with IMCD into the United States. The expanded agreement enables IMCD to offer Evonik’s VISIOMER® products for a wide range of applications, including coatings, adhesives and sealants.

“At IMCD, our priority is to deliver value to our customers through highquality products, formulation support, and dependable technical service. This expanded partnership strengthens our ability to support formulators with high-performance VISIOMER® Specialty Methacrylates and dedicated application know-how. We look forward to continuing to create value for customers throughout the U.S.,” has stated Muge Tamkan, Vice-President, Coatings & Construction, Americas.

“We are committed to providing our customers with the highest-quality products and services. Expanding our partnership with IMCD in the U.S. allows us to serve our customers more effectively and reinforces our presence in this key market. We are excited to build on our successful cooperation with IMCD,” has added Joao Souza, Head of Specialty Methacrylates for the Americas at Evonik.

For further information: www.evonik.com/visiomer

Classic car restoration: process integration and end-to-end quality control at Motor Classic

The restoration of classic cars is a growing industry within the European historic vehicle market, which exceeded $9 billion in 2024, with growth prospects of reaching over $22 billion by 20321. In Europe, the restoration sector alone is worth around $2.1 billion, confirming its status as one of the pillars of the aftermarket supply chain for historic vehicles. On this continent, the sector benefits from a particularly broad base: it is estimated that over 760,000 classic cars are registered for restoration work, supported by a well-established ecosystem of associations, organisations, and specialist operators2 Europe holds a central role thanks to its automotive heritage, the

1 https://www.htfmarketinsights.com/report/4378569-classic-car-restoration-market 2 https://www.fortunebusinessinsights.com/automotive-restoration-market-113004

presence of iconic brands, and a well-established base of collectors, making up about 30% of the global classic car market. Alongside Western Europe’s traditional hubs such as the United Kingdom, Germany, Italy, and France, Eastern Europe is gradually gaining momentum3. Interest in classic cars is increasing in this region, driven by new investors and collectors, as well as greater integration with Western markets through international auctions and sales channels. From a production perspective, Eastern Europe boasts several competitive advantages, such as lower operating and labour costs and the availability of technical skills rooted in local manufacturing traditions.

3 https://www.credenceresearch.com/report/classic-cars-market

Alessia Venturi ipcm®

However, this region also faces the same structural challenge affecting Western Europe, which is the gradual shortage of highly skilled labour, especially in high-precision manual work, which, however, is key to ensuring high standards of accuracy and quality in restoration. Across both sides of Europe, a hybrid model is thus emerging that combines industrialised processes with artisanal skills, with the aim of ensuring quality, traceability, and scalability in production.

This is exactly the approach adopted by Motor Classic (Tatabánya, Hungary), which began as a classic car restoration workshop and has since developed into a specialist coating shop, with an operational model that relies on vertical integration and direct control of every stage of the restoration process.

By transforming an entrepreneur’s bold vision, characterised by a forward-thinking and calculated risk-taking approach, into a tangible competitive advantage, Motor Classic now positions itself as a dependable industrial partner, focused on delivering high added value without engaging in direct competition but instead prioritising consistently high standards of quality.

This hybrid setup allows for the flexible management of both mass production runs and low-volume orders or individual units, typical of historic vehicle restoration, as well as testing and process validation

activities. Manual work remains performed by highly skilled operators, who can ensure high-quality surface finishes even on complex geometries and critical components.

A strong reputation in restoration

Founded almost thirty years ago, Motor Classic was the brainchild of Zsolt Nagy, who started out restoring motorcycles in a small garage in Környebánya (Hungary). From the outset, attention to detail and quality have been the company’s hallmark, enabling it to quickly earn a strong reputation. Its focus on restoring classic cars, particularly MercedesBenz models from the 1950s, 1960s, and 1970s, marked an initial phase of growth, accompanied by a steady expansion of its expertise and production capacity.

Over time, Motor Classic has adopted a development strategy centred on continuous reinvestment in technology and human resources, aiming to insource all critical stages of the car restoration process.

Today, it is organised into four integrated operational units: Classic car restoration, CNC machining, Surface treatment, Plating solutions & services, and Industrial decorative painting. This structure reflects a strategy of vertical integration that provides it with complete control over its workflow.

and

The surface treatments area of Motor Classic facility in Tatabánya, Hungary.

From left to right: Motor Classic focuses on restoring classic cars, particularly Mercedes-Benz models from the 1950s, 1960s, and 1970s. The two photos on the left show the before

after of the Motor Classic restoration work on a historic Mercedes-Benz vehicle.

Some time ago, Motor Classic decided to build a solid and modern technological foundation by making a major investment in a state-ofthe-art robotic coating line, which was the subject of an in-depth report by ipcm® in 20254. This is still one of the most flexible and efficient coating lines in Europe for plastic and metal components intended for the premium automotive sector.

A versatile and adaptable plant layout

Car restoration is Motor Classic’s core business and is executed through two operational models: acquiring vehicles directly for restoration and resale, and providing contract work on customers’ cars. The process begins with a thorough structural inspection of the vehicle, followed by abrasive blasting using glass beads. This method allows for the controlled removal of the old coating while preserving the integrity of the metal substrate.

4 A. Venturi “Flexible, automated, sustainable: inside Europe’s most advanced paint line”, ipcm® vol. VI, no. 93 May-June 2025 pp. 84-92. https://www.ipcm.it/en/open/ipcm/2025/93/92-100.aspx

The subsequent stages include structural repairs, welding, and the reconstruction of damaged parts, followed by surface preparation and finishing carried out in four manual coating booths.

All work is managed in-house on an end-to-end basis, reducing process variables and ensuring high quality standards and full traceability. Manual operations are performed by highly qualified technicians whose expertise, gained over many years, is a strategic asset, especially in labour-intensive processes where precision and manual dexterity are crucial.

The artisanal aspect remains, in fact, fundamental to achieving high finishing quality on complex geometries and critical components.

This integrated approach finds a natural extension in robotic coating, which allows for the flexible management of both mass production runs and work on individual parts or small batches, common in restoration projects, as well as process testing and validation activities. In this way, Motor Classic positions itself as an operator capable of combining industrial precision with skilled craftsmanship, establishing itself in the medium to long term as a reliable partner for high-added value work, without directly competing in the end market but focusing on quality, consistency, and process innovation.

Motor Classic repairs and reconstructs any damaged part of a historic car, including wheels

Restoration: a way of life and a driver of growth

“Restoring classic cars is not just a trade but a way of life that demands continuous learning, flexibility, pushing boundaries, and the pursuit of the highest quality. These core values still guide us today.”

With these words, Zsolt Nagy, the founder of Motor Classic, looked back on the history of his company, which has been growing steadily by reinvesting a large part of its profits in human development and cutting-edge technologies.

MADE IN ITALY

The body shell of a Mercedes Pagoda during the restoration phase, including filling and sandblasting.

Colouring with PVD: achieving premium decorative coatings with HiPIMS

Edited by Simone Colombo Kenosistec Srl, Casarile (MI), Italy simone.colombo@kenosistec.it

In recent years, HiPIMS PVD deposition technology has begun to stand out precisely because of its ability to improve both aspects simultaneously. Thanks to denser, more uniform, and better-adhered films, components maintain stable colours and enhanced durability over time. The colour precision and long-lasting performance make HiPIMS the ideal solution for mid- to high-end products.

In the field of industrial decorative coatings, balancing aesthetics and technical performance has always been a challenge. Components used in sectors such as furniture, fashion, metal accessories, faucets, and industrial design must meet two essential requirements: on one hand, they must deliver a flawless aesthetic result that can be easily reproduced across all coated parts; on the other, they must ensure long-term resistance to wear, corrosion, and daily use. These are very different challenges, yet they are becoming increasingly interconnected.

© Kenosistec

© Kenosistec

In recent years, HiPIMS PVD deposition technology has begun to stand out precisely because of its ability to improve both aspects simultaneously. HiPIMS, which stands for High Power Impulse Magnetron Sputtering, is an alternative to traditional magnetron sputtering processes and allows the production of coatings that are more compact, more adherent, and more uniform. The concrete benefits for finished products include more stable and precise colours, smoother and more uniform surfaces, improved resistance, and longer coating lifetime. To truly understand the value of this technology, it is useful to look not only at the final visual effect but also at what happens within the coating structure, down to the microscopic scale (Figs. 1 and 2).

