ipcm® n. 69 - May/June 2021

The smart journal for surface treatments

ISSN 2280-6083

ipcm digital on

® SPECIAL ISSUE ON AUTOMOTIVE & INDUSTRIAL CLEANING TECHNOLOGIES

INTERNATIONAL PAINT&COATING MAGAZINE

PVD SPUTTERING EXPERTS

www.myipcm.com 2021

12th Year - Bimonthly N° 69 - MAY/JUNE

THE INVISIBLE PROTECTION Approved by:

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Mystic Elegance XIRALLIC® NXT M260-70 SW AMUR BLACK

• Bluish black with silky-silvery shade • Strong hiding power • Intense darkness • Balanced black stylings • Charcoal black effect and “Living Sparkle®”

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

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www.merckgroup.com/en/expertise/surface-solutions

AUTOMATE YOUR PAINTING PROCESS Compact solutions for industrial plants DESIGNED, MANUFACTURED AND ASSEMBLED IN ITALY

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LestaSrl

CONTENTS MAY/JUNE 2021

© AdobeStock

06

© Raleri

MARKET CLOSE UP

28

Present and Future of the Powder Coatings Industry

© sd partners

44 05 12 14 18 26 30 34

HOW IT’S COATED Seeing Beyond the Ordinary: Exclusive, Increasingly Customised Finishes for Raleri’s Eyewear

© Maserati

FOCUS ON TECHNOLOGY AluCoating Perfectly Tunes in to its Paint Supplier to Manage Small Batches and Prove to be an Italian Coil Powder Coater of Excellence

EDITOR’S LETTER IPCM IN REVIEW BRAND NEW FOCUS ON TECHNOLOGY

Effective Passivation at Room Temperature: The Pre-Treatment Innovation that Convinced Gimi

40

SUCCESS STORIES

42

INNOVATIONS:PRESENT&FUTURE

52

BRAND NEW

57

ANALYSIS

68

Three Colour Management Technology Trends to Follow This Year

HIGHLIGHTS OF THE MONTH

Inkmaker Group Rebrands as IM GROUP in Conjunction with World Earth Day

58

76

SPECIAL ISSUE ON AUTOMOTIVE

FOCUS ON TECHNOLOGY Maserati MC20, the New Dream Super Sports Car: 100% Made in Modena

Tapematic Installs the First PST Line II in Italy at Metal Tech

Large Choice of Colours and Functionality for Long-Lasting Beauty of Fireplaces

HIGHLIGHTS OF THE MONTH

Preempting Market Needs: Mirodur’s Forward-Looking Vision

79 80

Technological Evolutions in the Finishing of Steel Car Wheels: Application with a Bell-Gun System Mounted on Robot in the new MW Plant in Romania

BRAND NEW

MEILLER Relies on AGTOS and SLF to Equip its New Surface Pre-Treatment Division

HIGHLIGHTS OF THE MONTH

Avin – A Strategic Partner for First Aid in Paintshops, Also in the Automotive Sector

84

FOCUS ON TECHNOLOGY

88

FOCUS ON TECHNOLOGY

92

SUCCESS STORIES

SPECIAL ISSUE ON AUTOMOTIVE

FOCUS ON TECHNOLOGY

SUCCESS STORIES

First Coating Line for Agricultural Trailers with Cutting Edge E-Coat and Powder Coating System

Agrikon’s Paintshop Goes Electrostatic

Dürr Delivers One of the Biggest Paint Shops to SAIC Volkswagen

CONTENTS MAY/JUNE 2021

© PPG

SPECIAL ISSUE ON AUTOMOTIVE

HIGHLIGHT OF THE MONTH

94

110

Covid-19 Might Increase Sales of Blue Cars, According to PPG 2020 Automotive Color Popularity Report

98 100 106 114 120

SPECIAL ISSUE ON AUTOMOTIVE

ART WITHIN SURFACES Beauty and Speed: when the Automotive Industry Meets the Art

© AdobeStock

© Comau

134

© Stephan Bauer

INNOVATIONS: PRESENT&FUTURE Comau’s New MATE-XT: A Robust, Lightweight Exoskeleton to Support Coating Operators and Reduce Muscle Strain

BRAND NEW

124

INNOVATIONS:PRESENT&FUTURE

PVD Sputtering Approved for Car Interior and Exterior Components: A Great Achievement of Italian-Made Excellence

130

INNOVATIONS:PRESENT&FUTURE Long-lasting Corrosion Protection for Large Vehicle Parts

FOCUS ON TECHNOLOGY

Fluiver Combines Long-Standing Expertise and Innovation for the Optimal Coating of Large-Sized Plastic Parts

INNOVATIONS:PRESENT&FUTURE

Arzuffi’s Line-Met System Conquers the Decorative Industry by Offering Maximum Automation at Reduced Costs

138

154

THE MARKETING CORNER B2B Marketing: How to Set Up an Effective Multichannel Strategy

FOCUS ON TECHNOLOGY

CBV Blechbearbeitung Improves its Production Depth, Flexibility, and Energy Efficiency with the Help of Italian-Made Technology

150 160

SUCCESS STORIES

At ISA’s Plant, a New Coating System 4.0 Proves Strategic for the Efficient Use of Energy Resources

INNOVATIONS:PRESENT&FUTURE

Alit’s Fastrip AP System for Sustainable Paint Stripping of Aluminium Profiles

142

BRAND NEW

144

INNOVATIONS:PRESENT&FUTURE New Perspectives for the Quality Control in Industrial Coatings

162 171

SPECIALIZED TRAINING

ipcm® Academy: Ten Years of Specialised Vocational Training for Over 130 Companies

STANDARD & LEGISLATION

Cleaning Processes Are Now Even More Important

ZOOM ON EVENTS ICT - INDUSTRIAL CLEANING TECHNOLOGIES

Tip top: our corrosion protection is thinner than a single hair.

And easier to maintain! Despite the wafer-thin coat thickness, our coatings achieve excellent results and offer a high level of protection. And even better: we address your wishes and requirements individually, instead of brushing you off with standard service. www.doerken.com

CORROSION EXPERTS

FASTRIP AP The new offline paint stripping solution for aluminium profiles.

FASTRIP AP is the latest plant developed

by Alit, that allows the chemical stripping of profiles up to 8 metres long.

DISCOVER MORE AT PAGE 138!

www.alit-tech.com

EDITOR’S LETTER

Richiedi la versione in italiano a info@ipcm.it

T

he post-Covid economic recovery, which was announced as early as September 2020, seems no longer to be a chimera but a reality.

Across Europe, strong demand conditions are leading to an acceleration in manufacturing, with increased confidence among companies, which are hiring again to cope with peak volumes.

The March data on the manufacturing PMI index in Italy, Germany, and France, released by IHS Markit1, show rising figures for all countries. Certainly, a part of such demand has been driven by the incentives that, although in different degrees, all European states have allocated for many industrial sectors, from construction to automotive, and for various innovation-focussed endeavours, from Industry 4.0 to sustainability.

Paradoxically, however, growing demand is accompanied by the threat posed by the scarcity of raw materials that I mentioned in my previous editorial, which unfortunately continues to affect all sectors worldwide.

Despite this, investments are increasing, also on the back of successful vaccination campaigns throughout Europe – a sign that the return to normality is near (albeit with new patterns).

This ipcm® issue is traditionally devoted to an in-depth look at the automotive coating industry.

From its articles, it emerges that strong recovery is indeed on the horizon, as are many new market opportunities to be seized.

In fact, you have a rich issue in your hands. We are proud to say that it even includes an extensive reportage on the paintwork of the latest dream car for all enthusiasts, the Maserati MC20, a supercar with an elegant soul. It is the first Maserati to be 100% made in Modena, thanks to a 100% Italian investment.

It is always the automotive sector that offers the most attractive ideas on innovation, which are then acquired, absorbed, assimilated, and transformed by other industries. Sometimes, however, the opposite can also happen. This is the case with the PVD sputtering metallisation technology, which, after having conquered many sectors, from design to decorative components for car interiors, has now also been approved for the finishing of car exterior parts, where quality and resistance requirements are much more stringent.

Another surprising sector is that of steel wheels – which have always been considered the “unlucky brother” of alloy wheels – where coating systems and application techniques have been extensively renewed and transformed to meet an emerging market demand: that of steel wheels with attractive design and finishes as an excellent alternative to more expensive alloy wheels.

Another significant aspect that emerges from this issue of ipcm® is the importance of assessing investments correctly and understanding when it is better to modify, upgrade, or renew a plant rather than replace it completely.

Finally, this issue ipcm® also welcomes numerous new companies that have decided to highlight their potential and innovations on its pages.

This is yet another symptom of the courage to invest in the post-Covid recovery that the European industry is showing from many quarters.

Alessia Venturi Editor-in-chief Direttore Responsabile

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https://ihsmarkit.com/index.html

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Present and Future of the Powder Coatings Industry Interview with Kevin Biller President of The Powder Coating Research Group – Columbus (OH), United States

W

e interviewed Kevin Biller, one of the

The powder coatings industry always

been buoyed by the healthy growth rates in the

leading international powder coating

shows great ferment. Could you give us an

Asia Pacific market and the slightly higher than

experts, in order to know what are

overview of its pre- and post- pandemic

GDP growth rates in the more mature markets

the most urgent current needs in the sector

situation?

in Western Europe and the Americas.

and to understand their future prospects. If

Pre-Covid, as the world ushered in a new

Consolidation during the 2010s had shrunk the

a climate of uncertainty persists, nevertheless

decade, the powder coating industry was faced

overall number of players down significantly to

considerable resources have been put in

with challenges as the economic recovery was

the point that less than ten players represent

place to combat it. In Biller’s words we find

beginning to slow down. The global market for

over 80% of the global market. This is especially

all the preconditions for the most important

powder coatings hovered around $10.5 to 11.0

true in the Western regions. North America is

challenges that the powder coating industry will

billion US and had experienced a compound

dominated by five producers: Sherwin Williams,

have to face.

annual growth rate of about 5.5% for the

PPG, AkzoNobel, ProTech and Axalta, while the

previous three to four years. That CAGR had

top players in Europe are AkzoNobel, Jotun,

© AdobeStock

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© The Powder Coating Research Group

Sherwin-Williams, Axalta, Tiger Drylac and Europolveri.

Organic market growth was predicted to wane over the next two to three years. U.S. manufacturing had hit a ten year low in September 2019 due to lower consumer demand and the uncertainty caused by Trump’s trade war with China. Some experts, me included, foresaw an economic recession on the horizon. In addition, scant market growth was expected in the automotive market. OEMs had committed to waterborne technologies and the “compact” process which neither entail any use of powder coatings. Slow growth that tracks overall automotive production was expected to occur in under-the-hood applications and alloy wheels.

As we all know, the world economy came crashing down at the onset of the coronavirus. The rebound, however, has varied depending upon how each region and country fared in fighting

Kevin Biller.

the pandemic. China instituted an aggressive and draconian shutdown and emerged remarkably quickly. As the rest of the world struggled with containing the virus, China experienced

2 0 ye a r s

an unprecedented “V-shaped” economic recovery. Globally the industry saw an overall growth rate of 17% in Q1 2021 versus Q1 2020, however it was mainly due to a spectacular 23% expansion in Asia. Europe rebounded with a 6% growth tally; however, North America has only experienced a meagre growth rate of 1.5% versus Q1 2020.

Competence in Shot Blast Technology

What are the sector’s current priorities, in general, and from a legislative point of view, in particular, in the US? Current priorities in the US and much of the rest of the world centre around meeting current customer needs in light of raw material price increases, continuing supply chain disruptions and exorbitantly long lead times. Key raw materials are in short supply due to plant shutdowns around the world, a scarcity of chemical building blocks due to the February freeze in Texas and the Gulf Coast and a dearth of shipping containers to move product around the world.

Legislation has been hinted at by government regulators nothing concrete has emerged in the last year. TGIC (Triglycidyl Isocyanurate), the polyester curing agent aggressively regulated in the EU, remains off the EPA’s list of Chemicals of Special Concern, therefore no active legislation is anticipated in the near future. Interestingly, TGIC is in short supply due to the shutdown of a couple of Chinese production facilities. This has created a new demand for HAA (hydroxy-alkyl amide), an alternative curing

As a full-range supplier, we design and manufacture shot blasting machines including filter and transport technology. ➜ New shot blast machines ➜ Second hand machines ➜ Service and spare parts ➜ Reparation & maintenance ➜ Inspection & consulting ➜ Performance improvement AGTOS | GmbH | D-48282 Emsdetten info@agtos.de | www.agtos.com

agent commonly used in Europe.

international PAINT&COATING magazine - MAY/JUNE 2021 - N. 69

303-01/21-4c-GB

regarding titanium dioxide and BPA (Bis-Phenol-A), however

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© AdobeStock

At present sustainability is one of the

recently developed a bio-based powder

costs. AkzoNobel recently introduced the

drivers of the entire industrial field. What

resin that checks two boxes of sustainability

Interpon Low-E collection of polyester powder

future do you foresee for the powder

– renewable plant-based feedstocks and

coatings which are designed to reduce the

coatings industry with respect to this

low temperature cure. This polyester-amide

curing temperature and/or curing time,

issue?

resin boasts an 85% bio-based content and is

without sacrificing the quality and properties

Sustainability is alive and well in the powder

capable of cure as low as 130°C. In addition, it

of the coating. These powder coatings can

coating industry and can take many forms.

exhibits excellent UV resistance as evidenced

be cured between 150 and 170°C, from 8 to

Obvious examples are the use of recycled

in laboratory testing (4000 hrs. QUV-B).

40 minutes. By using this range, coaters can

polymers and raw materials based on

Prototypes have been submitted to a few

reduce energy consumption and/or increase

renewable feedstocks such as plants. In

powder manufacturers for their support in

the productivity of their application process.

addition, sustainability can be engendered

eventual commercial scale-up potential.

This contributes to lower costs and also

with products requiring less energy to process

Rilsan Fine Powders, a division of Arkema,

improves their ecological footprint. Axalta

or produce. Furthermore, more highly durable

has developed a high-performance polymer

debuted a similar polyester product line called

products can enhance sustainability. The

designed for thermoplastic powder coatings.