A new form of sputtering

HiPIMS was developed as an evolution of magnetron sputtering processes used for thin film deposition. In the sputtering process, the target material is bombarded by energetic particles inside a vacuum chamber. This bombardment causes ionized atoms to be ejected from the target; these atoms then deposit on the surface of the components to be coated, forming a thin layer (Figs. 3 a, b, c).

The main difference between HiPIMS and conventional sputtering lies in how power is applied to the target. In traditional systems the power is relatively constant, whereas HiPIMS uses extremely high-power pulses delivered over very short periods of time. This type of power supply generates a much more highly ionized plasma, and a significantly larger portion of the particles forming the coating reaches the substrate in ionic form. This fundamentally changes the way the film grows on the component surface, enabling the formation of extremely compact films, although typically at the cost of a longer deposition time compared to more established technologies.

The properties of HiPIMS coatings

When the particles forming the coating reach the substrate in a more ionized state, they have greater mobility across the surface before stabilizing within the film structure.

This phenomenon brings significant advantages. First, it allows atoms to arrange themselves in a more ordered and compact way, reducing the voids that normally form during coating growth. The result is a much denser and more uniform layer, which also helps prevent corrosion from reaching the substrate. In addition, the energy of the ions promotes stronger adhesion between the coating and the base material. The film anchors more effectively to the surface of the component, reducing the risk of delamination or degradation over time. The result is a combination of extremely high density and excellent adhesion.

Colour precision in decorative coatings

In the industrial decorative sector, colour is a key factor in perceived quality and product recognition. Even small variations in a coating can create visible differences between parts belonging to the same production batch. One of the most interesting advantages of HiPIMS technology is its greater precision in colour reproduction, thanks to the ability to more easily achieve the desired L*a*b* colour coordinates and even obtain a wider range of colour shades.

In a production environment, this also means improved repeatability across different production cycles—an essential aspect when working with decorative components intended for mid- to high-end products.

Benefits visible even at the microscopic level

To fully understand the value of HiPIMS technology, it is useful to observe what happens within the coating structure at the microscopic level.

Figure 1 - Film growth with DC Sputtering.

Figure 2 - Film growth with HiPIMS.

Electron microscopy analyses reveal very clear differences between films produced with conventional sputtering and those deposited using HiPIMS. In traditional coatings, the structure can show a more columnar growth pattern, with voids between the crystalline columns. In HiPIMS films, however, the structure appears much more compact and refined, with more uniform grain size and a significant reduction in porosity. This increased compactness at the microscopic scale is precisely what leads to the improvements observed at the macroscopic level: more resistant surfaces, more stable coatings, and more uniform colours. In other words, what is visible under the microscope directly translates into the real-world performance of the final product.

The true premium coating for the industrial decorative sector

For companies operating in the decorative coating industry and looking to push their offering further, HiPIMS represents much more than a simple technological upgrade. The ability to obtain denser, more uniform, and more stable coatings allows manufacturers to respond more effectively to market demands, which increasingly require products that excel both in aesthetic quality and durability. This means being able to offer components that maintain their original appearance for longer, increasing the overall value of the final product.

Looking ahead: the future of PVD coatings

As deposition technologies continue to evolve and the focus on coating quality grows, solutions such as HiPIMS are becoming increasingly relevant in the industrial landscape. The combination of colour precision, film density, and mechanical resistance makes this technology particularly attractive for applications where aesthetics and performance must coexist.

In the industrial decorative sector—where surface detail and product durability are key factors—HiPIMS therefore represents one of the most promising additions for the development of advanced coatings. Another area where Kenosistec is investing significant effort is the improvement of process performance, with the goal of achieving faster coating cycles while maintaining exactly the same level of quality. Proprietary technologies and a strong focus on research and development will play an important role in achieving this objective.

Figure 3 - From top to bottom: Deposition with cathodic arc; Deposition with DC Sputtering; Deposition with HiPIMS.

© Kenosistec

DF/CASS filter units and DF/CASS/CC adsorbers: practical guidelines for designing, operating, and protecting operators

Defil’s DF/CASS filter units and DF/CASS/CC adsorbers provide modular solutions for air filtration and the removal of VOCs and harmful vapours in industrial processes, integrating system design, maintenance management, and safety measures to ensure operator protection.

Defil designs and manufactures singlestage or multi-stage filter units and filter containment structures, typically constructed from epoxy-coated galvanized sheet metal panels (RAL 5012) and, for special applications, from AISI 304 or AISI 316 stainless steel. Filters can be installed using slides, DFCT/Z subframes, or special fastening systems. Adsorber modules can house activated carbon in cartridges, cells, polyhedrons, or rigid pockets, in addition to the standard filter stages. These solutions are suitable for industrial and civil processes and can be combined to handle high flow rates: their modularity and the ability

to customize according to customer designs and specifications make DF/CASS/CC units versatile for many production needs. From a functional standpoint, DF/CASS filter units are used to filter air entering or exiting production processes.

Activated carbon stages (DF/CASS/CC) are installed downstream of the boxes, where necessary, to remove VOCs, organic vapours, acid vapours, or toxic gases. The type and configuration of activated carbon must be chosen based on the nature of the solvents and their expected concentration. The filter packs must be secured to ensure quick and safe

changeovers, reducing operator exposure times. For large-flow systems, coupling modules is feasible but must not compromise accessibility for inspection and maintenance. Maintenance must be regulated by written procedures that include intervention thresholds based on Delta P, extraction methods that reduce material dispersion, and closed containers for the temporary storage of used filters; disposal must comply with current regulations (CER codes where applicable).

Protecting workers’ health is an absolute priority. In spray painting, and particularly when using polyurethane coatings, isocyanates can be released - sensitizing substances that may cause irreversible occupational asthma. Filtration systems provide essential collective protection, but they are often not sufficient to keep isocyanate concentrations within safe limits. For this reason, it is essential to combine technical measures, organizational strategies, and appropriate personal protective equipment, as safeguarding workers’ health is not only a regulatory requirement but also a practical tool to reduce risks, contain indirect costs, and improve the quality of the production process.

For further information: www.defil.it

SurTec to showcase advanced surface engineering solutions at SurfaceTechnology GERMANY 2026

SurTec will showcase innovative coatings and electroplating technologies designed to improve performance, durability and design flexibility at SurfaceTechnology GERMANY 2026.

Surface technology specialist SurTec will present a broad portfolio of innovative and established surface treatment solutions at SurfaceTechnology GERMANY 2026, taking place from 5–7 May 2026. The focus will be on high-performance technologies for functional coatings, corrosion protection and decorative electroplating. The company will highlight integrated surface engineering solutions designed to meet demanding functional requirements while also enabling greater creative freedom in product design.

“Many of the challenges our customers face today — from regulatory compliance to process stability and increasing design flexibility — have been part of our development focus for years. At SurfaceTechnology GERMANY, we will demonstrate how our proven processes in functional coatings and electroplating can be combined into coordinated system solutions from a single source,” has stated Benjamin Diener, Head of Sales at SurTec Deutschland GmbH.

In the Functional Coatings segment, SurTec will present technologies designed for the locking,

sealing, assembly and disassembly of screws and other fasteners. The globally recognised precote® product range delivers process-reliable functional coatings suitable for a wide variety of industrial applications.

The portfolio also includes modern anti-friction coatings for metals, plastics and elastomers. These coatings provide controlled friction coefficients, reduce wear and support improved assembly performance and component functionality, ultimately helping to extend component service life and maintain process reliability in industrial manufacturing. Another key focus at the exhibition will be functional electroplating solutions for corrosion protection:

 Among the technologies on display is the SurTec 717 Zn/Ni process, known for its exceptionally stable performance and high deposition rate. The electrolyte system can operate using conventional technology or as a membrane process with SurTec technologies and MCA membrane anodes, enabling consistently high performance over extended operating periods.

 SurTec will also highlight its pioneering role in environmentally responsible technologies. The company developed the first Cr (VI)-free passivation, SurTec 680, which provides effective corrosion protection while meeting modern regulatory requirements. Combined with tailored sealers, these passivation systems enhance both corrosion resistance and functional properties such as dry lubrication.

In decorative electroplating, SurTec will showcase advanced trivalent chromium processes that open up new aesthetic possibilities for designers and manufacturers:

 The SurTec 851 process enables semigloss, non-reflective nickel surfaces with high uniformity, while the company’s trivalent chromium coatings provide a wide colour spectrum ranging from light to dark finishes.

 With SurTec 883 XT, introduced in 2017, SurTec achieved consistent colour values comparable to those of traditional hexavalent chromium processes. Complementary coloured electrolytes, including SurTec 881 ACL, SurTec 886 and SurTec 888, allow manufacturers to create warm to neutral dark tones for highquality decorative surfaces.

Together, these technologies combine modern process reliability with expanded design freedom for contemporary product finishes. Throughout SurfaceTechnology GERMANY 2026, SurTec specialists will be available at Booth 22 to discuss the company’s latest developments and applications in surface technology.

DÖRKEN: PFAS-free solutions at SurfaceTechnology GERMANY 2026

The entire bolt and fastening industry will be gathering at SurfaceTechnology GERMANY 2026 in Stuttgart from May 5 to 7, 2026 and Dörken will be there with its pioneering corrosion protection solutions.

Regulatory requirements for coating systems are increasing – and with them the pressure on manufacturers to quickly provide practical alternatives. DÖRKEN is responding to this development with a clear approach: using restrictions as a driver for innovation. The focus of the topics on the trade fair will therefore be clearly on PFAS-free systems with confirmed market readiness and OEM approvals. Dörken already offers PFAS-free solutions that meet the high requirements of the automotive industry. These include approvals from Volkswagen and Volvo. The DELTA-PROTEKT® TC 502 GZ topcoat has been approved in the VW TL 245 Ofl-t647 specification, while Volvo has approved several system combinations in the VCS 5737.41 specification: DELTA-PROTEKT® KL 100 or DÖRKEN® BASE 120 combined with DELTA-PROTEKT® TC 502 GZ SILVER, and DÖRKEN® Base 120 together with DÖRKEN® TOP 500 BLACK. Further sampling at renowned OEMs, particularly in the automotive and wind industries, is currently underway. This underscores the company’s innovative strength and its role as a pioneer in sustainable coating technologies.

Another highlight is DELTA-PROTEKT® KL 170

RT – a 1K zinc flake base system that cures at room temperature. The solution is used e.g. on wheel hubs and brake discs and offers significant advantages in processing: greater flexibility, simplified processes, and reduced energy consumption, as no curing process in an oven is required.

Dörken kindly invites all trade visitors to find out more about PFAS-free corrosion protection systems, room temperature-curing coating solutions, and the latest innovations in the zinc flake segment. The corrosion protection experts look forward to exchanging and providing individual advice in Hall 001, Booth C42.

For further information: www.doerken.com

© Dörken

ITAMID FL560S: performance evaluation in high-solid epoxy DTM coatings

Francesco Comparin ddchem Srl, Oppeano - Verona francesco.comparin@ddchem.it

Driven by stricter VOC regulations and growing environmental awareness, the coatings industry is increasingly moving toward high-solids and solvent-free solutions. In this article, ddchem presents the performance of ITAMID FL560S.

The growing environmental awareness of people, coupled with increasingly strict regulations on the use of organic solvents in the production of coatings, has driven the market towards increasing the solid content of coatings to reduce VOC emissions into the atmosphere, where they eventually degrade to CO₂ and contribute to global warming.

ddchem has always closely examined customers’ needs to develop solutions, with the ultimate goal of making the world a better place where chemistry can be trusted rather than demonized and where we can protect our precious and wonderful planet. ITAMID FL560S is the ddchem solvent-free formulated Polyamidoamine adduct that could be used to increase the solid content of coatings (Table 1).

In this article, ddchem will characterise this hardener in combination with the most common epoxy resin grades on the market. Using international test methods, ddchem will demonstrate the performance that can be achieved with ITAMID FL560S for DTM applications. The tests presented in this paper cover the curing profile at room temperature (RT), adhesion to a metal panel substrate, the flexibility of the coating, and chemical resistance through immersion testing.

Dry-time (ASTM D5895-13)

 Dry layer thickness = 60-70 microns

 Resins used (Chart 1):

- ITAPOX 320 (BADGE/BASFGE/reactive diluents - AGE Free, 1000 mPaꞏs, 100% solid content)

- ITAPOX 127 (BADGE/BASFGE/C12-C14 reactive diluents - 1000 mPaꞏs, 100% solid content)

- ITAPOX 75X (BADGE-based solid resin dissolved in Xylene – 75% solid content).

Looking at the dry-time measures, we can appreciate the relatively fast curing of the hardener that is generally considered recoatable after the stage III, also called the dry-hard time.

Bend Test (ISO 6860-2006)

 Dry layer thickness = 60-70 microns

 Resins used:

- ITAPOX 320 (BADGE/BASFGE/reactive diluents - AGE Free, 1000 mPaꞏs, 100% solid content)

- ITAPOX 127 (BADGE/BASFGE/C12-C14 reactive diluents - 1000 mPaꞏs, 100% solid content)

- ITAPOX 75X (BADGE-based solid resin dissolved in Xylene – 75% solid content).

 Results: ddchem ITAMID FL560S, in combination with the three chosen resins, achieved the highest score when used with ITAPOX 75X, with no cracking or defects appearing after bending. In contrast, when used with the two resins with 100% solids content, the system cracked within the first two centimetres of the coating. The test

was performed after one week of curing at 23°C/50% RH (Fig. 1).

Pull-off (ASTM D 7243-22)

 Dry layer thickness = 60-70 microns

 Resins used:

- ITAPOX 320 (BADGE/BASFGE/reactive diluents - AGE Free, 1000 mPaꞏs, 100% solid content)

Table 1: Extract from the TDS of ITAMID FL560S.

Chart 1: Dry-time measures for ITAMID FL560S, Dry layer thickness=60-70 micron.

Figure 1: Mandrel bend test and sample examples.

- ITAPOX 127 (BADGE/BASFGE/C12-C14 reactive diluents - 1000 mPaꞏs, 100% solid content)

- ITAPOX 75X (BADGE-based solid resin dissolved in Xylene – 75% solid content).

 Results: in order from the lower to the higher scores, we registered ITAPOX 320 + ITAMID FL560S > 65 Kg/cm2, ITAPOX 75X + ITAMID FL560S > 78 Kg/cm2 and ITAPOX 127 + ITAMID FL560S > 80 Kg/cm2. These values come from an average of three measurements and guarantee the adhesion of three systems on the metal panels used for the trials (QD612) after one week of curing at 23°C/50% RH (Fig. 2).

Chemical Resistance (ASTM D543)

 Immersion test

 Resin used: ITAPOX 50 (pure BADGE epoxy resin, 12500 mPaꞏs, 100% solid content, Charts 2, 3 and 4).

To translate the results into a score between 0 and 10, ddchem considered variations in key properties, such as weight gain or loss, Shore D hardness, changes in sample dimensions, and finally, changes in visual appearance (Fig. 3).

The chemical resistance of the ITAPOX 50 and ITAMID FL560S system after four weeks of immersion has shown excellent performance against most common acids, bases, and solvents commonly used in industry. The results provide insight that this hardener could also be used as a functional metal coating for specific process applications.

during the immersion test. Minor and major changes result in a reduction (malus) of the final score at the end of the test, even when all the other parameters remain unchanged.

Chart 2: Chemical resistance scores for ITAMID FL560S against common acids.

Chart 3: Chemical resistance scores for ITAMID FL560S against common bases.

Chart 4: Chemical resistance scores for ITAMID FL560S against common solvents.

Figure 2: Pull-off test’s dolly extraction example.

Figure 3: Visual aspect changing

Fire reaction and indoor air quality: new priorities for fire-retardant wood coatings

Edited by ICRO COATINGS S.p.A.

Chignolo d’Isola (Bergamo, Italy) info@icro.it

ICRO COATINGS S.p.A. is a leading company in the production of paints and coating systems, serving professionals and industries in the wood, metal, and plastic sectors. With an international presence, ICRO maintains a strong Italian manufacturing identity, combining technological innovation with the quality standards of Made in Italy.