Alesta BE+ in Mexico in 2020.

powder coating industry has technology

Rilsan® 11 is a member of the nylon family

More highly durable powders increase the

represented in all of these categories.

of polymers and is based on a monomer

longevity of a coated item leading to more

Sherwin-Williams recently debuted the

derived from castor beans. It can be used

sustainability. The need to refresh or repaint

Powdura® ECO Hybrid Coatings line. The

for a variety of coatings requiring durability

products is costly, labour intensive and

polyester resins used in these powders

including dishwasher racks, auto parts, potable

can involve field applied coatings with high

contains 25% pre-consumer recycled plastic

water pipelines, outdoor furniture, medical

VOC content. Additionally, coating failures

(rPET). SW touts these coatings as being easy

instruments and commercial grade outdoor

that instigate the replacement of a coated

to apply, having wide cure capability, and can

lighting.

item incurs the high costs of disposal and

align with third-party certifications such as

Low temperature cure is an important sub-

ultimate replacement. The powder coating

LEED, GreenGuard and BIFMA (the Business

genre of sustainable products. Reducing the

industry recently introduced “hyper-durable”

and Institutional Furniture Manufacturer’s

energy requirements to cure coatings reduces

technology that significantly increases the

Association). Battelle Memorial Institute has

their carbon footprint and saves operating

longevity of a coated asset.

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Coating longevity requires a combination of UV durability and corrosion resistance. Outdoor durable powder coating technology is well positioned to take on the high-performance architectural market. The North American architectural market abides by the AAMA specifications: 2603 (one year Florida), 2604 (five years Florida) and 2605 (ten plus years Florida). Powder coatings meeting the AAMA 2604 specification have been around for decades and have a sterling track record of performance in the field. These are typically based on “superdurable” polyester binders combined with high performance pigments, fillers and additives.

Powder coatings that meet the more stringent AAMA 2605 and Qualicoat Class 3 requirements have recently been commercialized and are gaining momentum in the architectural market. These powders are based on FEVE (fluoro ethylene vinyl ether) polymers and can last up to twenty years in UV intense environments such as South Florida and parts of the Middle East. Leaders in this arena are IFS Coatings, PPG, Axalta, ProTech and AkzoNobel. Prominent building projects have touted the use of AAMA 2605 powder coatings including the PNC Plaza in Pittsburgh (PPG Coraflon), 55 Hudson Yards (PPG Coraflon) and 10 & 30 Hudson Yards (AkzoNobel Fluromax) in Manhattan.

Digitalization is another important and recent theme. What do you think about its development in your industry?

As for digitalization, powder coating equipment makers have introduced more sophisticated coating application control software in the form of user-friendly apps. GEMA’s OptiStar® 4.0 controls crucial coating parameters such as pneumatic and electrostatic parameters. These relevant coating data can be then accessed to a mobile device with their Electrostatic App. Moreover, their DVC technology ensures precise and reproducible powder output and ensures consistent film thickness. Finally, GEMA’s PCC and SuperCorona software improves penetration, reduces back ionization, orange peel and picture framing.

Nordson’s latest gun control software is aptly named Encore® Engage. It features an easy-to-understand, 15-inch touchscreen with modern graphics and intuitive symbol-driven navigation. In addition, a guided recipe feature provides step-by-step navigation with pre-set options to help operators confidently create new recipes. Video tutorials and guided instructions provide greater visibility to key information and give additional support for critical tasks. For operators around the world, Encore Engage® includes several screen language options and its controller interface delivers easy navigation and enables industrial internet of things (IIoT)/ Industry 4.0 functionality for powder coating application.

Parker Ionics has focused on their exclusive Pulse-Power gun

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control technology. Their new GX8500A

meetings. We delivered live presentations

their MDF (medium density fibreboard)

powder application system features a

including animated question and answer

based product lines. As they make major

3G patented Super Pulse Power - corona

sessions. Pre-recorded videos were

conversions, competitors are expected

charging technology that provides superior

made demonstrating the powder coating

to follow suit. Hyperdurable end-uses will

first pass transfer efficiencies (FPTE) on

manufacturing process as well as application

slowly convert to powder especially in the

all shapes and substrates. In addition, it is

techniques.

demanding markets in the US and Middle

fully digital with simple controls featuring

In both the live and broadcast versions of

East. Supply chains for critical raw materials,

250 recipe capacity. Parker explains that

the course we had the students break into

the GX8500A is excellent for coating boxes,

small groups to tackle a formulating exercise.

take some time to get back to a modicum

wheels, piping, MDF and extrusions and that

Each group was given a specification to meet

of normality. R&D staffs are challenged to

it possesses the highest transfer efficiency

along with a list of various raw materials in

replace retiring formulators with the fresh

in the industry resulting in lower operating

which they had to use to formulate a powder

minds of new graduates. Innovation is

costs.

that met the requirements. PCR Group

sluggish with the trend toward an oligopoly of

lab technicians took these “new creations”

behemoth producers who are bogged down

The health crisis has stopped all

and made powder coatings based on their

in bureaucratic management.

events and face-to-face meetings, like

newfound formulating skills. Test panels were

For decades powder coatings’ pillars of

exhibitions and training courses. You

sprayed followed by evaluation and critique

efficiency, economy, excellent performance

have attended numerous events around

of their powders in a live broadcast.

and environmental compliance have

the world, and you have organized the

In addition to repackaging the PC Kitchen

compelled finishers to replace solvent-

Powder Coating Kitchen, a short course

we developed a regular podcast. The Ask

borne coatings. The potential for explosive

that introduces formulators, chemists

Joe Powder “powdcast” provides the listener

growth of powder coatings has always been

and scientists to the fundamentals of

to the latest news and information in the

tempered by barriers to entry mostly centred

creating a powder coating from the

powder industry in an entertaining and

around fear of radical change and the

ground up. How do you think the events

enlightening manner. The mythical Joe

potential for failure.

sector will change?

Powder then answers technical questions

Liquid coating technology is still superior

Because of Covid, we have had to modify

from people in the industry. On occasion the

to powder coatings for large scale articles

our approach to training. Our popular

podcast consists of an interview with industry

such as earth-movers, farming equipment

formulators’ short course, the PC Kitchen,

leaders. This podcast just posted its 28th

and aerospace/aviation. Regardless powder

originated as a live, hands-on experience

episode.

growth will be driven by conversions in the

held in the PCR Group laboratory. It

such as TiO2, pigments and base resins, will

finishing of heat sensitive substrates such

consists of lectures spanning the spectrum

Today it’s difficult to make a forecast

as engineered boards, composites and

of formulation fundamentals, powder

of the economic situation over the next

plastics. In addition, hyperdurable powders

processing and application technology.

years. From your point of view, could

will gain market share at the expense of more

Live lab demonstrations are intermingled

you give us some indications of future

traditional liquid coatings due to the ability

with presentations enabling the student to

developments both in the US and in all

to meet everchanging environmental and

participate in powder processing, application

the world?

sustainable goals of regulators. And finally

and evaluation techniques.

Innovation in powder technology will open

incremental improvements in corrosion

Social distancing and travel restrictions

new markets in the heat sensitive substrates

resistance and durability will be realized

compelled us to shift this two-day course

and hyperdurable markets. Major furniture

especially in the pipeline coating market

to a series of four consecutive Thursday

makers have expressed strong interest in

which will drive modest growth.

afternoons of live broadcast via Zoom

converting liquid paint lines to powder for

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IN REVIEW

March and April in review Two months with important changes, starting from the new website up to a new section in our magazines… and a new colleague.

A

s anticipated, after months of work, on March 1st our new

applications spanning several manufacturing fields but it also includes

website went online (www.myipcm.com)!

a comprehensive supplement devoted to the coating of architectural

Available in 5 languages, the website features new graphics,

profiles and design objects, with a wealth of innovations especially in

an enhanced user experience, a responsive layout that optimises the

the powder coating sector.

navigation via mobile, new features and new tools to promote your

The March/April issue of ipcm® launches also a new section – How It’s

brand and products. The News section of the website features all the

Coated – inspired by the well-known tv program “How it’s made” and

latest news on sector trends, products and technologies, research

aimed at describing the production cycle and the coating phase of

and development, fairs and events and much more, and ipcmPedia

particular products. The first of these that we presented is MAMBO

allows you to get all the information you need on the major sector

(www.ipcm.it/en/open/ipcm/2021/68/34-36.aspx), the first 3D-printed

players, and is also a powerful search engine that crawls all the pages

fiberglass boat in the world.

of our website to provide answers to your queries.

The month of April has always been dedicated to the preparation The most important international trade shows

and release of the first issue of the year of ipcm®_Protective Coatings

To stay up-to-date with the scheduled trade shows and discover

(www.ipcm.it/en/magazine/protective-coatings/2021/37.aspx). In this

where you can grab a copy of our magazines, we have created a

issue we have found how the pandemic has brought out new needs

dedicated fair calendar (www.ipcm.it/en/exhibitions.aspx). Moreover,

in the industry, which force companies to push on the accelerator of

in the Exhibitions section (www.ipcm.it/en/calendar/2021-05.aspx), it

Research and Development. These include the demand for greater

is possible to find all the information on the trade fairs represented

efficiency, durability and effectiveness of paint products and the

by us: PaintExpo, PaintExpo Eurasia, DeburringExpo and FABTECH

need to reduce dependence on oil derivatives for the formulation of

México.

coatings, as well as VOCs.

New edition, new section

The new session of the ipcm® Academy training courses

In March, the issue no. 68 of ipcm International Paint & Coating

has begun

Magazine was also published. It not only covers a variety of topics and

On April 8 we started the first session of the ipcm® Academy training

®

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N. 69 - MAY/JUNE 2021 - international PAINT&COATING magazine

Barbara Pennati and Ilaria Paolomelo, ipcm

®

course aimed at training the new professional

eos’ tree

figure of Technician of Industrial Surface Finishing

On the occasion of the international day dedicated

Processes, included in the QRSP (Regional

to our Planet, celebrated globally on Thursday 22

Framework of Professional Standards) of the

April, we presented the lime tree that was given to

Lombardy Region and recognized at national and

us last Christmas by the girls of our editorial staff.

European level.

The tree is planted in Bollate (province of Milan)

In the first three training days, the 13 students

in “Il bosco dei ricordi”, a project that involves the

addressed the topics of corrosion, pre-treatment

annual absorption of over 210,000 kg of CO2.

and waste water treatment and purification.

Finally, in the last days of April, the participants of

The new partnership with Assovernici

the 2020 edition of our training course received

eos and ipcm® strongly believe in the importance

the certificate of competence as Technician of

of associations and networking for business

Industrial Surface Finishing Processes.

development.

To this end, we have established a new

ipcm at the “Alluminio&Acque” conference

partnership with Assovernici - Produttori Italiani

On Wednesday April 14, the editor-in-chief of the

Vernici, an association that represents the main

ipcm magazines, Alessia Venturi, participated in

manufacturers of construction and industrial paint

the digital conference “Alluminio&Acque” with a

and coatings with the aim of promoting the Italian

presentation entitled “The role of an international

sector, enhancing its excellence and specificity.

®

®

magazine in the dissemination of innovative technologies: promoting dialogue between

A new special colleague

suppliers and users”.

Last but not least, this month we welcomed a new

The conference was organized by CIE Srl and MST

friend/colleague: Falcor, a 3-month-old Miniature

Chemicals with the collaboration of ipcm® and the

Schnauzer puppy.

AITAL Association with the aim of getting deeper

His work within the editorial office is very

understanding of the technologies, processes,

demanding: allowing cuddles here and there,

chemicals and plants to save, purify and recycle the

playing and accompanying the girls of the editorial

water coming from metal finishing lines and anodic

office on their coffee break every day.

oxidation of aluminium.

BRAND-NEW © AkzoNobel

AkzoNobel Launches its Second Global Start-up Challenge AkzoNobel announces the launch of Paint the Future’s second global start-up challenge.

F

ollowing the success of the 2019’s Paint the Future event, on May

Officer. “Our first global start-up challenge was a first for our industry and

18, AkzoNobel launched Paint the Future’s second global start-

our ecosystem has grown amazingly since then to include 2,137 active

up challenge. Start-ups had to submit solutions addressing five

members. It’s a launch pad for great ideas that’s attracted a diverse group

challenge themes:

of start-ups, suppliers, academia and customers.”

• Enhanced functionality;

Those participating will have the chance to accelerate their solutions in

• Customer experience;

the paints and coatings industry and form partnership opportunities and

• Smart application;

investments. The 2019 programs have already resulted in 18 successful

• Circular solutions;

solutions.

• Smart manufacturing and supply chain.

“Our new company strategy is all about building on our strong foundation

Following the launch of the challenge, exploration and enrichment of the

and pioneering ways to grow and innovate,” says AkzoNobel CEO, Thierry

submissions will continue through July 20. Then, select finalists will be

Vanlancker. “That’s why it’s the perfect time for round two of our global

invited to a collaboration event in late 2021, where the challenge winners

start-up challenge. We’re excited to see what potential collaborations the

will be announced.

start-ups have in store for us that will help us bring surfaces to life for our

Paint the Future is led by AkzoNobel and powered by thousands

customers.”

of connections around the world making it the industry’s largest collaborative innovation ecosystem.

“Paint the Future is our dedicated ecosystem designed to accelerate

For further information:

innovation in paints and coatings,” says Klaas Kruithof, Chief Technology

www.letspaintthefuture.com/global-challenge-2021

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BRAND-NEW

Assovernici Becomes a Supporting Member of the Advertising Standards Authority Assovernici, the Association representing the Italian manufacturers of building and industrial coatings, has become a supporting member of Italy’s Advertising Standards Authority (IAP), to promote responsible advertising in the coating sector for the benefit of consumers and businesses.

W

ith the aim of

on rules which are on the one hand, validated, but on the other hand

becoming the

open to social and technological evolution to ensure the protection

reference point

of consumers and fair competition,” notes Vincenzo Guggino,

of a virtuous system of

Secretary General of IAP.

commercial communication focusing on the values of

For further information: www.assovernici.it

truthfulness and responsibility, in April Assovernici became a supporting member of Italy’s Advertising Standards Authority © Assovernici

Massimiliano Bianchi.

(IAP).

For the Association, joining IAP is part of a process based on the shared values of responsibility,

information and transparency, aimed at establish a consistent ‘coating culture’ and supporting the development of fair businesses.

Indeed, despite the fact that most everyday objects are coated and that the sector generates a turnover of around 2 billion Euros in Italy alone, end users still have little knowledge of paint products.

“In line with our code of ethics, being an IAP member enables us to provide our companies with clear criteria for the management of correct and truthful communication towards competitors and consumers,” states Assovernici President, Massimiliano Bianchi.

“Moreover, it gives us the opportunity to contribute to regulations compliance and the definition of rules that are consistent with the nature and characteristics of our sector, which is still little known to the general public and must become increasingly widespread and comprehensible, in order to encourage the responsible management and correct use of coatings.”

Assovernici’s commitment to promoting transparent communication is a key promise in the current Covid-19 pandemic: a period of proliferation of misleading advertising for disinfectant, antimicrobial and antiviral coatings often not scientifically validated and documented.