In today’s wood coatings industry, fire safety and indoor air quality are no longer separate aspects, but increasingly interconnected design parameters. This sets the context for the development of ICRO COATINGS’ fireretardant systems, recently updated to meet Euroclass B-s2,d0 requirements and soon to comply with the emission criteria set out in the GREENGUARD certification managed by UL Solutions. The integration of fire reaction performance and emissions control is indeed one of the main challenges facing the coatings industry, as it entails ensuring active protection against fire without compromising the healthiness of indoor environments.

Balancing the design value and combustion risks of wood

A material commonly used in interior design and commercial fit-outs, wood mainly consists of cellulose and lignin, high-carbon substances that actively promote combustion. The fire behaviour of wooden elements can be altered using fire-retardant coating systems that reduce their contribution to fire, limit flame spread, and control smoke and dripping. For wooden products and construction elements (excluding flooring), the European fire reaction classification is covered by standard EN 13501:2018-1, based on the tests specified in:  EN 13823:2020+A1:2022 and  EN 11925-2:2020.

The Euroclass B-s2,d0 classification indicates a system with very low contribution to fire (B), controlled smoke production (s2), and no flaming droplets or particles (d0). The d0 parameter is particularly relevant in public spaces, where dripping can aid the secondary spread of fire and pose greater risks to occupants.

Clear systems for substrate protection and enhancement

One of the long-standing challenges with fireretardant treatments for wood concerns their aesthetic impact, as enhancing the appearance of exposed timber is often essential in commercial fit-out projects and spaces of high architectural significance.

The fire behaviour of wooden elements can be altered using fire-retardant coating systems that reduce their contribution to fire, limit flame spread, and control smoke and dripping.

ICRO COATINGS’ two-component polyurethane system ECL 1450 is classified as Euroclass B-s2,d0 for use on walls and ceilings in wood substrates with a nominal density of ≥ 510 kg/ m³ and a thickness of ≥ 12 mm, in accordance with the criteria set by regulatory tests.

It includes:

 two coats of clear, fire-retardant primer (totalling 320 g/m²) and

 one coat of fire-retardant protective top coat (100 g/m²), totalling 420 g/m² of paint products.

Under heat and flames, the resulting coating shields the substrate from rapid temperature increases, delays wood carbonisation, and limits oxygen supply to the affected surface. Besides its fire-retardant qualities, it retains chemical and physical characteristics appropriate for professional furniture: resistance to cold liquids (EN 12720), good surface hardness (ASTM 3363 – F), high adhesion (ISO 2409), resistance to dry and humid heat (EN 12722 and EN 12721), and effective antiyellowing properties.

The two-component polyurethane system ECL 1450 s classified as Euroclass B-s2,d0 for use on walls and ceilings in wooden substrates.

Overspray free paint application with EcoPaint Jet

Revolutionar y pr e cision in automatic appl ic ation br ings ef f icienc y to pr o duc t customization. Dürr’s solution EcoPaintJet applies sharp-edged paint lines on surfaces, pushing the limits for efficient and resources av ing co ating: No over spr ay, no mor e masking of your product www verind.it

ICRO Coatings

The GREENGUARD certification ensures compliance with strict limits on chemical emissions, combined with a Euroclass B-s2,d0 rating for fire reaction performance.

Indoor air quality: keeping emissions under control

Alongside fire safety, indoor air quality has become a key consideration in designing high-occupancy environments. Coated wooden surfaces can emit volatile organic compounds (VOCs), especially in energyefficient buildings with controlled ventilation systems. The GREENGUARD certification, developed by UL Solutions, verifies that products meet strict limits on chemical emissions, helping to maintain indoor pollutant levels compatible with healthy environments. Ensuring that a fire-retardant system complies with GREENGUARD standards means providing a fire protection solution that minimises emissions, combining safety with environmental well-being.

Carbon footprint and environmental impact assessment

In this context, measuring the environmental impact of products is becoming increasingly important. Consistent with this approach, ICRO COATINGS was the first Italian company in the sector to develop a method for calculating the carbon footprint of its paints, adopting the ISO 14067:2018 standard (Systematic Approach) and obtaining system certification by Certiquality. This enables the assessment of the carbon footprint of products throughout the entire production process, ‘from cradle to gate’, and integrates environmental impact as a parameter during paint formulation, alongside technical and application requirements.

An integrated approach to performance

The evolution of fire-resistant systems fits into a broader certified management strategy that includes:

 ISO 9001 for quality management of processes

 ISO 14001 for environmental management

 ISO 45001 for occupational health and safety and

 ISO 14067 for the calculation of products’ carbon footprint. This combination of compliance with fire safety regulations, control of indoor emissions, and certified environmental management reflects a paradigm shift in the coatings sector, moving from mere compliance to integrated performance.

Conclusions

This converging focus on fire reaction and indoor air quality can reshape the role of fire-retardant wood coatings. A system classified as Euroclass B-s2,d0 and compliant with the latest standards for emissions is more than just a technical response to regulatory requirements: it is a design tool that helps to create safer and healthier spaces.

ICRO COATINGS was the first Italian company in the sector to develop a method for calculating the carbon footprint of its paints, adopting the ISO 14067:2018 standard (Systematic Approach) and obtaining system certification by Certiquality.

©

CEER can quickly integrate new models and flexibly increase production capacity with the EcoProBooth box modular concept.

SUCCESS STORIES

World premiere: Dürr installs its Paint Shop of the Future for CEER

Dürr builds an innovative and sustainable paint shop for CEER, the first Saudi automotive company and Saudi-born EV brand.

Dürr is building an innovative and sustainable paint shop for CEER, the first Saudi automotive company and Saudi-born EV brand. The order was placed back in 2023, and the project is currently in the installation phase. AGVs will transport car bodies flexibly between stations based on demand in the modular system. The latest application technology paints the interiors and exteriors of electric vehicles in the same box. In addition, there will be a box for fully automatic two-tone application without overspray. High-tech and sustainability go hand in hand. Dürr supplies the latest generation of ovens which, combined with electric exhaust air purification systems, save energy and reduces CO2 emissions. The new facility will be one of the most advanced painting factory in the automotive world.

For the first time, Dürr is fully implementing its Paint Shop of the Future concept at CEER. The modular design includes the latest innovations to drive complete automation. The plant uses digital solutions from Dürr’s DXQ product family to reduce downtime and maximize systems’ efficiency. The new system at CEER Manufacturing Complex located in the King Abdullah Economic City will begin production in the fourth quarter of 2026.

Efficient high-tech products benefit the environment CEER relies on Dürr’s new generation of ovens. The EcoInCure heats the body from the inside to reach massive body components more directly. This is particularly advantageous for electric vehicles, as they require

– among other things – well reinforced rocker panels to protect their batteries in the event of a side impact while simultaneously preventing overheating in thinner parts of the body shell. This drying method is more environmentally friendly, reducing the required heating process time for the body is by up to 30% compared to conventional systems. An Oxi.X RV from Dürr CTS cleans exhaust air from the oven using the principle of regenerative thermal oxidation (RTO). The oxidation reactions, which purify the process exhaust, occur entirely within the heat exchange media. Since the system operates using electricity, there is no open flame and therefore none of the unwanted by-products of flame combustion.

Another notable feature is Dürr’s EcoPaintJet Pro, an award-winning overspray-free painting system. CEER can utilize this to offer its customers cars with a two-tone paint finish. The EcoPaintJet Pro technology marries customer-specific product design with automated production. Bodies can be painted with two contrasting colours simultaneously, reducing paint consumption and eliminating plastic waste since the EcoPaintJet Pro does not require masking with adhesive tape. The system can also paint complex patterns such as lettering and logos.

The CEER project is currently in the installation phase.

“Innovation is a key driver of performance and sustainability in vehicle production. The paint shop of the future will deliver great flexibility, energy and paint efficiency, and exciting premium vehicle paint finishes,” said Dr. Lars Friedrich, CEO of Dürr Systems AG. “We are pleased to have the opportunity to partner with CEER to create one of the most modern car production lines in the world.”

Flexible box concept instead of rigid painting lines

CEER can swiftly incorporate new models and easily scale production capacity with the Paint Shop of the Future. The key lies in implementing a modular concept, where flexible EcoProBooth boxes replace traditional lines with their rigid cycle times. In the box concept, the robots paint the interior and exterior of the car bodies in just one box. The new universal atomizer from the EcoBell4 Pro series meets the highest painting quality standards. Dürr’s EcoProFleet AGVs are constantly in motion and flexibly transport bodies between workstations and the high-bay warehouse based on demand. DXQlogistics.control, Dürr’s tailored software solution for the AGVs’ control logic, controls material flow digitally following work deck utilization, equipment, and availability.