“We welcome Assovernici as a new member of IAP: it is a tangible demonstration of commitment to responsible communication, based

international PAINT&COATING magazine - MAY/JUNE 2021 - N. 69

15

BRAND-NEW

Evonik Joins the MIT-IBM Watson AI Lab to Accelerate Innovation with Artificial Intelligence Evonik extended its collaboration with IBM in the field of digitalization until 2025 and became the first chemical company in the world to participate in the MIT-IBM Watson AI Lab for research and development of AI.

E

vonik has extended its strategic partnership with technology

Hahn has a positive view of the strategic partnership with IBM, which

firm IBM until 2025. Making this decision early creates more

has been in place since 2017: “The joint work has helped to drive

opportunities for longer-term projects. Additionally, Evonik

forward digital transformation in a targeted manner. Evonik sees itself

will be part of the R&D project for artificial intelligence at the

as a pioneer in digitization in the chemical industry. Our partnership

Massachusetts Institute of Technology (MIT), becoming the world’s

with IBM and our new commitment to the MIT-IBM Watson AI Lab

first chemical company to join.

further substantiate this claim”.

Artificial intelligence is a critical tool for innovation and improvement

During these years, Evonik and IBM have already studied new

in the chemical industry and Evonik is looking forward to joining

opportunities to create a collaborative intelligence between humans

the MIT-IBM Watson AI Lab and its advisory board to help with its

and machines, in pilot projects. Experts now have the ability to

ideas and applications through materials discovery, formulation

access and analyse valuable information in an easy and intuitive

technology, knowledge management and market analysis to advance

way. New connections between data can now be found and chemist

general applications of AI in the chemical industry. At the MIT campus

can intuitively explore and compare formulations and their related

in Cambridge, Massachusetts, experts are studying the potential

properties to find ideas for new products.

uses and effects of AI. “Bright minds from science and business are

Evonik and IBM have also managed to build Artificial Intelligence

working jointly together on digital progress. We are delighted to be

that will further accelerate the research for new materials. Working

part of it,” says Henrik Hahn, chief digital officer (CDO) of Evonik.

in close collaboration with IBM Research, a Deep Neural Network

“The work on artificial intelligence is also a litmus test of what digital

that predicts properties or new formulations for high-performance

systems can do: for example, we are looking at how decisions can

polymers was also developed and trained. These forecasts support

be made better, more systematically and faster with the help of

researchers in their search for new products and solutions.

algorithms,” says Hahn. “Ultimately, it’s about the value AI can add to the company,” he says.

© Evonik

© Evonik

16

For further information: https://corporate.evonik.com/en

N. 69 - MAY/JUNE 2021 - international PAINT&COATING magazine

Henrik Hahn.

BRAND-NEW

Dr. Martin Welp Resigns as Managing Director at Dörken After more than 11 years, Dr. Martin Welp, Managing Director of Dörken Coatings GmbH & Co. KG, has left the company for personal reasons.

A

fter more than a decade, Dr. Martin Welp

management of Dörken Coatings with the support

resigned from his position as managing

of Dr. Gerhard Reusmann.

director at Dörken Coatings GmbH &

Dörken Coatings’ customers will retain their

Co. KG. On February 1st, 2010, the graduated

usual contacts and can continue to rely on the

chemist joined Dörken MKS-Systeme GmbH &

company’s expertise in corrosion and surface

Co. KG, and with his management partner, Dr.

protection, decorative design and tinting

Gerhard Reusmann, developed the company

technology.

into the leading supplier of micro-layer corrosion

“The management and employees of Dörken are

protection system.

saddened to lose Dr. Martin Welp, a real ‘doer’ who

Then, in 2020 he first took over the management

had a decisive influence on the company over so

of CD Color GmbH & Co. KG and Protec

many years,” said Thorsten Koch. “Together with

Systempasten GmbH, and then was appointed

the shareholders, we express our appreciation and

managing director of the newly founded Dörken

special thanks to him - and wish him all the best

Coatings, into which the Dörken MKS, CD-Color and

for his private and professional future.”

®

Protec® companies were transferred.

In order to continue the initiated strategy, Dörken

For further information:

board Thorsten Koch will temporarily join the

www.doerken.com

© Dörken

The drying racks in different colours for which Gimi is famous all over the world.

FOCUS ON TECHNOLOGY

Effective Passivation at Room Temperature: The Pre-Treatment Innovation that Convinced Gimi Monica Fumagalli ipcm

®

FHP Monselice – Freudenberg Household Products, former Gimi Spa, a long-established household goods manufacturer, was one of the first firms to use the nano ceramic surface conversion products developed by DN Chemicals. The aim was providing excellent paint adhesion performance, good anti-corrosion performance, and low sludge production, while working at room temperature for the entire process.

18

N. 69 - MAY/JUNE 2021 - international PAINT&COATING magazine

FOCUS ON TECHNOLOGY

© ipcm

© ipcm

A segment of the conveyor.

D

rying racks are among the most commonly used everyday

made of stainless steel or aluminium and some accessories made

items: a simple object created a long time ago as a practical

of plastic. These products need to be able to withstand a high

solution for hanging laundry, first outdoors and then indoors

moisture degree due to continuous contact with wet clothes, so

in homes with increasingly small areas and no outdoor spaces or

perfect adhesion of the powder coating to the substrate is essential.

with limited terraces and balconies – and, precisely because of these

This explains why we turned to DN Chemicals, a Group specialising

dual characteristics, not easy to manufacture.

in the provision of surface pre-treatment solutions, which is already

Gaudenzio Preti, the Engineering Manager of the company, which is

a supplier to other Freudenberg’s divisions. We urgently needed a

a long-established producer and distributor of household products,

solution for the pre-treatment of steel that would guarantee higher

confirms it: “Clothes drying racks have always been considered

paint adhesion and, at the same time, simplify the management

outdoor products, although their industrial differentiation has led

of our process and the maintenance of tanks by reducing sludge

to the development of different solutions. We distinguish between

formation.”

outdoor and indoor racks, but the latter, although designed for indoor use, must still guarantee a five-year outdoors use without

Gimi, a brand that is present in every home

corroding.” This has an impact on the choice of the most suitable

“Want to bet we’re already in your house?” was the claim of Gimi’s

materials and coatings.

advertising campaign a few years ago – a bet certainly won by this

“Gimi’s drying racks are made of mild steel, with a few exceptions

firm based in Monselice (Padua, Italy), given its brand’s worldwide

international PAINT&COATING magazine - MAY/JUNE 2021 - N. 69

19

reputation and staggering figures, thanks to its million drying racks produced per year.

“Our company was founded in 1970 and it quickly established itself in the household product sector,” explains Preti. “The turning point came in 2016, when Gimi was acquired by German Group Freudenberg, whose Home&Cleaning division, of which we are a part, has 16 plants worldwide.”

The acquisition by Freudenberg brought about a radical change in both Gimi’s production management and sales target.

“Earlier, Gimi manufactured about 1,600 different items, which were becoming increasingly unmanageable in terms of production. Fortunately, we were able to reduce them to ‘only’ 400.”

A never-changing product with an ever-changing structure Drying racks have remained unchanged since they have been devised. “The © ipcm

materials with which they are made have changed and, in the course of their

The pre-treatment tunnel.

industrial development, they have been joined by electrical devices such as dryers, but no product has ever been able to replace them completely. Today, we can see them in the most diverse forms and structures: from the most common, traditional floor-standing ones to the extendable, balcony, tower, vertical, and garden ones, with one or more levels.”

In the Monselice plant, production starts with the steel coils from which tubes are profiled and then welded and cut. “One of the added values of our production is the in-house processing of around 380 km of tubes per day. The convergence of these two production lines creates semi-finished products, which, once loaded onto the conveyor, travel along a 3,8 km-long loop through the cleaning, coating and assembly departments.” © ipcm

Different components entering the pre-treatment tunnel.

20

N. 69 - MAY/JUNE 2021 - international PAINT&COATING magazine

I prodotti specifici diEuropolveriperil

COIL COATING

Europolveri ha creato una nuova serie di prodotti denominati Serie 2 Architectural Flex che è il contenitore di tutti gli articoli idonei per applicazione su nastro continuo (Coil Coating) e lamiere piane (PCM).

Il “Coil Coating” è un processo di preverniciatura in bobina, nato negli anni ‘50 principalmente su nastro di acciaio, che ha cambiato il modo di concepire la progettazione dei prodotti finiti e che, grazie alla sua economicità di lavorazione, si è diffuso a tal punto che oggi si stima che l’80% delle superfici piane come tetti, facciate continue, controsoffitti, pannelli insonorizzanti, grandi elettrodomestici, prodotti per la refrigerazione, etc. siano realizzate partendo da nastri preverniciati.

Zaniolo CdA - 02.21

Powder Coatings series

Architectural Flex Prodotti specifici per applicazioni su nastro continuo Coil Coating

I rivestimenti in polvere Architectural Flex permettono: stabilità di spessore e tinta per realizzazioni architettoniche di grandi dimensioni (> 500 m2), applicazione di 60-80 micron in mano unica, migliore resistenza alla corrosione rispetto a materiali rivestiti in post-verniciatura, processi a ciclo chiuso che non rilasciano inquinanti all’esterno, l’utilizzo di rivestimenti privi di VOC e SVHC (sostanze pericolose come TGIC e metalli pesanti) conservando le caratteristiche tecniche degli enti omologatori/normativi come ECCA (European Coil Coating Association), Qualicoat, GSB, AAMA e totale riciclabilità del prodotto finito e suo recupero.

I rivestimenti Architectural Flex sono altamente customizzati perchè devono rispondere a necessità specifiche di velocità e tecnologia di applicazione e reticolazione calibrando i prodotti in base ai requisiti impiantistici.

Per ulteriori informazioni potete contattare il servizio clienti a: info@europolveri.it

www.europolveri.it

FOCUS ON TECHNOLOGY

Finding the most effective pre-treatment solution The difficulties faced regarding the adhesion of powders to the tubes’ surfaces were the main reason that pushed Gimi to look for a new pre-treatment solution. “We want to provide our

Get more from water

customers with objects that are impeccable in terms of corrosion resistance as well,” states Preti. “We are aware that our products feature a few critical areas in terms of paint adhesion, such as the holes we use to hang the semi-finished products onto the conveyor’s racks and the tubes’ joints. Indeed, in order to check our paint adhesion performance, we carry out rigorous tests in a humidistat and a salt spray chamber: it was during these tests that we realised that the results could be improved. Out of the suppliers which established a partnership with Freudenberg, we chose DN Chemicals, as it was already operative in the plant in Mombello Monferrato (province of Alessandria). Their innovative products convinced us not only because they achieved perfect adhesion results in our tests, but also because they guaranteed a process that was considerably more sustainable than our previous one, as well as facilitating system maintenance and reducing operating costs.”

“Our old pre-treatment plant,” indicates Gimi coating department manager Michele Melloni, “included a metal phosphating operation. Due to our high production volumes, this created a huge amount of sludge to be disposed of from our tanks of about 35,000 litres and required high energy consumption. Thanks to the solution offered by DN Chemicals, we now use a degreasing

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

© ipcm

The outside of the pre-treatment tunnel.

Beware of imitations, buy the original!

info@waterenergy.it

www.waterenergy.it

process with a mixture of surfactant products operating at room temperature, thus avoiding the formation of foam. The process then includes a rinsing phase in mains water and a conversion phase based on zirconium salts to prevent oxidation.”

“The product supplied is called Dollcoat ZR 114 and it falls into the category of nano ceramics,” notes DN Chemicals sales executive Roberto Rebuffo. “Gimi was one of the first companies to use this particular product, which has the advantage that it can be used at room temperature. The potential of this innovative technology is interesting especially for surfaces that are not heavily contaminated by oils, calamine, and other difficult-to-remove pollutants, as is the case here. This innovation will certainly see further important developments in future, especially if used in conjunction with © ipcm

surfactants to be added to the degreasing solutions that provide excellent performance

Workpieces drying after pre-treatment

at temperatures above 15 °C.”

The advantages of the new pre-treatment technology “Already four years ago,” says Melloni, “we abandoned phosphodegreasing. Thanks to this nanotechnology pre-treatment process, we have now been able to reduce energy consumption in this delicate production stage while obtaining higher quality results. This is proven by our salt spray tests, where we achieve 200-hour values, the 50% reduction in sludge production, which avoids frequent change over of our sedimentation tanks, and the extension of our pre-treatment baths’ service life from 6 to 12 months. This, in turn, reflects on the system’s maintenance, which has become less frequent and easier to manage.

“A further energy-saving step has been taken with the introduction of nano ceramic passivating products, which guarantee © ipcm

One of the coating booths with a Lesta articulated robot.

22

N. 69 - MAY/JUNE 2021 - international PAINT&COATING magazine

excellent performance while operating at room temperature. Finally, in order to

FOCUS ON TECHNOLOGY

optimise waste water management, about four months ago we

control panel in both automatic and semi-automatic modes.

installed a filter press supplied by Water Energy (San Pietro in Casale,

“During daily operation, the pre-set waste water flow is constantly

Bologna, Italy), a company specialising in water treatment solutions

filtered and then returned to the treatment tunnel. In this way, most

with which we have worked for a long time.”

of the sludge created during the work cycle is immediately removed

“It is a fully automated solution designed to keep the phospho

from the phospho degreasing bath. Then, at the weekend, a pump

degreasing bath continuously filtered during the working activity,”

is activated to transfer the entire waste water volume into a suitably

explains Water Energy owner Tommaso Ponara, “while, at the same

sized, truncated cone-shaped tank from which, after a certain

time, enabling to perform one-off filtering operations on the entire

period, the liquid is returned to the bath through the filter press. The

waste water volume to keep it perfectly purified. The semi-automatic

residual sludge in the conical part of the tank is then also removed.

system provides for the automatic forward and backward movement

The final filtration stage is controlled by the differential pressure

of the hydraulic cylinder by means of a hydraulic control unit and

switch. The safety guards consist of photoelectric curtains applied on

control panel. Opening and emptying is controlled by the electrical

both sides of the operating area.”

© ipcm

© ipcm

Frames exiting one of the 5 one-colour booths.

The curing oven.

international PAINT&COATING magazine - MAY/JUNE 2021 - N. 69

23

© ipcm

© ipcm

Handling of parts along the 3,8 km-long loop circuit.

Coated frames.

© ipcm

One of the most complex segments of the conveyor.

24

N. 69 - MAY/JUNE 2021 - international PAINT&COATING magazine

© ipcm

The detail of the filter press installed by Water Energy.