Smart factory due to DXQ software

Digital solutions from Dürr’s DXQ product family turn CEER’s paint shop into an intelligent factory. The DXQcontrol modular solution is an innovative manufacturing operations management (MOM) system with a microservices architecture that delivers a high level of flexibility and consistency. The MOM comprises over 50 functionalities for manufacturing planning, execution, control, monitoring, optimization, and predictive analysis. DXQanalyze provides information based on specific systems and uses, enabling it, for example, to forecast the remaining service life of system components or to establish links between quality results and machining processes, taking transparency about the operating behaviour of machines and systems to a whole new level.

“Our goal at CEER is to build a world-class manufacturing facility, setting new benchmark for efficiency and sustainability,” said James DeLuca, CEO of CEER. “This Paint Shop of the Future will place CEER at the forefront of automotive manufacturing innovation, allowing us to offer our customers in Saudi Arabia and the wider region a level of customization they have never seen before. The result will be a more environmentally friendly manufacturing process and the ability to offer customization in car colours, finishing, and intricate details that will excite the public.”

In autumn 2024, Dürr opened its subsidiary Dürr Systems Arabia LLC in Jeddah, Saudi Arabia, to further strengthen its customer relations in the region.

The EcoPaintJet Pro paints a contrasting colour fully automatically and without overspray.

Dürr's EcoProFleet AGVs are constantly on the move and transport car bodies flexibly as required.

State-of-the-art technology: Dürr’s Paint Shop of the Future.

SECOND GENERATION OF ANODIZING LINES & Z.L.D. TECHNOLOGY

One Group, One Vision:

Engineering Excellence for ZLD & Anodizing Finishing Lines

Anodizing & P

Waste Wa Chemicals

Waste Wa

CAT anticipates future challenges with a water-based coating line for automotive components

CAT Automation has designed and built an automated coating line for an Italian manufacturer of plastic and aluminium components for the automotive industry, capable of handling fully water-based cycles. The new plant guarantees high aesthetic and functional performance, maximum application flexibility, and a substantial reduction in environmental impact, making it a future-proof solution.

Aleading Italian company specialising in the production of plastic and aluminium components for the automotive industry has recently embarked on a strategic conversion of its coating line to anticipate market developments over the next ten to fifteen years. The decision to invest in a new plant was driven by the need to find a solution combining high aesthetic standards, compliance with strict OEM requirements, and a significant reduction in environmental impact. The choice fell on a completely water-based coating technology that surpasses the traditional hybrid approach still widely used in the automotive sector.

A robot performs mechanical brushing using special bristles, onto which isopropanol is sprayed through ionising nozzles.

The three application booths are equipped with articulated robots installed by CAT Automation.

systems for two-component products. In addition, there are intermediate flash-off areas between the booths, sized according to the type of paint applied. The process concludes in the baking oven, typically set at around 80 °C, with the option to operate at lower temperatures depending on the type of products. The dwell time ranges from approximately 45 to 90 minutes. Afterwards, the components move to the cooling area and then to the manual unloading station.

With UV paints, used for specific types of components, the process involves an initial phase of solvent evaporation at low temperatures, followed by very rapid exposure to ultraviolet lamps for final drying.

The benefits achieved

Operational since mid-2025, the plant has already delivered tangible benefits across various areas. In terms of quality, automation and precise parameter control ensure greater repeatability, less waste, and high aesthetic standards, fully aligning with the requirements of the automotive industry. Insourcing the coating process has also provided direct control over this critical production stage, meeting an increasingly important customer requirement.

From an environmental standpoint, adopting a fully water-based cycle has greatly decreased VOC emissions. The implementation of coating operations has also removed the need for external handling of semifinished products, reducing CO₂ emissions, logistics costs, and transport times.

Finally, the flexibility of this plant, which can handle water-based, highsolids, and UV cycles, is a strategic competitive advantage: the company can respond quickly to new market demands, reduce time-to-market, and expand its offerings with low environmental-impact finishes that maintain high aesthetic and performance standards.

This project by CAT Automation shows how technological innovation and sustainability can come together in tangible and replicable industrial solutions, actively supporting the green transition of the automotive sector.

Robot control panel.

Paint supply system.

The

most

important industry events at your fingertips

myFAIR is a free web app that can be accessed from both desktop and mobile devices, which allows you to stay up-to-date with the leading events of the surface treatment sector.

The Way of Sportin’ Life. Lechler’s Colour Design at Fuorisalone 2026: exploring the role of colour in sport-inspired living spaces

At Fuorisalone 2026, Lechler’s Color Design presents The Way of Sportin’ Life, a project that brings together sports culture and interior design by translating athletic attitudes into a colour and material language for living spaces.

The concept stems from a specific reflection: how does a home change when sport is not an occasional activity but a mindset that influences everyday life? The goal is not to rethink the home gym but to build a complete living environment – from bedroom to kitchen, walk-in closet to workspaces – where sport, recovery, concentration, and performance naturally coexist.In this scenario, the Colour Design project transforms the sporting experience into an applied language through surfaces, finishes, and colour choices that reflect four distinct attitudes to movement.

Colour as a design tool

The heart of the project lies in its ability to translate energy, discipline, balance, and ambition into surface solutions. Colours and finishes are not just decorative elements but tools that can change the perception of space, the interaction with light, and users’ emotional responses. The collection is divided into four thematic environments – WOOD, BRONZE, SILVER, GOLD – each corresponding to a distinct approach to sport and, as a result, to different colour and material configurations.

WOOD / Recreational - A focus on recovery

WOOD interprets sport as a practice of wellbeing and body awareness. The environment is designed to foster calm and regeneration. Coated surfaces feature warm, natural tones: earthy colours, soft greens, and warm beiges. Deep, matt finishes absorb light, softening contrasts and creating a cosy, immersive atmosphere. In this context, colour becomes a welcoming element, shaping a space that promotes physical and mental recovery.

BRONZE / Amateur - Energy and contamination

BRONZE embodies a dynamic home where sport blends naturally into everyday life. The space is fluid and hybrid, free from rigid structure. The palette is bright and vibrant, including intense yellows, purples, and vivid blue-greens. Finishes become more dynamic, enhancing brightness and bringing surfaces to life.

Here, colour plays a rhythmic, expressive role - serving as a visible sign of movement, participation, and connection between physical activity and living spaces.

SILVER / Active - Precision and performance

With SILVER, the project moves into a more technical, performancedriven dimension. The space is defined by control, measurability, and concentration. The colour scheme features cool tones: greys, silvers, and balanced primary accents. Technical surfaces interact with light and reflective materials, emphasising precision and intensity. Finishes work with light and reflective elements, amplifying the perception of precision and discipline. In this context, colour defines the space, supporting a design approach focused on functionality and performance.

GOLD / Competitive - Control and identity

GOLD embodies the competitive side of sport, where every choice is driven by results. The space becomes more intimate and focused, free of superfluous elements. Painted surfaces evoke deep golds, warm metallics, dark greens, and amaranth shades. Finishes are tailored and compact, never ostentatious, with a tactile sense of solidity and authority. Here, colour goes beyond decoration, asserting identity and expressing determination and control.

An integrated colour narrative

The Way of Sportin’ Life brings together previous colour experiences into a single collection. For the coating and surface industry, it shows how colour design can evolve from a simple aesthetic concept into a strategic tool that reflects social behaviour, attitudes, and change. Because sport does not just shape the body: it defines spaces, habits and, through colours and finishes, even the way we live.

WOOD thematic environment’s colour palette.

GOLD thematic environment embodies the competitive side of sport, where every choice is geared towards results.

HIGHLIGHT OF THE MONTH

How PVD meets demand for customisation and high-quality finishes in the decorative sector

From an interview with Luca Pegorari

Protec Surface Technologies, Bedizzole (Brescia, Italy) luca.pegorari@protectim.com

The growing demand for high-quality coatings and customised surfaces has made PVD a key technology in the decorative sector. From fashion to taps, eyewear to cutlery, this process delivers thin, uniform deposits, highquality finishes even on complex geometries, and high functional performance. In this interview, Luca Pegorari, Executive Sales Manager at Protec Surface Technologies, explains how his company’s solutions can meet the needs of the most demanding manufacturers.