FOCUS ON TECHNOLOGY

Characteristics of the coating plant

entire production department in general and

The Power&Free conveyor provided by Conveyors

our surface treatment area in particular in the

Nord Srl (Inzago, Milan, Italy) picks up the parts

most appropriate way – from the revamping of

after the pre-treatment tunnel and it takes

the conveyor, which attains its minimum speed

them to the coating plant. “Installed in 2001,

precisely in the coating area and for which we

the conveyor is the core of our production

are planning to switch to the RFDI technology, to

department,” says Gaudenzio Preti. “The conveyor

the reduction of our powder consumption levels,

handles about 630 trolleys, which complete the

which currently stand at several tonnes per day.”

circuit in around 2 and a quarter hours.”

The intention is also to implement a fully

The coating system is equipped with both

automatic control system for the pre-treatment

automatic and manual booths. These latter ones

phase. “In this regard,” says DN Chemicals sales

are usually used for complex-shaped parts.

director André Bernasconi, “we have offered

“When production was transferred to the current

to Gimi an automatic process control system

plant,” explains Melloni, “we installed two 6-axis

through data logging. It will thus be possible

LeBot A6 series robots and one 5-axis R500

not only to trace every batch in real time, but

series robot produced by Lesta (Dairago, Milan)

also to retrieve any recorded data for the

for coating the simplest components, such as the

already pre-treated products. Finally, in order to

drying racks’ legs; the remaining parts are coated

further improve the adhesion of coatings to the

automatically. Each booth is equipped with 14

substrates, together with Gimi’s management

guns, which we are considering to replace in

we have planned to integrate an osmotic rinsing

future. In fact, we are assessing the possibility to

phase at the end of the pre-treatment tunnel.”

implement the dense phase technology, thanks

“Freudenberg’s acquisition also resulted in some

to which we may achieve 20% savings. We use 5

changes in our relationships with suppliers,”

of the 7 booths for monochrome white and grey

states Preti. “As a multinational company, its

applications and the other 2 for different tints.

management wants to deal with same-level firms.

The epoxy or epoxy-polyester powder coatings

This is also why we started working with DN

must comply with the parameter of 75-micron

Chemicals, which has lived up to our expectations

thickness. The workpieces are then cured in an

and with which we will continue to collaborate by

oven at 190 °C for 25 minutes and then unloaded

testing their most innovative products.”

and sent to our 3 assembly lines, producing a finished drying rack every 2 seconds.”

The future of Gimi The continuous updating of products and machines belongs to a wide-ranging project designed to maintain the company’s production standard up to the reputation by which Gimi is known throughout the world. “The Freudenberg Group has required a technological upgrade of the equipment used in our plant, considered outdated. In view of the huge production volumes that we will have to manage in the coming months, when we expect a strong increase in demand for our more specialised products, we have decided to switch from two to three shifts. In order to do so, we need to equip our

BRAND-NEW

Covestro Completes Acquisition of Resins & Functional Materials Business from DSM Covestro succesfully completed the acquisition of the Resins & Functional Materials business (RFM) from the Dutch company Royal DSM.

W

ith the aim of becoming one of the the leading global suppliers

manufacturing, and an advanced solar coatings business. In addition,

for sustainable coating resins and further expanding its

Covestro is enhancing its technology portfolio to include water-based

portfolio, Covestro acquired DSM’s Resins & Functional

hybrid technologies, powder coating resins as well as radiation curing

Materials business.

resins.

The transaction received regulatory approval after Covestro and DSM

“With this transaction, we are strengthening our extensive portfolio with

signed an acquisition agreement in late September 2020. The integration

further innovative products and technologies that will enable us to meet

of RFM will expand the Group’s revenues by around EUR 1 billion and will

our customers’ needs in optimal fashion. Now our focus is on integrating

add more than 20 sites to its global production network.

the teams, leveraging talent and providing the best possible support for

“The acquisition of RFM significantly contributes to the implementation

our new and existing customers”, adds Sucheta Govil, Chief Commercial

of our new Group strategy. With this transaction, we are taking another

Officer at Covestro.

important step towards sustainability, while at the same time generating

Following a comprehensive analysis, Covestro expects permanent

sustainable growth,” said Dr. Markus Steilemann, CEO of Covestro.

(“run-rate”) synergy effects to build-up to about EUR 120 million per

“We are looking forward to meeting our new colleagues and warmly

annum from full integration by 2025. These consist of approximately

welcoming them to Covestro.”

two-thirds of cost and one-third of revenue synergies.

Through the acquisition of RFM, Covestro is adding to its portfolio a complete range of water-based polyacrylate resins, as well as strong

For further information:

brands in terms of sustainability such as Niaga , solutions for additive

www.covestro.com and www.dsm.com

®

© Covestro

26

N. 69 - MAY/JUNE 2021 - international PAINT&COATING magazine

made

in Ita ly

BRAND-NEW

SAT Presents the C-Expert Powder Coating Booth

FOR. . TEC SRL

Senza titolo-5 1

22/01/2014 12:08:51

The new C-Expert booth is designed for powder coating of profiles with complex geometries and is perfectly integrated with the new SAT VISI-1 vision system for automatic powder coating.

S

AT has launched the new C-Expert powder coating booth specifically designed to efficiently and uniformly coat profiles with complex geometries, even at high speeds.

Due to the increasing average weight of profiles and the complexity of geometry in the architecture sector, companies are often forced to vary the speed of the conveyor on the vertical line. The new booth, on the other hand, allows to maintain a constant speed. This implies a greater production capacity and a significant reduction in waste. C-Expert is also perfectly integrated with the new SAT VISI-1 vision system for automatic powder coating, allowing repeatability of results and coating efficiency.

“We are convinced this booth is a game-changer for high-end and demanding markets. It’s the best vertical booth SAT has ever designed”, said Andrea Trevisan, CEO of SAT. For further information: https://c-expert.com and www.sataluminium.com

© SAT

PAINT STRIPPING OVENS Forni pirolitici per termosverniciatura e...

Sverniciatura bilancelle

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Rigenerazione motori elettrici

Pulizia estrusori

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Hooks paint stripping

Gas tanks paint stripping

Electric motors regeneration

Extruders cleaning

Body work restoration

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mail: info@fortec-inceneritori.it web: www.fortec-inceneritori.it

?

HOW IT’S COATED

Seeing Beyond the Ordinary: Exclusive, Increasingly Customised Finishes for Raleri’s Eyewear Interview with Francesco Rambaldi, CEO of Raleri Srl

From motorsports to sunglasses and eyeglasses, Raleri’s products constantly evolve through the development of more and more original and customised solutions, obtained through 3D printing and the use of innovative finishing technologies.

Raleri established itself in the eyewear

Already in the early 1990s, the design studio

electronic components to match this project,

sector by developing a very specific

which I founded had been recognised for its

have led me to gain experience in countries

product: tinted visors for motorcyclists.

skills in the 3D modelling of turbines for some

such as Japan and the USA, which are known

Can you briefly describe how did

Italian energy companies of international

to be at the cutting edge of technology. At the

you start this project and how your

standing. At that time, I had the idea of

same time, an analysis of the optics sector,

company has evolved to gain its current

wearing a helmet with an automatic electro-

targeted at creating the best product on

technological expertise?

dimming visor, which would make riding

the market, has led me to acquire in-depth

The idea came from my passion for

his motorbike much safer and much more

knowledge, in order to begin producing top-

motorbikes, combined with my work

pleasant.

quality items such as lenses for sports goggles

experience in the technology and IT sector in

Several trips abroad, aimed at seeking out

or spectacles, as well as lens supporting

particular.

manufacturers and suppliers of LCDs and

structures.

© Raleri

28

N. 69 - MAY/JUNE 2021 - international PAINT&COATING magazine

?

HOW IT’S COATED

Raleri’s range currently includes products for

prompted us to use 3D printing for spectacle

different sectors, from sport to fashion. Could

frames as well. The finishes we use have been

you describe their standard production cycle?

specially designed for this kind of product to make

Raleri employs several people with vertically-

it even more distinctive and unique.

integrated expertise and skills ranging from 3D design to IT and from marketing to product

In contrast to commonly used 3D printing

development, all united by the passion for extreme

processes, Raleri prints its glasses directly

sports such as mountaineering, parachuting, and

in colour. Can you explain in detail how

obviously motorsports. Here, we can personally test

this works and what subsequent surface

our products, which are then either sold under the

treatments are required?

Raleri brand or made with private labels for different

We use the brand new HP MJF 580 printer that

industry brands.

allows printing directly in full colour, thus making

Regardless of whether the project is based on a

the process much faster. It is all about creating the

customer briefing or on our own idea, we always

right print job to give the final product optimum

entrust different professionals with the various

performance in terms of resistance.

aspects of the production cycle, including design,

We can then apply different physical and chemical

3D modelling, prototyping for approval of the final

treatments depending on the effect we want to

product, and actual industrialisation, which can be

achieve.

carried out in our production facilities in Italy or at the customer’s premises. Raleri takes care of the

What future do you think this new printing

entire production cycle up to the delivery of the end

technology will have and how will your

product or the fine-tuning of production in the end

products’ surface treatment evolve in

customer’s plant.

relation to it?

There is no doubt that 3D printing is the future,

How important is the surface treatment of

when it comes to manufacturing personalised

your products, from cleaning to finishing?

products. In particular, the needs of customers

With 3D printed objects, surface treatments such

requiring products made from digitally produced

as cleaning and finishing are very delicate, but

models are changing. The impact of professional

essential steps in order to be able to offer superior

3D printing is evident on the production processes

quality products with highly customised finishes.

implemented for prototyping, but also on

To date, we believe we can implement a few

integrated logistics processes, because it enables

unique processing stages on our products, such as

to manufacture a few parts in a very short time and

ultrasonic cleaning or microblasting, deep coating to

at an acceptable cost, compared with other options

obtain a different colour effect from the one offered

on the industrial market.

by the printer, and vibro finishing and semi-gloss

3D printing can therefore bring clear advantages

finishing to achieve unique results on the treated

over conventional production methods for

surfaces with aged wood, volcanic pumice stone, or

everyone, as it enables an idea to be transformed

soft touch effects.

into a finished product starting from a drawing

COMPLETE SOLUTIONS for

HANGING and

MASKING

made on a home or office computer.

You have recently implemented a new technology for manufacturing glasses with

For further information:

complex finishes: 3D printing. What was the

www.raleri.com

reason for this integration?

Its infinite potential for creating unique, customisable pieces was the basic reason that

www.rostirolla.it

© Mr.Whiskey/Shutterstock

ANALYSIS

Three Colour Management Technology Trends to Follow This Year Rik Mertens Datacolor AG Europe – Dietlikon, Switzerland

rmertens@datacolor.com

In the paint and coatings industry, colour consistency can be difficult to get right, in large part because we all interpret colour differently. The integration of a digital colour management workflow eliminates the potential for mismatched colour associated with visual evaluation and ensures accuracy, enabling an effective and streamlined colour control process.

T

he subjectivity of visual colour measurement increases the risk

The implementation of digital colour management tools

of errors during the paint and coatings production process, and

The adoption of digital colour management positively impacts supply

inaccurate colour measurements can delay production and lead

chains for many industries by reducing the time and costs of product

to increased business costs.

development, and paint and coatings is no exception. Digitalization is

Since products delivered by paint and coatings manufacturers are held

proven to increase speed to market by adding objectivity to the colour

to the highest industry standards, fast and accurate colour matching

management process, and it prevents time-consuming errors by enabling

is fundamental. A comprehensive digital colour management strategy

the virtual communication of digital colour standards globally.

positions manufacturers for success – saving time and resources and

A digital colour workflow usually includes hardware and software

increasing speed to market by enabling them to get colour right on the

components working together to ensure colour accuracy. One of the most

first try.

important tools is a colour measuring instrument or spectrophotometer.

Here are three trends driving colour management technology, which

Spectrophotometers measure light reflected or transmitted across the

will be particularly relevant as the industry prepares for an adjustment

visible spectrum and compare it to reference samples.

to post-pandemic normalcy.

Spectrophotometers also provide spectral data that can be used to

30

N. 69 - MAY/JUNE 2021 - international PAINT&COATING magazine

ANALYSIS

calculate tristimulus values for various conditions and calculate colour

are able to meet tolerances using numbers, eliminating the time and

recipes for commercial colour matching. Modern spectrophotometers

expense of physical sample shipment. This is crucial for effective virtual

take precision to an even higher level by measuring the temperature

communication among paint and coatings companies with employees

of the sample that can influence colour perception, preventing wrong

spanning the globe.

colour decisions within or out of specifications due to temperature variations.

The rise of cloud-based software and big data

To be effective, spectrophotometers must consistently agree in their

In addition to embracing sophisticated colour management

measurements. Fortunately, colour management technology has

equipment, we are also seeing a rise in the use of state-of-the-art

advanced over the years to improve inter-instrumental agreement

software. The debut of artificial intelligence, advanced new sensors

(IIA). IIA references how closely two or more colour-measurement

and cloud computing is modernizing colour management across

instruments of a similar model read the same colour. The closer the IIA,

all sectors of the paint and coatings industry. In industrial paint and

the more likely colours will be consistent across products, materials, or

coatings, cloud-based software allows professionals to share colour

locations. The precision of IIA in newer spectrophotometers is so high

measurements straight from the job site, and in in the retail sector it

that no relevant deviation can be detected from one device to another.

facilitates seamless communication between painters, consumers and

Additionally, the recent introduction of advanced colour management

paint shops.

devices like hyperspectral spectrophotometers allows us to measure

Throughout the paint and coatings industry there continues to be a

items such as very small components and multicoloured, multitextured

need for data-based decisions to drive production. The introduction

samples that were previously “unmeasurable” with traditional

of cloud-based software now enables professionals to predict trends,

spectrophotometers.

push out promotions and balance inventory utilizing all the colour

The digitalization of the colour management process also enables

data stored in the cloud. On a larger scale, cloud-based software

instant communication of data across the world. With the subjectivity of

is closing the gap between how big data is analyzed and how it can

visual colour measurement removed, this data can prove whether you

inform critical industry decisions. Importantly, the cloud also ensures

consistency and quality. Users can identify errors and take action to

spectrophotometers enable colour measurement data to be sent

fix them in real time – providing reassurance that they always have the

within seconds wherever needed for matching. This is particularly

latest information from whichever device is used to recall it.

relevant for coatings professionals for whom the hassle of preparing

The implementation of cloud technology also mobilizes solutions,

and shipping physical samples is eliminated, since colour can be

improves speed to market and streamlines colour professionals’

measured anywhere at any time. Automated colour measurement also

interaction with the colour control process. It allows paint and

helps paint and coatings professionals get colour right on the first try,

coatings professionals to reassess how they manage colour data and

guaranteeing quicker speed to market.

ultimately increase customer satisfaction. Cloud-based solutions are

Newer portable colour matching devices also work in real time with

also optimized for the future – created to grow, expand and reform

apps, allowing users to search colours and create palettes on their

themselves to fit the changing needs of the marketplace.

phones. These devices are trained with machine learning techniques, enabling a correlation between 45/0° and d/8° spectrophotometers,

The movement to portability

providing paint and coatings professionals with cost-effective colour

Portable spectrophotometers have evolved tremendously in recent

measurement solutions that can be easily integrated with their existing

years. In fact, their performance is now so high that they can be readily

colour management software.

used as a benchtop replacement when there is a need to take colour

Modern portable colour measurement devices also offer great IIA

matching on the go. This makes them particularly useful for painters,

with benchtop equipment. This is crucial for colour experts across

retailers and manufacturers.

the globe relying on portable devices to efficiently communicate with

Portable devices enable painters to quickly identify and share their

one another, as well as with benchtop equipment – to ensure existing

colour choice with any paint retailer, anywhere in the world to get

colourant sets or pigment databases do not have to be remeasured

paint made without the shipment of physical samples. For retailers

every time.

in paint shops, portable devices make it easy to work away from the

While accurate colour measurement can be challenging, modern

counter. The smaller and lighter devices allow them to measure large

tools and technology help experts establish an effective workflow by

samples that are too big to be brought inside, such as door frames

ensuring consistency. Pandemic-fueled changes to the industry have

or siding transported by truck. Lastly, sales representatives for paint

highlighted the importance of digital colour management to ensure

and coatings manufacturers no longer need to physically carry fan

speed to market, and as talk of returning a “new normal” continues, the

decks, which are expensive to produce and update, since they are now

efficiency offered by digitalization will likely remain extremely important

available on mobile devices. Furthermore, portable instruments make

to the success and productivity of paint and coatings professionals.

it fast and easy for them to identify available colours.

Even in a post-pandemic world, the ability to streamline colour

Today’s portable spectrophotometers allow colour measurements to

management globally will be critical for quality production in the paint

be made anywhere without sacrificing accuracy. Even better, they are

and coatings market. Its importance will only grow as technology

convenient, easy to use and fast. Additionally, some types of portable

continues evolving to meet the industry’s ever-changing needs.

© Datacolor

High end benchtop spectrophotometer.

32

N. 69 - MAY/JUNE 2021 - international PAINT&COATING magazine

© Datacolor

Portable spectrophotometer.

© Datacolor

Portable look-up device.

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© IM GROUP

P96 dispensing head.

HIGHLIGHT OF THE MONTH

Inkmaker Group Rebrands as IM GROUP in Conjunction with World Earth Day Edited by IM GROUP San Gillio (Turin), Italy

O

n 22 April Inkmaker Group became IM GROUP. The official

systems and processes, its software, the technology it uses and how

launch - in the planning for approximately two years - was

it uses it to its global teams around the world – and most significantly

filmed on location, at Inkmaker’s Headquarters in Turin, Italy,

externally. In fact, after acquiring several companies since 2019,

which are now also the headquarters of IM GROUP. It was screened

combining expertise, intel, technology and hardware, Inkmaker’s

for private viewing on World Earth Day and for public viewing

strategy was to consolidate all its brands under a single holding group

thereafter on You Tube, throughout the media globally and on the

brand, originally known as Inkmaker Group.

group’s brands websites.

From 22 April the group has been rebranded as IM GROUP, with its

The Group has been evolving on many fronts, both internally - from its

own distinct identity, to better compete in the marketplace as a total

34

N. 69 - MAY/JUNE 2021 - international PAINT&COATING magazine

HIGHLIGHT OF THE MONTH

solutions provider.

result of its core values of being Truthful,

“The decision to rebrand Inkmaker Group

Responsible, Understanding, Safe and

as IM GROUP - said Christophe Rizzo, CEO

Tailormade to ultimately position the group,

EMEA/Americas, IM GROUP - stems from

as the leader you can TRUST.”

the group’s VISION, which is to evolve our the advantages of our products, to new

How this evolution is affecting operations in Asia Pacific

markets. Since October 2019, Inkmaker has

IM GROUP is evolving on all fronts and in all

made large investments, on the acquisitions

its locations globally. “We have expanded our

of the businesses of Rexson and Valtech, in

premises in Malaysia, to house our Tinting

UK; Tecnopails, in Italy; and most recently

and Engineering brand, Teko together with

technology to expand in our fields and adapt,

Swesa, in Germany. The driving strategy

Inkmaker” - Roberto Guerra, CEO Asia Pacific,

behind these acquisitions was to create a reliable complete supply chain - serving predominantly, but not only, the ink, paint

© IM GROUP

IM GROUP, said. “In Thailand, this year we just opened a sales and service office, with

Inkmaker’s founders.

our own staff. We are gaining market share

and coatings industry - to sustain our core

in Philippines. The big one of course is China,

businesses. This meant restructuring our

and its credo” – explains Silvio Cimenti,

suffice to say that due to our larger premises

brands into various specialities, yet to still be

Global Director of Branding, Marketing and

we can now double the number of standard

one strong force, hence the need to rebrand

Communications, IM Group. “The symbol

machines we ship monthly, from an average

the existing Inkmaker Group brand, to have

is a face created from a series of triangles

of 5 or 6 units to 10 to 12 ink and paint

an identity of its own, as an autonomous

inspired from the Inkmaker logo in blue

dispensing systems. More importantly, the

holding brand. This is the evolution of

to convey trust, confidence and high-

real added value for us, is the capability to

Inkmaker Group, which is essentially that of

technology. The triangles converge, like the

build more complex units, which is where IM

Inkmaker”.

many brands and skills of the Group, to form

GROUP’s R&D is investing a lot of resources.

Due to its acquisitions, Inkmaker grew

a strong whole - a distinct ‘human identity’ -

Smart factory and Industry 4.0 are driving

by 25% globally. Taking into account the

depicting a technological engineering leader

our growth and when you build complete

current challenges the pandemic has caused

with a ‘human touch’. The face is embellished

production lines for a paint and ink company

this is still on track with its vision. Having

with a crown, representing the Group’s

it’s important to have enough space to work

the holding brand IM GROUP to steer all

determination to maintain its leading

in total safety.”

speciality brands, the company foresees all

position in the industries it serves. The

In Shanghai, the IM GROUP expansion

its brands to grow exponentially.

symbol is flanked by the words “IM GROUP”,

plans have already been brought forward.

“The name “IM” has a historical meaning for

in a custom designed font to communicate

“In April 2020, we were in the news, when

us” - Valentina Cigna, Global Director of HR

the Group’s various fields of business such

we expanded our facilities to double the

and President of IM GROUP, explains. “The

as paint, coatings, ink, speciality-chemicals,

size of our previous production area” – says

‘I’ and the ‘M’ are acronyms deriving from

adhesives and much more. Below the

Lau Kar Seng General Manager, Inkmaker

the name “Inkmaker”, the founder of the

logo, in steel grey, the Group’s credo and

Shanghai and Board Member of IM GROUP.

group, and it meant a lot to us to remember

positioning line; “The Colour of Trust”, a

“At the time it was at the height of the

those who, in 1987, founded Inkmaker: Carlo

Covid-19 pandemic, but we had to do it to

Musso, Luciano Longobardi and - especially

meet the escalation in demand. The move

for me - my father, Giuliano Cigna. He would

has resulted in being hugely beneficial to us.

have been very proud of this moment.”

Bigger premises mean we can manufacture more machines and can now offer a greater

The new logo

variety. We are already offering customers

The rebranding also entailed the creation of

the entire portfolio of our brands. So, for

a new logo, able to communicate the values

us the new IM GROUP brand will certainly impact business positively, in China. It

and mission of IM GROUP. “The logo is made up of a symbol, a logotype

The logo of IM GROUP.

creates a platform for us to promote all our

international PAINT&COATING magazine - MAY/JUNE 2021 - N. 69

35

© IM GROUP

Interior of a dispensing head.

© IM GROUP

Dispensing valve detail inside the dispensing head.

brands individually, or working in unison with a single focus, as a total

goodwill ambassador, Alice Guerra, as foundation chair. It will have 2

solutions provider.”

scopes: to bring social activities, to members of the local communities,

The commitment to social responsibility and sustainable practices

where IM GROUP operates and to offer career development, and growth opportunities to the youth in those communities.

“On a private level, we have always been active in this field, especially

A safe work environment is certainly high on IM GROUP’s agenda,

in South-east Asia, working closely with children with special needs

along with technology but the Group is also evolving the way in which

through workshops and activities” says Cigna. “Now we will be bringing

its products are impacting the environment, its carbon footprint.

this activity to the next level and into our IM GROUP.”

“This is precisely the reason that we chose to launch IM GROUP on the World Earth day”- states Valentina Cigna. “We are making a global

Becoming a total solutions provider

statement of our commitment to further our social responsibility and

The acquisitions carried out throughout the years derived from the

sustainable practices. To action this, IM GROUP is partnering with

group’s goal of transforming IM GROUP into a total solutions provider

Deloitte to create a roadmap to reduce our eco-impact - the current

for total process engineering.

resources we use and waste we create - so we too can do our part in

“Being a total solutions provider is our mission, and this is precisely

reducing environmental pollution. And to align our ethical principles

why we acquired the brands that we did” – states Gianluca Incerti,

for a safe work environment with those of the United Nations’ Global

Global Commercial Director, IM GROUP. “Our strategy is to create

Compact1.”

“areas of excellence” dedicating each of our brands to a specific

Additionally, the group is forming an IM GROUP Foundation, to be

expertise, that can come together—like our logo—to form a strong

ready by end of this year, which will be followed by IM GROUP’s

force. Each brand can still work individually with its existing clients in its own markets and when required share their expertise—offering

1

https://www.unglobalcompact.org/what-is-gc/mission/principles

36

N. 69 - MAY/JUNE 2021 - international PAINT&COATING magazine

Total Solutions—for example on large turn-key plant engineering

HIGHLIGHT OF THE MONTH

projects. This guarantees resource optimisation and high flexibility to manage projects of all sizes. This was one of the key reasons for forming the holding brand, IM GROUP, in the first place. For example; Rexson and Vale-tech had their own unique technology, now, that we are one large team, we are consolidating each brand’s strength and combining, resources, technology and software and we can take a tremendous advantage in the integration with Inkmaker to offer state of the art solutions.”

Clean Efficient Versatile OptiCenter® OC09

With the restructuring of its own brands Inkmaker will focus on ink dispensing and software design; Rexson will be predominantly for paint as well as liquid ink, Vale-Tech will focus on narrow-web and paste-ink dispensing—so UV flexo ink and offset inks; Swesa mainly for food, pharmaceutical, corrugated packaging, cosmetics and more; Teko will remain in POS Tinting and R&D Training and Tecnopails for Filling Solutions.

“Externally, we believe this decision, makes it clearer for our clients to differentiate our brands, and their purposes. Internally, for us, we can focus our R&D attentions on developing that brand’s expertise.” — continues Incerti. “Dividing the market-sectors across each brand, was one of the key factors in the creation of IM GROUP brand and will be an important advantage, to differentiate the GROUP, in the market. Another such advantage, which has been playing a major role since the acquisitions, is Inkmaker’s legendary software”.

Inkmaker’s Software, the brain behind IM GROUP A significant investment has been made into the Software & Automation division purposely to ensure, not just a smooth transition with new brands in the family, but also to increase the level of our technological capabilities. Inkmaker’s software is the essence of the company’s systems and by incorporating them into the newly acquired brands’ machines, it elevates the productivity and performance of those brands to a much higher and more energy-efficient level.

“Inkmaker’s software, now known as IM GROUP’s “IMAESTRO” was designed inhouse by our Software team” explains Francesco Nesti, Global Director of Software & Automation IM GROUP. “It has always defined us as a leader amongst our competitors, therefore it plays a major role in the operational execution of IM GROUP’s global strategy. We have since expanded our software line to another one, called IMPRIMO, which we recently released with our Inktransfer/supply system, Inktrasyst, and another three are under development, planned for release by next year.”

Make color change work for you!

OptiCenter OC09 is the gateway solution for low to medium powder consumers seeking to improve powder utilisation efficiency of their multi-color processes, by eliminating multiple fluidised hoppers and reducing operator involvement. The system stands out through its clean color change and extensive range of upgrade option to adapt to future process and production demands.

On a customer service level, earlier this month the Software & Automation team launched a new training programme for customers called ASIST—Advanced Software Intelligence Systems Training—which combines IoT automation and artificial

Gema Europe Srl | Via Goldoni, 29 20090 Trezzano s/N | Italy T +39 02 48 400 486 F +39 02 48 400 874 gemapowdercoating.com

intelligence, with the skills

15 years. With my technical

© IM GROUP

of IM GROUP’s experts, to

team, we have been studying

boost the training level of

the various machines, of our

our systems. The programme

brands, their capabilities

consists of four certifications,

and performances and their

known as CMYK, and covers

related market positionings.

many new features from

In order to meet

the group’s basic machine

this—market-segment

structures to in-depth

distribution—several

workings of its software and

machines were removed,

offers techniques to improve

while others have been

efficiency, reduce costs and

re-designed to meet higher standards of mass

shorten response time to market demands.

IM GROUP Team during the event.

customisation, reliability and performance and to

Machinery developments

give wider and broader solutions to our customer’s needs. One

“Our global strategy is to offer “Total Process-Engineering” to

such example is that we are integrating and upgrading the whole

our clients worldwide” – says Enrico Mattiazzi, Global Director of

Rexson and Vale-tech product range to improved versions. Others

Engineering, Production and Supply Chain, IM GROUP.

are planned for upgrades throughout the year. The most important

“Therefore, our acquisitions are part of that strategical plan to reach

feature of this re-engineered and integrated range of machines is

that goal, and consists of re-organising and broadening our product

the synergy with our IMAESTRO software that will greatly benefit our

range to ensure our Group’s growth sustainability for the next 10 to

clients.”

© IM GROUP

38

N. 69 - MAY/JUNE 2021 - international PAINT&COATING magazine

SUCCESS STORIES

Tapematic Installs the First PST Line II in Italy at Metal Tech Italian manufacturer of in-line fully automated UV varnishing and metallization equipment Tapematic has installed the first PST Line II in Italy at Metal Tech Srl, an industrial coating contractor. present, we have still decided to expand the

successful installation of the in-line 3D

services offered to our clients, by investing

sputtering coating system PST Line II at

in a Tapematic PST Line II” declares Silvio

Metal Tech Srl (Palazzolo Sull’Oglio - Brescia), a company specialized in spray coating and

© Tapematic

T

apematic Spa announced the

Martina, Metal Tech’s Chief Operating Officer.