“Protec has always stood out among its global competitors for its attention to detail and aesthetics, with Italian-made PVD systems capable of producing thin-film metal coatings unique in the worldwide market. The coatings we have researched and developed for over 1,000 global customers are designed to deliver an unrivalled metallic aesthetic that passes the most stringent laboratory tests. Fashion accessories, eyewear, watches, cutlery, handles, and taps are the main sectors where our expertise is best reflected,” says Luca Pegorari, Executive Sales Manager at Protec Surface Technologies, a Plato Holding company.

In recent years, the luxury and high-end design and manufacturing industry has seen growing demand for coatings that are not only functional but also capable of communicating identity, quality, and distinctive values. Designers and manufacturers are seeking solutions that combine aesthetics and durability while ensuring uniformity, resistance, and colour stability over time. In the field of fashion accessories, such as buckles, padlocks, and buttons, as well as watch components, there is a focus on refined colours and multi-layer metallic coatings in striking, on-trend hues. Colour consistency, finishing quality, and wear resistance are essential requirements that must be guaranteed consistently in every production run, regardless of the size of the parts to be coated or the types of material. Similarly, taps and bathroom fittings require monochromatic coatings that can withstand scratches, abrasion, and chemicals and maintain their colour over time. In the eyewear sector, the challenge becomes even more technical: applying finishes evenly to light and delicate materials, often featuring complex shapes and small details: here, the ability to customise colours and treatments is a strategic competitive advantage for brands and designers. Cutlery, handles, and knobs, finally, require finishes that combine aesthetics and hypoallergenic robustness; their surfaces, which are subject to intense daily use, must maintain their aesthetic and functional properties for a long time. This growing demand for customisation and high performance has been prompting manufacturers to invest in advanced technologies. PVD (Physical Vapour Deposition) is now recognised as an effective solution for decorative applications: carried out in a vacuum environment, it deposits thin metal layers on complex surfaces, ensuring uniformity, surface hardness, and colour stability across batches, with superior tribological, chemical-physical, and durability properties compared with traditional processes.

In recent years, the decorative sector has seen rapid shifts in the needs of manufacturers and designers. What are the main trends you have observed, and how are demands for materials, finishes, and production processes evolving?

“The decorative sector is Protec’s core business: thanks to over thirty years of experience, we have developed an in-depth understanding of the needs of producers across various industries. We collaborate with leading manufacturers of components for the fashion industry, as well as for taps, eyewear, and cutlery. These are all industrial sectors in which aesthetics, quality, and customised coatings are decisive factors for the success of a product.

Today, coating is no longer perceived as a simple aesthetic element but as a distinguishing feature that enhances the product and positions it at the high end of the market. There is therefore growing demand for customised surfaces, exclusive colours, sophisticated metallic effects, and uniform finishes, even on complex geometries or small components. At the same time, it is essential to ensure stable results and colour consistency across different batches, especially in production processes characterised by frequent changes in collections or coating materials. In this context, PVD is one of the most effective technologies for achieving high-end decorative coatings. Carried out in a vacuum environment, it can deposit thin metal layers even on complex surfaces, ensuring uniformity, surface hardness, and high colour repeatability over time. In addition to its aesthetic value, it improves scratch, abrasion and chemical resistance and helps prevent corrosion, compared with most traditional treatments.

It is also important to note that all our customers work with parts made from different types of materials, ranging from Zamak and brass to steel, aluminium, and even ABS. Our systems must be able to coat all these

Protec’s headquarters located in Bedizzole (BS), Italy.

components in the same shade, so our knowhow is critical to making assembled products appear perfectly uniform, with different materials blending seamlessly.”

The growing demand for customisation calls for increasingly flexible production. How important is this aspect in plant design?

“Flexibility is now one of the main requirements for any manufacturer of equipment for the decorative sector. Companies need to be able to quickly manage colour changes, different finishes, and components of varying sizes while minimising plant downtime. This is why Protec’s systems are designed and engineered to ensure ease of use, reduced maintenance, and quick transitions between processes.

In addition, the ability to configure the same system with different evaporation technologies is a distinctive feature of our product range, so much so that our most versatile system solutions carry the suffix -Flex in their names to emphasise their operational versatility.”

How do you respond to market demands in practice? What is your range of systems for the decorative sector?

“Our range is designed to meet a wide variety of production needs, from the deposition of precious metals onto small parts to the coating of bathroom furniture components over 1.5 metres long. In particular, we offer the following solutions for the decorative sector:

 Nanoflex 400 is a compact and versatile hybrid PVD-PECVD system with a chamber measuring 400 mm in height and 850 mm in diameter, ideal for small and medium-sized components or for R&D. Its 5 available flanges can integrate various technologies, including cathodic arc, magnetron sputtering in multiple configurations, and plasma beam source, making this plant a true PECVD system capable of evaporating a liquid or gaseous precursor.

 PowerFlex is Protec’s top-of-the-range series, designed for larger production volumes or large components. The two available models differ in the internal dimensions of the chambers:

The tapware and cutlery sectors are among those where PVD technology proves to be an effective solution for high-end decorative coatings.

© Protec

© Protec

PowerFlex PF1100 has a diameter of 1000 mm and a height of 1100 mm, while PowerFlex PF1500 has a diameter of 1000 mm and a height of 1580 mm. Both solutions support the installation of all evaporation technologies, making this PVD&PECVD hybrid system versatile, suitable for treating large components, and capable of applying the coating uniformly across the parts’ entire surfaces and along the entire height of the chamber.

 DecoCoat 700, with a chamber measuring 850 × 850 mm, is our entry-level decorative system. It is a robust machine with 4 arches and a single door, delivering high deposition quality, repeatability, and a wide variety of colours.

 In 2026, we will launch new plants, initially designed for other sectors (medical, technical, and tribological) and now adapted for decorative use with coatings that boast high technical properties.

A key element of our offering is the wide range of evaporation sources, which allows the number and arrangement of sources to be tailored to specific process and customer requirements. This approach ensures flexibility, reduces plant downtime, and optimises productivity without compromising aesthetic and functional quality, while also enabling plant upgrades at a later date should customer requirements evolve.”

Looking ahead, what will be the main drivers of the decorative industry?

“Our research and development team is investigating the possibility of depositing PVD directly onto materials such as brass or Zamak, thereby eliminating the need for galvanic pre-treatment before deposition. This is a complex technological challenge, but one that is in high demand in the market, both to simplify production processes and to increase sustainability while reducing production costs. Another important aspect concerns the development of new niche colours and finishes, which are particularly in demand in the fashion and tap industries. To meet this need, Protec has a research centre with eight engineers specialising in physics and materials science, who are committed to the continuous development of innovative processes and customised solutions.

Finally, there is growing interest in advanced functional coatings, such as easy-to-clean treatments featuring transparent hydrophobic layers that can be superimposed on existing PVD finishes to improve cleanability and fingerprint resistance without altering the aesthetics, maintaining a metallic appearance, and avoiding the classic ‘plasticlike’ effect.

To this end, we have developed the new Nitidus Touch machine together with Arzuffi PVD, another subsidiary of our Group. It is a compact, high-vacuum batch chamber system designed specifically to apply this type of coating to decorative components already finished with PVD.”

Powering the Industrial Future

What added value do Protec and Plato Holding offer the sector?

“We play a central role within Plato Holding, formed by the merger of three leading Italian companies: Arzuffi PVD, with forty years’ experience in developing vacuum systems for plastic and glass coating; Protim, a leading decorative PVD coating contractor in Italy and Europe; and Protec, a leader in the design and supply of PVD and PECVD systems for decorative and functional applications. Plato Holding was created with the primary objective of establishing an Italian and European centre of excellence in the vacuum coating sector, combining machinery production and coating services within one innovative entity recognised nationally and internationally.