“For many decades, Tapematic has designed

decoration for cosmetic packaging, food &

and built in-house high-quality industrial

beverage, as well as household appliances

equipment dedicated to the decoration of

and automotive products.

packaging. Having known Tapematic since

The new PST Line II is a modular system

2010, we have monitored their progress in creating reliable and cost-effective inline

which allows in-line sputtering and UV the finest quality products, together with

sputtering and UV coating equipment. In

friendliness.

significant benefits for them in terms of

early 2020, I first saw the PST Line II, and

“It’s a pleasure for us to collaborate with

efficiency and environmental protection.”

immediately realised that this was the

an Italian excellence like Metal Tech” says

The installation has been completed, and

equipment that would have allowed us to

Davide Perego, Tapematic’s Chief Operations

Metal Tech has already started offering their

offer the quality requested by high-end

Officer. “The Tapematic PST Line II is the

customers this service of Inline Sputtering

customers, and in a green and cost-effective

perfect answer for the needs of inline

and UV coating, utilising the top of the range

way”.

sputtering, UV coating and decoration to

Tapematic equipment; thereby allowing

the highest standards of cosmetic packaging

unbeatable final quality, high output, and

requirements. The PST Line II will allow

importantly, all in an eco-friendly way.

For further information:

Metal Tech to offer to their end customers

“Despite the difficult global situation at

www.tapematic.com

© Tapematic

coating, ensuring cost-efficiency and eco-

40

N. 69 - MAY/JUNE 2021 - international PAINT&COATING magazine

NORTH AMERICA’S LARGEST METAL FORMING, FABRICATING, WELDING AND FINISHING EVENT

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© Rembrandtin Coatings GmbH

INNOVATIONS: PRESENT&FUTURE

Large Choice of Colours and Functionality for Long-Lasting Beauty of Fireplaces Rikarda Breckner Rembrandtin Coatings GmbH – Vienna, Austria

rikarda.breckner@rembrandtin.com

Rembrandtin supports fireplace manufacturers with innovative coatings and new design options.

I

n the past, fireplaces were simply used to heat the rooms where people lived. Manufacturers of fireplace coatings focussed only on the functionality of the coatings – while accepting limitations with regard

to appearance and design. Coatings producer Rembrandtin has been developing fireplace coatings in many colours for many years. With its innovative coating systems, Rembrandtin managed to combine functional and aesthetic properties in a top-quality coating. The new High Scratch Resistant System ensures that fireplaces and pellet stoves remain decorative elements in living areas for a long time and they offer many benefits to manufacturers and end users.

Temperature resistance, adhesion, and corrosion protection are standard properties of a high-quality fireplace coating. Today, a fireplace is more than just a plain piece of equipment – in modern architecture, it is an elegant eyecatcher and a stylish accessory. Designs are numerous and the small choice between black and grey fireplaces does not any longer satisfy customer demands. Therefore, the experienced coatings producer Rembrandtin formulates innovative fireplace coatings and opens up completely new design options. The latest development is a new High Scratch Resistant System which is available in specific colour shades and even with special effects such as metallic or pearlescent for fireplaces and stoves. The new system is compatible with fireplace refinishes in spray cans.

The innovative two-component fireplace coating provides colour retention up to 650 °C. This brand-new product stands out because of the glass-hard, high-gloss surfaces combined with an easy-to-clean effect.

With a high solid content of 60–80%, this coating meets the increasing environmental requirements (VOC, high solid content) and therefore is a trendsetting product.

Offering a large choice of colours, high gloss and high surface hardness, the High Scratch Resistant System is ideally suited for decorating pellet stoves, fireplaces and in general all decorative parts exposed to high temperatures.

This product helps fireplace manufacturers to further optimise production

INNOVATIONS: PRESENT&FUTURE

processes. The coating can be applied with the existing equipment,

and oxygen is very high compared to purely organic binders.

i.e. there will be no additional cost for purchasing new machines or

Thus, temperatures of up to 650 °C can be covered. The properties of

equipment. Because of the short drying times at room temperature

a coating are not only determined by the binder, pigments and fillers

processing times can be reduced, and finished products can be

also have an effect. Today, a wide range of colours and special effects

delivered to end consumers immediately after processing.

for stoves can be formulated on the basis of silicone resins. The large

The application makes the difference The new coating system can be applied using air atomisation, airless, airmix or electrostatic procedures. The use of coating machines and

choice of colours unlocks new possibilities for fireplace designers.

Special effect coatings are increasingly formulated with interference pigments.

coating robots is also possible. In the fireplace sector, most coatings

About Rembrandtin and the THERMODUR brand

have to be resistant to temperatures of up to 600 °C. The applied

For decades, Rembrandtin has been a specialist for high performance

coating systems are dried at room temperature or force-dried in order

coatings for niche segments in all industrial sectors, among them high

to be sufficiently stable for transport to the customers.

heat resistant coatings. With the THERMODUR line, Rembrandtin offers

The exposition to high temperatures during the first heating of the

top quality coatings for every high heat resistant application. Renowned

fireplace triggers a curing reaction in the coating system forming a hard,

international producers of equipment exposed to heat stress have been

chemically inert coating film. Due to the optimised formulation, this

counting on coatings innovations from Rembrandtin for many years.

reaction does not produce any odours or fumes.

THERMODUR coatings are economical, functional, and meet highest

Insights into the coating formulation: optimum properties thanks to silicone resins

quality standards. In addition, they open up new possibilities for coating fireplaces, stoves, stove inserts, toasters, etc. As member of HELIOS and part of KANSAI PAINT Rembrandtin belongs to a globally leading coatings

Silicone resins have an inorganic basic structure and therefore are

group and benefits from access to a worldwide service and knowhow

extremely heat resistant because the binding energy between silicon

network, particularly in the field of R&D.

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FOCUS ON TECHNOLOGY

AluCoating Perfectly Tunes in to its Paint Supplier to Manage Small Batches and Prove to be an Italian Coil Powder Coater of Excellence Monica Fumagalli ipcm

®

Two companies with the same customer-oriented vision are paving the way for the development of new plant and aesthetic solutions in the field of coil powder coating: AluCoating, a company extremely dynamic and flexible specialising also in the production of small batches of pre-painted aluminium, and powder coating manufacturer Stardust have created an innovative synergy that goes beyond commercial partnership.

I

n the urban landscapes that we cross every day, we frequently get

its architectural design has been able to integrate seamlessly into its

the chance to lay our eyes on particular structures that differ in

surroundings.

shape and colour from conventional buildings: they are characterised

Thanks to its endless customisation possibilities, one of the

by the alternation of different geometries and the aesthetic impact of

architectural elements that is becoming more and more popular in

their cladding is obtained though original colour effects. Its shape and

the building industry is pre-painted metal, which is increasingly used in

tint are a building’s calling cards, which make it easy to assess whether

cladding, façades, doors, and windows for its aesthetic and functional

© sd partners

The new façade of the San Gerardo Hospital in Monza is made of AluCoating pre-painted panels coated with Stardust powders.

44

N. 69 - MAY/JUNE 2021 - international PAINT&COATING magazine

FOCUS ON TECHNOLOGY

performance, especially in terms of thermal

is another significant factor: currently, for

and acoustic insulation. However, today’s

example, architects tend to prefer matte and

designers also demand an almost unlimited

textured colours that recall natural materials.

range of colours and effects to coat it.

Meeting the most diverse and complex

© ipcm

requirements of architects, designers, and “When I started working in the coil coating

specifiers is our greatest challenge.”

industry some thirty years ago,” says Paolo Di

90% of AluCoating’s production is intended

Massimo, one of the world’s leading experts

for the window and door, curtain wall, and

in this field and the owner of AluCoating Srl, a

cladding sectors.

company specialising in the powder coating of

“We wanted to specialise even more in the

aluminium coils, already visited by our editorial

coil coating sector, by integrating the most

staff in 20121, “we used to apply about a dozen

innovative technological solutions, and to

of colours. Now, a company with a customer

create a company structure that’s was able

portfolio as large as ours may have up to 500

to handle small and very small batches of

ready-to-use tints in stock. Each shade also

colour, in order to meet the demands of such

comes with a number of different finishing

a complex market. This is why we have set

effects, which means that the colour range

up a production system equipped with ad

offered is very diverse. The speed at which

hoc plants, which is still being implemented

aesthetic and architectural trends change

and improved. As for the choice of paint

F. Stucchi, “AluCoating: A new company to meet the growing need for pre-powder coated aluminium,” in ipcm® International Paint&Coating Magazine no. 16 (July/ August 2012), Vol. 3, pp. 48-56. https://www.ipcm.it/en/open/ipcm/2012/16/54-62.aspx 1

products, we have established a partnership

From right to left: Stefano Rota and Paolo Di Massimo from AluCoating, Alessia Venturi from ipcm®, Maria Contrini from AluCoating, and Guido Pozzoli from Stardust.

with Stardust Powder Coatings Srl, a company based in L’Aquila (Italy) that formulates and produces powder coatings even in small

© sd partners

Design-wise, the differently coloured panels recall the outline of the Resegone mountain, hidden from the view of the city’s inhabitants by the imposing structure of the new hospital.

international PAINT&COATING magazine - MAY/JUNE 2021 - N. 69

45

batches on order, offering a rapid and accurate customer service even

requests, including colour matching between a coil and the aluminium

in the case of very limited quantities.”

profiles and frames already chosen for a building. In order to achieve this goal, AluCoating is equipped with a modern continuous-flow

Producing small and very small batches proves to be the winning choice

powder coating plant for aluminium coils and a line for flattening and cutting sheet metal to size, which we deliver to distributors or, more

“One of the most critical issues in our sector,” explains Stefano Rota,

rarely, directly to users. It also has an advanced laboratory capable of

the Sales Manager of AluCoating (Corzano, Brescia, Italy), “is the need

developing any colour requested by our customers together with our

to equip one’s own factory with the means to meet the most complex

paint supplier. We have found the perfect partner in Stardust, because

© ipcm

The station for the loading of blank coils on the decoiler.

The outside of the pre-treatment line.

© ipcm

A bird’s eye view of the continuous-flow powder coating plant.

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© ipcm

© ipcm

The powder management unit with an integrated ultrasonic sieve and dense phase powder transfer pumps.

EPISTOLIO EPISTOLIO

FOCUS ON TECHNOLOGY

towards the future

it is one of the few that gives us the possibility of purchasing the exact quantity of paint we need, even if it is a limited batch, and always delivers it in the shortest possible time. This enables us to

SOLUZIONI ROBOTIZZATE DI ROBOTIC PAINTING SOLUTIONS VERNICIATURA

meet our customers’ deadlines without any limitations.”

“We have been working with Stardust for three years now,” confirms AluCoating laboratory manager Maria Contrini. “Together with its lab, we have already developed several colours. We are currently formulating new tints with special effects, including the textured one, particularly popular in France and Germany – which, together with the Italian market, are our main target markets.

However, we do not focus on aesthetics alone: our materials have to be highly flexible, in order to adapt to the post-forming processes carried out by our customers, and the same applies to their coatings. In collaboration with Stardust, we are therefore developing products with improved mechanical characteristics that do not compromise the aesthetic result of finishes in terms of both opacity and colour. We aim at formulating coatings that outperform the market requests, thus making AluCoating able to preempt its customers’ needs.”

Maximum control of each process step All raw materials and pre-coated coils or sheets undergo rigorous mechanical and chemical tests. “Our tests on incoming raw materials involve both aluminium and coating powders,” indicates Contrini. “This avoids the risk of unpleasant surprises during production. When we receive the materials, we can already predict what the final effect on the finished products will be. We then carry out further tests after each step of the pre-treatment process, which includes fluotitanation and fluozirconation operations and with which we guarantee the high corrosion resistance of our products, as certified by a Machu test.

“As for the mechanical tests, we carry out stress tests on the painted sheets, as well as destructive bending, impact, and deformation tests and adhesion tests. Finally, we check the colours for compliance with European specifications and our own internal standards and we verify the absence of any surface defects.

“One of the elements that characterises us is the careful management of our entire production process. We follow our products from the arrival of the raw materials to the dispatch of the coated coils, and even after delivery to the customer by

Epistolio Srl.

providing product certificates. Our company is ISO 9001, 14001,

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

and 45001 certified, so that we can assure our stakeholders that we follow precise, standardised procedures in production.”

Shared projects Di Massimo adds: “We coat our coils with Class 1 and 2 polyester

Publierre_Milano

powders with premium performance in terms of weathering

resistance. Their only limitations are related to

© ipcm

the mouldability and elasticity of the film.”

“We are now focussing on Class 2 products, particularly in the super matte range,” notes Stardust CEO Guido Pozzoli. “We chose to improve the mechanical characteristics of this type of paints based on the current trend among architects and specifiers towards special tactile effects, which is now surprisingly spreading in the automotive industry as well.

Stardust manufactures powder coatings in compliance with both traditional aesthetic standards such as PANTONE and RAL DESIGN and more recent ones, such as NCS. In particular, we have recently established a partnership with the developers of the NCS colour system, which is based on a logical method of sorting the entire colour spectrum and identifying each tint with a special code.

The possibility of using an unambiguous The two quick-colour change, movable booths.

language that leaves no room for errors or misunderstandings and of choosing from a greater variety of colours are significant benefits for users. In fact, in the last three

© ipcm

years, we have noticed a progressive increase in demand for NCS colours in the construction sector, even in a country like Italy, particularly attached to its manufacturing traditions.”

Harmonising with one’s own powder supplier AluCoating and Stardust have been working together for a long time to achieve the same goal and they have created an almost symbiotic relationship that goes beyond a mere commercial partnership, strengthened by the similarities between these two companies. “Our approach to the market in terms of fast and accurate service,” emphasises Pozzoli, “is one of the aspects we have in common: working on orders with small and very small batches means speed is definitely a strength. Our two firms work symbiotically because they are aligned and this contributes to a mutually satisfactory The detail of the coating guns mounted on the reciprocator.

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partnership.”

FOCUS ON TECHNOLOGY

“The most appreciated features of our pre-painted coils,” states

“Another factor we have been working on,” says Rota, “is the

Di Massimo, “include aesthetic performance durability and batch

programming of our workflow according to the requirements

homogeneity: it can happen that a distributor keeps its panels in

of the batches to be painted. Thanks to our two Gema Europe

stock for a long period of time thus running the risk that, when they

MagicCylinder® booths, which are movable and guarantee quick

are used, architectural elements coated in the same colour may look

colour change operations, we can perform a continuous-flow process

different due to colour changes. The colour development study we

without the need to stop the conveyor belt and unload the batches

carry out together with Stardust ensures that this does not happen on

in the oven. We have perfected two colour change procedures: one

our coils.”

involves moving the booths with the coil in motion, whereas the other

Optimising the powder coating of coils

is based on the application of an ‘insert’, i.e. a small service coil that is about 35 m long which is recovered and used several times; with both

“In order to achieve excellence, we have found the right balance

methods, we can change colour in one minute.”

between powder quality and plant equipment,” states Di Massimo.