Our main contribution is our consolidated know-how in designing high-tech equipment and developing high-level, customised, efficient, and reliable solutions. Thanks to the experience we have acquired in the decorative sector, we can meet the most complex needs of manufacturers, ensuring coating uniformity, process repeatability, and the integration of advanced technologies such as cathodic arc, magnetron sputtering, HiPIMS, and plasma sources for PECVD coatings. Within the Group, Protec and Arzuffi work in synergy: Arzuffi’s R&D laboratory focuses on developing new PVD coatings, possibly supported by UV technology, whereas Protec’s laboratory can test their mechanical, chemical, and anticorrosion resistance and enable the in-depth characterisation of deposits. This integration eliminates the need for external suppliers, reduces response times, and gives us full control over all process stages. Alongside innovation, the values that guide Plato Holding are Italian-made quality and sustainability. Each project stems from a constant search for more efficient, flexible, and high-performance solutions, with a particular focus on reducing energy consumption and optimising production cycles.

The aim is to deliver a complete package of technologies and services that support customers from the coating development phase through to machinery supply, while ensuring high quality standards and responsible resource management.

Protec enables Plato Holding to offer comprehensive solutions across all sectors where surface quality is critical, including taps and fittings, fashion accessories, cutlery, automotive, lighting, security printing, and advanced tribological applications. Our experience, combined with the expertise of Arzuffi and Protim, makes Plato Holding an international benchmark provider, capable of delivering innovative technologies, reliable processes, and customised services that meet the most demanding requirements of customers worldwide.”

The Protec plant range is designed to meet a wide variety of production needs, from the deposition of precious metals onto small parts to the coating of bathroom furniture components over 1.5 metres long. Right photo: overview of a PVD system chamber.

06 – 08 October 2026

Exhibition Centre Düsseldorf, Germany

DISCOVER INNOVATION

CONNECT WITH INDUSTRY

LEADERS

UNLOCK NEW OPPORTUNITIES

ALUMINIUM is the meeting place for the global aluminium industry –the platform to discover innovations, explore sustainable solutions and build valuable business connections.

Gain insights, meet leading suppliers and shape the future of aluminium.

The secret to perfect coating? Effective masking

From an interview with Matteo Cuman, Guerra Srl - Zelo Buon Persico (Lodi), Italy commerciale@guerrasrl.it

In the surface treatment sector, masking is crucial to ensuring high quality, precision, and consistency. Protecting surface areas that must not be coated is essential to prevent defects, unnecessary paint consumption, and rework costs. We explored this topic in depth with Guerra Srl, which has been supporting manufacturers for years with a wide range of masking products, filters, and other industrial coating technologies.

The need for masking devices has emerged with the development of industrial coating. As production processes demand increasingly high precision and quality standards, it has become crucial to protect areas that need to remain uncoated, critical areas such as coupling surfaces or threads, and surfaces with tight dimensional

tolerances. From early artisanal solutions, made with general-purpose materials applied manually, the industry has gradually transitioned to advanced technical systems designed to withstand high temperatures, chemical agents, and intensive production cycles while ensuring quick application and consistent results. Today, masking is a strategic phase of the

industrial process, directly affecting the quality of end products and optimising production costs. In the current landscape, one-size-fits-all solutions are no longer enough: each project requires components that are tailored to the workpieces’ shape, the operating conditions, and the curing or baking temperatures in the ovens. Application speed, complete residue removal, and material durability are also key factors for ensuring production efficiency and process continuity.

Headquartered in Zelo Buon Persico (Lodi, Italy), Guerra Srl offers a comprehensive range of masking solutions, from conical plugs and silicone caps to films and adhesive tapes designed to meet the most demanding application requirements. Thanks to highperformance materials that resist high temperatures and can be reused multiple times, combined with solutions tailored to customers’ designs or samples, it ensures reliable protection and consistency while meeting the strictest production standards across all industrial sectors.

Standard and customised masking systems to meet every need

“In our production plant, we use plotters to manufacture various types of adhesive tapes and discs. The main materials we use are green polyester, yellow polyamide, and vinyl, selected

Overview of the Guerra masking devices’ production department.

for their high performance and practical, effective application. All our solutions are designed to leave no adhesive residue on surfaces, facilitating subsequent operations and preserving the integrity of the treated parts,” says Matteo Cuman, Guerra’s sales manager.

Standard production includes simple shapes such as circles, squares, and rectangles, suitable for various industrial applications. Nevertheless, the company can also develop fully customised special shapes, based on technical drawings or samples directly supplied by customers. This approach enables it to precisely meet even the most specific and complex requirements. “Our strength lies in our ability to customise each product according to specific needs. We offer different types of tapes and adhesives in standard sizes, such as 10, 20, 25, or 30 millimetres, which are always in stock for immediate dispatch. However, when a project demands special dimensions, we have dedicated machines to cut our masking devices to exact specifications, with no minimum order,” explains Cuman. “Finally, in cases involving particularly complex geometries or delicate components, we use application tapes, transferable supports that ensure accurate and controlled masking application. This solution guarantees precise positioning, minimises the risk of errors, and optimises processing times while delivering consistently professional and reliable results.”

Plugs and other protective devices

“In addition to films and adhesive tapes, Guerra Srl offers a complete range of silicone plugs and caps designed to meet the masking requirements of the most varied industrial processes. Our range includes standard conical plugs, plugs with handles for easier removal, double cone plugs for through holes, and screw plugs and caps available in different shapes and sizes to suit multiple types of components,” illustrates Cuman. Silicone masking solutions stand out for their high thermal resistance, as they can

withstand temperatures of up to 315 °C, making them suitable for even the most demanding production cycles. Additionally, the possibility of reusing them multiple times and their easy cleaning reduce waste and optimise management costs while ensuring efficiency and reliability over time.”

Guerra Srl: a one-stop shop for all coating needs

“The masking phase is much more than just an ancillary step in the coating process: it is a strategic element that guarantees quality, precision, and surface protection. Through our use of high-quality materials, customised options, and flexible production, we set ourselves apart as a reliable partner capable of meeting all requirements in the industrial coating sector. Whether for small quantities or orders of thousands of pieces, Guerra Srl

handles every order with the same care. Finally, our lead times are flexible: small volumes can be produced within a day, and larger orders generally require a few more days. Our main goal is always achieving total customer satisfaction with our effective, dependable, and reliable technical solutions,” Cuman concludes.

One of the plotters that produce various types of adhesive discs.

Interstuhl relies on Dürr products for seat surface coating

Interstuhl Büromöbel GmbH & Co. KG relies on modern coating technology from Dürr for the production of its work chairs for industrial and laboratory applications. The new system automates the coating of the inner surfaces of foam molds.

Utilizing the modular EcoSupply2 Core paint supply station and a 2K process controlled by an EcoAUC, Interstuhl has achieved an efficient coating process with up to five colors.

Interstuhl Büromöbel GmbH & Co. KG, headquartered in Meßstetten, is one of Europe’s leading chair manufacturers, producing high-quality office chairs for over 60 years. The company now employs innovative coating technology from Dürr in the production of its industrial and laboratory chairs. The EcoGun AS AUTO pro spray gun precisely coats the inside of the foam mold. As soon as the liquid PU foam is poured into the mold, it absorbs the coating and assumes its color.

“The paint used is special—it serves multiple functions,” explains Fabian Schilt, Head of the European Industrial Sales Team at Dürr.

The EcoSupply2 Core ink supply station is space-saving.

“In addition to providing color, it provides the necessary conductivity. Since the chairs are used in cleanrooms and ESD areas, among other environments, it is essential that no static charge is generated.”

Compact paint supply with EcoSupply2 Core

In September 2025, Dürr supported PU plant specialist Hennecke with the installation of painting equipment on an existing robot at the Interstuhl site in Meßstetten-Tieringen.

The system includes a painting robot equipped with the EcoGun AS AUTO pro spray gun, six EcoSupply2 Core stations for paint supply, and the EcoAUC 2K control unit. Interstuhl currently processes three colors, but the system is already designed to handle up to five colors. The EcoSupply2 Core paint supply station is space-saving and user-friendly. It is ideal for industrial applications where painting occurs in confined spaces. At

Interstuhl, the systems are additionally equipped with pumps from the EcoPump9 series, valves, and paint change blocks—components that have particularly impressed the company. This is due to the paint material used has special requirements: it is difficult to flush, hardens quickly, and tends to clog valves.

Ready for practical use

Extensive testing at the Dürr Test Center in Ledeč nad Sázavou, Czech Republic, proved that Dürr valves have no dead space – no material settles, ensuring reliable and clean processing. “We were convinced by Dürr right from the first demonstrations of the painting technology,” says Andreas Kunst from Interstuhl. “The technical team was always there to support us and led the project to success with a great deal of expertise and commitment.”