For about four years now, AluCoating has been using the nitrogen-

“Our coating plant is designed to apply seven to ten colours per day.

based paint application system patented and distributed by Eurosider

The two booths’ technology and the integration of accumulators that

(Grosseto, Italy). “Since we work with flat sheet metal,” explains

allow the coils to be removed even if they are not finished are the key

Contrini, “this choice was motivated not by the need to improve

to the efficiency of our production system. We have also optimised

penetration, but to reduce our powder consumption and to break

the coil unloading phase: this is usually an underestimated aspect, but

free from the influence of the environmental conditions. Finally, we

it has a major impact on production management.”

integrated a device called coatmaster® for checking the thickness

The GSB-project seal for coated aluminum.

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GSB: Quality and safety for coatings of aluminum components.

Added value for builders, architects and metal workers.

··

The new GSB-project seal contains all required quality statements Pretreatment Coating Material Coater

© ipcm

The Eurosider nitrogen-based coating system.

Ap C oa t e p r o v e d d A lu PREM minium IUM A p p ro C r- fr e ve d P retre atm e / Lic ent en

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

international PAINT&COATING magazine - MAY/JUNE 2021 - N. 69

49

© ipcm

© ipcm

coatmaster® measures the coatings’ thicknesses before curing.

Detection of the applied film’s thickness.

of the coating layers before curing and we are currently installing a

to improve the mechanical aspect. We are currently developing a

system to label each product so that important information such as

prototype able to apply the oxide layer with the coil in motion, i.e.

the coils’ number and processing data can be written on their back.

without immersing it in the tank.”

Innovation in the future of pre-powder coated coils

“Regarding Stardust’s commitment to the coil coating field,” states Pozzoli, “our laboratory will devote the rest of the year to optimising

“One of the most critical issues in the powder coating of coils,” says

the formulation of our powders in order to achieve greater resistance

Di Massimo, “is the difficulty of obtaining application consistency

to weathering and chemical aggression. One of our goals is to

due to the point geometry of the powder dispensers, although they

introduce bonderised coatings also in the field of coil powder coating,

maintain its oscillating movement of the flat sheet. Finding a different

with the performance degree of liquid coatings. Indeed, the real

application solution would expand the number of fields in which

challenge is to formulate bonderised coatings with high post-forming

pre-powder coated coils can be used.” Finally, the AluCoating team

mechanical strength.”

is developing a way to improve the anti-corrosion characteristics of

All of this will certainly help the upcoming revolution in coil powder

aluminium. “We are trying to improve the corrosion resistance rate of

coating to further contribute to providing architects, designers, and

the aluminium by applying an oxide flash in the pre-treatment phase.

specifiers with the endless possibilities of colour choices they are

The results are very good from a chemical point of view, but we need

increasingly demanding.

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HIGHLIGHT OF THE MONTH

Preempting Market Needs: Mirodur’s Forward-Looking Vision From an interview with Marco Vitelli, Massimo Vitelli, and Riccardo Vitelli

© Mirodur

Mirodur factory in Aprilia (Italy).

T

he world of paints and coatings has

Belgian company that had developed a paint

in industrial paints, producing water and

always been extremely competitive

used to protect mirrors. Hence the name

solvent-based liquid coatings for both the

and carving out a place for one’s own

Mirodur, from “miroir durée”, referring to

heavy industry and the general industry. Our

company in this environment is no easy

the durability of mirrors guaranteed by this

production area extends over 15,000 m2, of

task. Italian firm Mirodur has managed to

coating. They started producing this paint in

which 8,000 m2 are covered. Besides coatings,

do so thanks to its ability to innovate and

a small factory on the outskirts of Rome and

we have developed our Miromix colour mixing

preempt the needs of the sector through both

they were immediately successful, especially

systems with converters and colouring pastes

new technologies and new products, thus

because this sector did not exist in Italy at the

of our own production. This has allowed us to

establishing itself in the international market

time. This opened up new growth prospects

collaborate with several retailers, which are

and getting included on the vendor lists of

for our father and uncles, thus enabling them

increasingly crucial for the quick distribution

leading companies such as Gazprom.

to move to a larger factory in Pomezia. The

of small batches especially at a time when all

ipcm had the opportunity to interview two of

range of paints offered was also extended to

companies tend to stock less.

the three generations carrying on Mirodur’s

include industrial coatings. In 1982, it became

Massimo Vitelli: Another business branch

story: Marco Vitelli and Massimo Vitelli, sons of

necessary to move to an even larger building

that is very important to us and that has

one of the company’s founders and its current

in Aprilia, which is still our headquarters today.

contributed to the reputation of Mirodur is

directors, and Riccardo Vitelli, its marketing and

In 2016, finally, we acquired the industrial

the design and production of our Turbomill

communication manager, belonging to the third

branch of Turin-based Albesiano-Sisa Rossi,

devices. More than thirty years ago, we

generation of the family.

bringing its production operations here to

patented a paint production machine, which

Aprilia.

we decided to market in the 1980s: since

®

How was Mirodur created?

then, we have sold more than 1,500 Turbomill

Marco Vitelli: Our father, Ugo, together

How is Mirodur now?

devices in over seventy countries around

with his brothers Mario and Renato, founded

Marco Vitelli: Nowadays, we no longer

the world, both to small and medium-sized

Mirodur in 1957. They bought a patent from a

deal with the glass sector, but we specialise

firms and to multinational companies. It is an

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N. 69 - MAY/JUNE 2021 - international PAINT&COATING magazine

HIGHLIGHT OF THE MONTH

© Mirodur

Turbomill, the immersion mill with a patented rotating basket system designed and manufactured by Mirodur.

immersion mill with a patented rotating basket

have a stock of finished products: our fifteen

organised production and our Turbomill

system: the centrifugal force created by the

mills are used to develop ad hoc paints at the

systems, which help cut production times.

rotation of the basket compresses the beads

time of our customers’ requests. In order to do

and gives them greater shear force, thus

so, we closely cooperate with each customer

What are your target sectors?

ensuring excellent grinding results despite

from the very first moment, providing it with

Massimo Vitelli: The most important

having a smaller grinding chamber than other

the know-how of our technicians to create

sectors for our firm are those in which two-

mills. Milling and cleaning times are also

its required product according to the time

component, solvent-based or water-based,

shorter, bringing a significant advantage in

schedule and characteristics of its coating

epoxy or polyurethane paints are used. We

terms of production times.

plant, the intended use of the paint, and its

cater for both the general industry, including

expected performance. Clearly, our service

the ACE and earthmoving sectors, where

Besides product diversification, what is

does not stop at the product development

functionality and aesthetics go hand in hand

your main strength?

stage: we are also present in the subsequent

in terms of quality and performance, and

Marco Vitelli: Undoubtedly our service.

phases, from the first application to the

the heavy industry. A particularly important

Mirodur has distinguished itself in the market

resolution of any problems or any emergency

sector for us is oil & gas, where we have many

by its ability to fine-tune its coatings to its

interventions. We manage to do all this despite

important customers, especially in Russia. This

customers’ needs and production lines. In fact,

being a small-to-medium sized company

has led us to certify several of our products,

apart from a few standard ones, we do not

with thirty-five employees thanks to a very

including Epomir PTG, a ultra high-solids

INNOVATIVE FINISHING TECHNOLOGY FOR SOPHISTICATED SURFACES

Venjakob Maschinenbau – more than 50 years of innovation in surface technology made in Germany Surface pretreatment | Coating | Drying technology | Automation | Exhaust air cleaning www.venjakob.com anzeige_IPCM_#69-2021_214x62.indd 1

06.05.21 09:11

epoxy coating applied inside gas pipelines and approved

by SNAM, Gazprom and C4Gas – an excellent calling card at the international level. We are the suppliers to two of the three largest Russian pipes manufacturers; we are still providing them with our coatings, albeit at a slower pace due to Covid-19.

Marco Vitelli: Another important field is the military one. Indeed, we have developed some coatings, including finishes with special IR reflective pigments, that have been certified by the Italian Ministry of Defense Directorate General for Land Armaments for the application on vehicles of the Defense Administration.

We operate also in the field of the remediation of tanks containing petroleum products, solvents or acids. We are one of the leading manufacturers of this type of paints for non-destructive remediation and this has enabled us to work with one of the largest applicators in the industry.

Therefore, epoxy paints have carved out an increasingly

© Mirodur

Tintometric plant.

important role in our production volumes, in addition to our well-established paints for the general industry.

How are you coping with the current situation, which is dominated by the pandemic and by several problems in the supply of raw materials?

Massimo Vitelli: Despite the difficult year marked by the pandemic, Mirodur has never stopped working, in fact reaching in 2020 the same turnover as 2018, after a record-breaking 2019. Currently, another challenge, partly triggered by Covid-19, is that of raw materials’ supply issues and rising prices. In many years of business, we have had to deal with several raw material crises, but these were limited

© Mirodur

to individual products. Now, this situation is affecting all of the more than 600 raw materials we have in our catalogue,

Mirodur’s laboratory.

as well as several other sectors besides coatings. This leads me to think that we will never get back to where we started.

Therefore, we will need to plan production for the long term in order to be able to stock up on the raw materials that are essential to us, such as epoxy resins, isocyanates, and titanium, as well as to implement a strategy geared towards innovation and flexibility in order to be able to cope with every situation. We are trying to meet the demands of the market as much as possible and, in some cases, to preempt them, as we have done in the past with our gas pipelines paints: we were the first to make solvent-free internal flow coatings. If a company is not able to continuously renew its offer and production methods, it cannot survive.

© Mirodur

Solvents storage and distribution plant.

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Discover the magic of colours

EXHIBITION

9-11 SEPTEMBER 2021 ISTANBUL EXPO CENTER

8th INTERNATIONAL Paint, Paint Raw Materials, Construction Chemicals and Adhesives Raw Materials Laboratory and Production Equipments, Exhibition

Supporter:

Organiser:

In Cooperation With:

Media Partners:

turkcoat-paintistanbul.com

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

SPECIAL ISSUE ON AUTOMOTIVE

58

FOCUS ON TECHNOLOGY

68

FOCUS ON TECHNOLOGY

76 79

Maserati MC20, the New Dream Super Sports Car: 100% Made in Modena

Technological Evolutions in the Finishing of Steel Car Wheels: Application with a Bell-Gun System Mounted on Robot in the new MW Plant in Romania

BRAND NEW SUCCESS STORIES MEILLER Relies on AGTOS and SLF to Equip its New Surface Pre-Treatment Division

80

HIGHLIGHT OF THE MONTH

84

FOCUS ON TECHNOLOGY

88

FOCUS ON TECHNOLOGY

92

SUCCESS STORIES

94

HIGHLIGHT OF THE MONTH

98 100 106

Avin – A Strategic Partner for First Aid in Paintshops, Also in the Automotive Sector

First Coating Line for Agricultural Trailers with Cutting Edge E-Coat and Powder Coating System

Agrikon’s Paintshop Goes Electrostatic

Dürr Delivers One of the Biggest Paint Shops to SAIC Volkswagen

Covid-19 Might Increase Sales of Blue Cars, According to PPG 2020Automotive Color Popularity Report

BRAND NEW INNOVATIONS: PRESENT&FUTURE PVD Sputtering Approved for Car Interior and Exterior Components: A Great Achievement of Italian-Made Excellence

INNOVATIONS: PRESENT&FUTURE Long-lasting Corrosion Protection for Large Vehicle Parts

110

ART WITHIN SURFACES

114

FOCUS ON TECHNOLOGY

Beauty and Speed: when the Automotive Industry Meets the Art

Fluiver Combines Long-Standing Expertise and Innovation for the Optimal Coating of Large-Sized Plastic Parts

© Adobe Stock

international PAINT&COATING magazine - MAY/JUNE 2021 - N. 69

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FOCUS ON TECHNOLOGY

SPECIAL ISSUE ON AUTOMOTIVE

Maserati MC20, the New Dream Super Sports Car: 100% Made in Modena Alessia Venturi ipcm

®

In 2020 a new dreamlike supercar was born: the Maserati MC20. With this car, Maserati goes back to its origin and, given its importance, the house of the Trident chose to bring in-house all the production processes of MC20, including the unprecedented coating stage, which is performed on a robotized coating system designed and born by the cooperation of CMA, Imel and Sames Kremlin.

T

he First of Its Kind. A few words but extremely effective to describe

this has been developed to make the MC20 stronger, faster, safer, and

the MC20, Maserati’s new supercar, produced entirely in Modena

dynamically phenomenal, thanks to its high flexural and torsional rigidity.

(Italy), where the Trident company has its headquarters.

It is the first Maserati car to feature the Nettuno engine, a patented

MC20 is the first in its category for many reasons. It is the first Maserati

F1-derived technology for a phenomenal 3.0L, 630hp V6 engine, fully

car with a carbon fibre monocoque chassis. Ultra-light and high-tech,

developed and assembled in Modena.

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FOCUS ON TECHNOLOGY

It is the first Maserati car with butterfly doors, which not only look great

company’s origins, Blu Infinito (Infinity Blue) inspired by the concept

but also make it easier to get in and out of the vehicle.

of anodising, Rosso Vincente (Winning Red) which is the colour “par

It is the first Maserati car to be 100% made in Modena. Designed in

excellence” of the Italian motor sport, Nero Enigma (Enigma Black) that

Italy and produced in Italy, the MC20 is conceived to achieve perfection.

is surprisingly bright to the point of seeming almost liquid, and Grigio

Body processing, car assembly, coating, and engine assembly are all

Mistero (Mystery Grey) born of the idea of fusion between metal and

performed at Maserati’s historical manufacturing heartland in Modena, a

the major fluidity of the car’s surface, model and shape.

factory that has been completely redesigned to house the production of

These are the six launch colours of MC20, made with water-based

the MC20, the only car to be produced here.

coatings from Basf’s Color Pro series, except for the last one, which is

The MC20’s finishes are also the result of Italian genius when it comes to

a “liquid metal” product from PPG. Alongside them, a very wide range

coating. The six completely new exterior colours are applied in a robotic

of off-the-shelf colours will be available together with many other

system that simultaneously paints the bodies and their related plastics

personalisation options within the Maserati Fuoriserie customization

(another unique feature in its category). This was designed by CMA

program.

Robotics (Pavia di Udine, Italy), which coordinated a group of companies Italy) for the preparation and coating booths and the flash-off and

From naming to design, an epic return to Maserati’s racing origins

baking ovens and Sames Kremlin for the coating management unit.