Robot setup with 2K dosing technology. Interstuhl Büromöbel GmbH & Co. KG relies on Dürr's advanced painting technology for the production of its work chairs used in industrial and laboratory settings.

Industrial finishing is undergoing a paradigm shift

Manuela Casali

UCIF – Italian Surface Treatment Equipment Manufacturers’ Association, Milan, Italy ucif@anima.it

There will be a common thread linking the twelve presentations at the UCIF SMART’26 conference on 20 May: the idea that industrial finishing is not merely evolving but fully redefining itself.

The convention will not offer a series of isolated business cases but will instead paint a picture of a sector rethinking its fundamentals. The topics addressed, ranging from process innovation and measurable sustainability to digitalisation and organisational culture, converge into an integrated vision in which technology, efficiency, and industrial responsibility are part of the same project. One of the clearest signs of this transformation is the systemic redesign of processes. Activities that for years were considered auxiliary operations or unavoidable nuisances, such as chemical paint stripping or surface pre-treatment, are now approached in a radically different way. New formulations, integrated plant solutions, and advanced control systems make it possible to reduce consumption, waste, and environmental impacts not incrementally but structurally. It is no longer a matter of optimising what already exists: the paradigm is changing, and so is the way we conceive of the entire production cycle. Process water management is another key indicator of industrial maturity. The SMART’26 speeches will reveal a clear shift in perspective: waste water is no longer a cost to be contained but a resource to be leveraged. Advanced technologies enable the recovery of critical metals with extremely high efficiency, thereby contributing to the resilience of European supply chains, while advanced sensors and control software enable the

reuse of operational solutions and predictive consumption management. Sustainability ceases to be a statement of principle and becomes a technical variable that can be measured and compared.

The automotive sector continues to offer further opportunities for development, confirming its status as a privileged testing ground for innovation and technology transfer. Highly efficient application systems, integrated digital platforms, and artificial intelligence algorithms reduce waste, setup times, and maintenance interventions, paving the way for increasingly flexible, circular, and energyoptimised paint shops. The solutions developed to meet the stringent standards of OEMs become benchmarks that can be transferred across other manufacturing sectors.

Digitalisation cuts across many areas, with one distinctive feature: it strengthens process robustness. Digital twins, data analysis, and AI do not replace engineering but enhance it. Reduced trial and error, greater repeatability across plants, and real-time monitoring of critical parameters: competitiveness depends on the ability to make processes predictable and stable.

Alongside the technological dimension, the cultural dimension is also emerging as a key theme. For example, adopting objective metrics, such as green chemistry parameters, provides the industry with a common language for assessing industrial choices. At the same time, the focus on social sustainability and peoplecentric organisational models shows that performance and resilience also depend on the importance placed on people and on consistent corporate values.

SMART’26 will therefore provide a unique vantage point on the future of European industrial finishing, offering expert insights, technical discussions, and strategic networking opportunities to help understand where the sector is headed and how to navigate its transformation.

Participation is free of charge, but registration is required, and places are limited. This is a valuable opportunity for anyone keen to play an active role in the new trajectory of industrial finishing.

The winners of the GI Awards 2026

The 8th edition of Global Industrie will be held from March 30 to April 2, 2026, at Paris Nord Villepinte (Paris, France).

For four days, Global Industrie transforms into the largest factory in France. The exhibition showcases innovations shaping the future of industry in a context defined by reindustrialization, industrial sovereignty, and sustainability challenges, featuring 2,300 exhibitors and more than 3,000 machines in operation.

A highlight of the event, the GI Awards recognize the most outstanding industrial innovations. In 2026, 21 innovations were shortlisted from around one hundred applications. Following the Grand Oral held on Tuesday, March 30, the jury - composed of industry professionals and journalists - selected four industrial solutions across four categories: Responsible Industry, Digital Innovation, Industrial Performance & Efficiency, and Technological Transformation. A special “Startup” Award, dedicated to an industrial startup, and the Jury’s Favourite Award were

also presented. The awards ceremony will take place on Wednesday, April 1, 2026, on the exhibition’s Grande Scène.

Innovation trends from the GI Awards 2026

 Democratizing access to advanced industrial technologies to enhance business competitiveness.

Several innovations are making tools that were once complex or costly accessible to a wider range of industrial companies. Forx offers an autonomous mobile robot capable of detecting pallets using artificial intelligence, deployable without any specific infrastructure and available through a rental model. Fuzzy Logic Robotics, with WeldMate, simplifies welding automation via a no-code interface operated from a tablet, allowing operators to program a robot in just a few minutes. Meanwhile, Misutech enables manufacturers to anticipate machining

defects through digital simulation, supporting production decisions and reducing scrap.

 Putting people, safety, and working conditions at the heart of industrial transformation.

The awarded innovations also aim to make industrial environments safer and more ergonomic. Safehear enhances communication in noisy environments with a system that filters background noise while clearly transmitting the human voice. Labadis facilitates the handling of heavy parts with a compact lifting system that reduces physical strain and improves workstation ergonomics. Finally, Seabery’s augmented reality paint simulator enables operators to train more efficiently while minimizing the risks and costs associated with learning.

Through these innovations, the winners exemplify an industry that combines technology, performance, and progress for the men and women who drive it forward.

For further information: www.global-industrie.com/en

EDITOR IN CHIEF

ALESSIA VENTURI venturi@ipcm.it

EDITORIAL DIRECTOR

FRANCESCO STUCCHI stucchi@ipcm.it

EDITORIAL OFFICE redazione@ipcm.it

PAOLA GIRALDO giraldo@ipcm.it

MONICA FUMAGALLI fumagalli@ipcm.it

NICOLE KRAUS kraus@ipcm.it

MATTEO SOTTI sotti@ipcm.it

ILARIA PAOLOMELO paolomelo@ipcm.it

FEDERICO MELIDEO melideo@ipcm.it

GIULIA GENTILE gentile@eosmarketing.it

MARTINA STUCCHI mstucchi@ipcm.it

MEDIA SALES

FRANCESCO STUCCHI stucchi@ipcm.it

ILARIA PAOLOMELO paolomelo@ipcm.it

MARTINA STUCCHI mstucchi@ipcm.it

NICOLE KRAUS kraus@ipcm.it

GRAPHICS

ELISABETTA VENTURI grafico@ipcm.it

TRANSLATIONS

CHIARA FOPPA PEDRETTI chiara.foppapedretti@gmail.com

PRINT

SEBEGRAF SRL | info@sebegraf.eu

EDITED BY

EDITORIAL BOARD

Prof. Stefano Rossi

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

SUBSCRIPTION SERVICE / SERVIZIO ABBONAMENTI

Sale only on subscription - Vendita solo su abbonamento E-mail: info@ipcm.it

Subscription Rates 2026

Annual subscription print + digital:

EMEA €110,00 (postage included)

Rest of world €350,00 (fast airmail shipping included)

Single copy: €15,00

EMEA (postage included) - Rest of world (postage excluded)

Back issues: €30,00

EMEA (postage included) - Rest of world (postage excluded)

Subscriptions can be made via payment online at www.myipcm.com. Subscription and the sale of individual issues are exempt from VAT under Italian law: Article 74.1, letter C of DPR 633/72, DM 29/12/1989.

Tariffe Abbonamento 2026

Abbonamento annuale cartaceo + digitale:

EMEA €110,00 (spese postali incluse)

Rest of world €350,00 (spedizione via aerea inclusa)

Fascicolo singolo €15,00

EMEA (spese postali incluse) - resto del mondo (spese postali escluse)

Arretrati €30,00

EMEA (spese postali incluse) - resto del mondo (spese postali escluse)

Gli abbonamenti possono essere sottoscritti con carta di credito sul sito: www.myipcm.com. L’Iva sugli abbonamenti, nonchè sulla vendita di singole copie è assolta ai sensi dell’art.74 comma 1 lett. C DPR 633/72, DM 29/12/1989.

Redefining Surface conversion

DOLLCOAT GP 107

A new line of nanotechnologic conversion for corrosion classes C3H – C4H – C5M

DOLLCOAT GP 107 based on graphite engineered by

Multimetal no rinse product to be used at room temperature

Compatible with any plant and applied by spraying, deep immersion or by nebulization modules

Excellent pre-cataphoresis pretreatment