“Every inch of the MC20 is built for unique driving pleasure. It was

Bianco Audace (Bold White) a yellowish, warm white with a bluish mica

created in the spirit of a dream sports car, but it can also be used in

to recall marble grains, Giallo Genio (Genius Yellow) for a return to the

everyday life thanks to its extreme driveability,” states Vito Cascione,

also excelling in their respective industries, including Imel (Codroipo,

© Maserati

© ipcm

An MC20 in the Blu Infinito tint undergoing final approval.

Elegance and sportiness are the key features of MC20, the new Maserati supercar, here in the Bianco Audace colour.

international PAINT&COATING magazine - MAY/JUNE 2021 - N. 69

59

SPECIAL ISSUE ON AUTOMOTIVE

© ipcm

A full view of the compact coating line designed by CMA Robotics and Imel.

The double flash-off and polymerisation oven is branded with the Modenese company logo.

the Plant Manager of Maserati’s Modena factory, but also the person

of the MC20. With 7 new body processing stations, 20 assembly

who coordinated the providers development team of every single

stations, a testing zone with 8 work areas, an assembly line for

component of the MC20 and acted as the Supplier Quality Manager of

the legendary 630hp Neptune engine, and a robotic coating line,

this ambitious project. “The MC20 is a versatile car that can compete

Maserati’s investment in innovation is tangible. “In this production

at all levels on the track, but is also suitable for urban and extra-urban

plant, Maserati has created a team of highly skilled specialist

driving. The distinguishing feature of Maserati cars is precisely this

operators, capable of manufacturing a product of the highest level,”

combination of impressive racing skills with the elegance and usability

explains Vito Cascione. “This factory is over 80 years old and its

properties required to travel comfortably and safely while having fun

history is that of a car production workshop with a craftsman soul,

and driving with ease.”

which had never used an automated coated process until now. In the

With its mid-back engine, the MC20’s lightweight construction ensures

recent past, Maserati’s super sports cars have always been painted

an extraordinary balance between weight and power, for breathtaking

externally. However, given the importance of MC20, the Group’s

acceleration and top speed. The driving mode selector includes five

strategic choice was to insource the entire car production process

options (Wet, GT, Sport, Race, and ESC OFF) to adapt the car’s set-up

in order to make the best of its operators’ expertise. In particular,

to any route. “Another unique feature of the MC20 is its frontal lifter,

with regard to coating, the intention was to raise the quality of our

which allows lifting the nose to avoid any contact of the underbody

bodywork finishes.”

area (which has an aerodynamic function for the ground effect), adjusting not only the damping element (i.e. the shock absorber) but

The reasons for the investment

also the elastic one (i.e. by increasing the suspension spring’s stroke).

CMA Robotics, a specialist in articulated coating robots and the

This mechanism enables the nose to be lifted 5 cm off the ground and

prime contractor for the MC20 painting project, collaborated with

avoids any damage to the car,” says Cascione.

Stellantis Group’s Central Technologies department and coordinated

A strategic choice: 100% produced in Modena Maserati chose to completely rethink its Modena factory as a function

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all suppliers to build this plant. The resulting line consists of a preparation booth for the application of masks and protection devices and the control of incoming primed surfaces; a coating application

FOCUS ON TECHNOLOGY

booth equipped with 2 7-axis robots mounted on the walls; and 2 ovens, i.e. a flash-off and a baking one, of the extra 700 tvs (2 ventilators) type. These have perimeter sandwich panels made with pre-painted Fe/Zn sheet metal and glass wool insulation, as well as a totally insulated plenum made in pre-painted Fe/ Zn and Fe/Zn sheet metal and featuring a > 99% high-efficiency filtering ceiling. Already the supplier of a flame hardening robot1 for the Maserati Levante’s bumpers produced at the Mirafiori plant in Turin (Italy), CMA was included among the tender partners and then chosen because of its product performance, quality, and competitiveness degree and for its availability to act as the prime contractor for the entire project, involving Imel and Sames Kremlin.

The investment made to insource Maserati’s coating process was mainly aimed at resolving an issue that has historically been crucial throughout the automotive world: colour matching, particularly evident on captivating colours such as those obtained with three-layer systems and particularly difficult to Monica Fumagalli The Advantages Of Robotics 4.0 For The Flame Hardening Of Maserati Car Bumpers, in ipcm® 57, Vol X, May-June 2019, pp. 86-96

1

© Maserati

Coating bodies and plastics at the same time, on the same system, and with the same paint products guarantees perfect colour matching among each bodywork and its accessories, such as the fuel filler flap.

SPECIAL ISSUE ON AUTOMOTIVE

© Maserati

An MC20 body with its plastics in the coating preparation box.

All surfaces have been treated with a primer.

achieve between car bodies, which are typically “make” productions

the same time of application, with the same baking temperature, and

(i.e. coated in-house), and their plastic components, which are typically

under the same environmental process conditions – all of this in a

“buy” productions (i.e. externally supplied). “Colour matching, but also

robotic cycle,” indicates Cascione. “This guarantees practically perfect

gloss matching pose great challenges to OEMs, particularly when

colour and gloss matching results.”

applying three-layer coatings (i.e. with two base coats and a final

“One of the objectives of this coating plant’s project was to avoid

clear coat) and matte resins,” notes Maserati Paintshop Responsible

having staff inside the booth, so we opted for a solution with two

Antonio Laurino. “This is because, even with the same coating product

antropomorphic robots,” says Antonio Laurino. “Underneath the

and the same colour, the very process of applying and baking paints

doors, we inserted stabilus systems with a weight control device that

is highly influenced by process parameters, which, although tightly

enables the robot positioned on the same side as the butterfly door

controlled on most car parts, have natural fluctuations. Here in

to open it, paint it, and close it by itself. This eliminated the need for

Modena, for example, we work in a temperature range with tolerances

both operator intervention and the installation of door-opening Scara

from 2 to 4 °C, but we have noticed that even in such controlled

robots.”

ranges there can be deviations in both colour and gloss matching, which become even more evident if the plastics are coated by

Coating systems

contractors.”

For the MC20, Maserati uses one-component water-based paint

“This is why Maserati’s industrialisation choice for the MC20 car was to

products, typically coloured base coats applied wet-on-wet, and

coat everything together, i.e. the bodies and the plastic components

high-resistance and ceramic-based two-component clear coat. The

to be mounted on them, which include mirror caps and arms, fins, fuel

systems applied vary according to colour:

door, handles, and of course bumpers. In this way, our cars’ coloured

• Blu Infinito (Infinity Blue) and Grigio Mistero (Mystery Grey) are

components (mounted on the car bodies or suitably spaced on a

three-layer pastel colours made up of base coat 1 + base coat 2 +

skid) are coated on the same plant, with the same paint product, at

glossy clear coat;

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N. 69 - MAY/JUNE 2021 - international PAINT&COATING magazine

FOCUS ON TECHNOLOGY

© Maserati

Bodies, bumpers, and other plastic components are coated automatically in the new robotised booth with 2 wall-mounted, 7-axis articulated robots supplied by CMA Robotics.

• Rosso Vincente (Winning Red) is a metallic colour obtained with base

paintshop. All components are then fixed to the bodywork by means

coat + pigmented glossy clear coat;

of spacers to form a complete skid to be subjected to coating. The car

• Nero Enigma (Enigma Black) and Giallo Genio (Genius Yellow) are

bodies transport systems have been provided by OLCI Engineering,

one-coat pastel colours consisting of base coat + glossy clear coat;

a company belonging to Efort WFC Holding Spa Group, of which also

• Bianco Audace (Bold White) is a matte, pearl-effect three-coat

CMA Robotics is a part.

system consisting of base coat 1 + base coat 2 + 30-gloss matte clear

The system performs the following operations:

coat.

• Skid change (from Maserati’s trolley to the new coating system’s

“The car’s main material is carbon fibre, which is used for its

skid);

monocoque chassis, roof, and bonnet,” indicates Vito Cascione. “We

• The body is loaded in the new coating system (via door/blower);

then use SMC for cover skins, PUR RIM for bumpers, and welded

• The body is taken to the preparation/cleaning box. During handling

extruded or die-cast aluminium for frames structural parts. All exterior

from the loading station to the box, it is subjected to the action of an

bodywork components (skins and plastics) are supplied to us already

air blade;

primed, and, after suitable sanding operations, we apply the base

• Body cleaning through manual blow-off and tag-reg operations;

coat.”

• The body is sent to the automatic coating booth, with a floor dry

Configuration of the MC20 coating system

filtration system; • Automatic base coat application on the car’s interiors with the

The system provided by Imel is very compact, with a functional

opening of moving parts;

reinterpretation of space. In it, the bodies make several “back and

• Automatic base coat application on the car’s exteriors;

forth” movements among the booth and the ovens to receive the

• The body is taken to the flash-off oven;

entire coating system.

• From the flash-off station, the body is sent to the coating booth;

Bodies and components are prepared in pre-existing boxes in the

• Automatic clear coat application on the car’s interiors with the

international PAINT&COATING magazine - MAY/JUNE 2021 - N. 69

63

SPECIAL ISSUE ON AUTOMOTIVE

© Maserati

© Maserati

Bianco Audace, the car’s launch colour, is a three-coat system including a metallic base coat and a matte clear coat.

Each of the two robots has two guns, one for applying the base coat(s) and one for the clear coat.

opening of moving parts;

of liquid or powder coatings. Additional flexibility is guaranteed by

• Automatic clear coat application on the car’s exteriors;

the particular configuration of their hollow wrists, which allow easily

• The body is transported to the final baking oven (90 °C for 60

reaching any point of the part being processed through the 360°

minutes);

rotation of each axis.

• Extraction from the oven;

A point-to-point system is used for programming the work cycles;

• Skid/trolley change-over;

this consists of detecting and processing geometrically significant

• Cooling to room temperature;

points on the surface to be painted by means of special software.

• Final approval and polishing.

Corrections can be made at any time to points, speeds, junctions,

The automatic coating booth is equipped with 2 articulated

and process parameters. The programs are stored and managed by

robots type GR 6150 HWW supplied by CMA Robotics. These are

a personal computer integrated in the control unit. They are ordered

electronically controlled machines with 6 degrees of freedom of

by alphanumeric codes on a compact flash device. Program selection

rotation and one of translation, designed for automatic spraying

can be done manually via the standard keypad, with a quick search

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N. 69 - MAY/JUNE 2021 - international PAINT&COATING magazine

FOCUS ON TECHNOLOGY

system, or automatically via remote control. The robots installed in the Maserati coating booth are also equipped with a translating carriage installed on the wall, which is their seventh interpolated axis, to increase their working area.

The robots guarantee automatic control of spraying parameters to eliminate the need to manually adjust the spraying pressures. All parameters are set and stored with the programs during the robots’ learning phase, but they can also be changed later. Each time the program and/ or the execution speed is changed, whether the cycle is stopped or during coating, the parameters are automatically updated. The paint mixing and feeding unit is located in a room with REI 120 walls and an additional extraction system complete with an ATEX ventilator. It guarantees up to 30 changes per hour (required for room approval) and it was equipped by Sames Kremlin to handle 8 one-component water-based base coats in 25 L drums for less frequently used colours, as well as 2 one-component water-based base coats and 3 two-component solvent-based clear coats (and

© ipcm

Vito Cascione, in the foreground on the right, with Antonio Laurino behind him, and two other operators.

their 2 catalysts) in 100 L tanks for the most frequently used

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SPECIAL ISSUE ON AUTOMOTIVE

© Sames Kremlin

The Sames Kremlin’s coating management unit for automatic handling of the paint products needed to produce the 6 launch colours of the MC20.

products. The unit is completed by its relevant cleaning stations.

MC20: a dream on four wheels

The management system for each one-component water-based

The arrival of the Maserati MC20 has inflamed enthusiasts.

product consists of a pneumatic elevator, a lid equipped with a

The MC20 is an all-round car: careful study of aerodynamics has

pneumatic motor, a safety two-hand control panel, and a 3.5:1 stainless

made it an elegant car, without the attachments typical of racing cars,

steel diaphragm pump for feeding the circuit. It also features an ATEX

with a cosy cabin, an infotainment system perfect also for journeys,

load cell for checking the product level through a digital display. As for

and unique driveability characteristics that makes it suitable for

the 100 L-tank feeding systems, each tank is topped up via a semi-

everyday use.

automatic device using the same feeding pump (3.5:1 stainless steel

The cars are already “fully booked”, and this bodes well for another

pump) thanks to a 3-way intake valve. The product is then taken directly

great market success for Italian-made excellence.

from semi-openable tanks equipped with a continuous level control

“In the year of the 700th anniversary of Dante Alighieri’s death, I

device.

like to think that my current role as the MC20 Plant Manager is a

All stations of the “paint kitchen” are equipped with a 10” automotive

form of contrapasso: having developed all the components of the

paint filter and a back pressure regulator. Through a flexible circuit,

MC20 during my previous job as the Supplier Quality Manager, I

each of them feeds the colour-change valves located on the Robots

will certainly not be allowed to complain about the people who

1 & 2. The product management system on board the robots is

developed this dream car!” says Vito Cascione with pride. “And I am

completed by flow regulators and gear pumps, for perfect product

sure there will be no need to.”

control and dosing up to the application operation.

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N. 69 - MAY/JUNE 2021 - international PAINT&COATING magazine

© MW Romania

A steel wheel manufactured in the MW plant in Dragasani, Romania.

FOCUS ON TECHNOLOGY

SPECIAL ISSUE ON AUTOMOTIVE

Technological Evolutions in the Finishing of Steel Car Wheels: Application with a Bell-Gun System Mounted on Robot in the new MW Plant in Romania Alessia Venturi ipcm

®

Steel wheels are being increasingly used within the automotive market not only as the entry-level option in small and medium car purchases. This is why they are now offered with a distinctive design and premium aesthetics. MW in Dragasani, Romania, has thus decided to invest in state-of-the-art technology to finish its steel rims for passenger cars and light commercial vehicles, purchasing a future-ready painting installation supplied

by Trasmetal and with an automotive-derived application technology by Verind.

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FOCUS ON TECHNOLOGY

F

or a long time, and even today in some markets, we have

as well as all the developments in application systems that MW has

considered steel rims to be the “unlucky brother” of alloy

tried and tested in its various European plants. “Steel wheels have

wheels, typically intended for the premium fittings of cars of

numerous functional advantages over alloy wheels, which are often

all types. Currently, however, steel wheels are being reconsidered.

unknown to most people,” begins Marco De Andreis, the General

In markets such as Germany, where car buying behaviour is

Manager of MW Romania. “I am referring to their lower weight

characterised by greater technical awareness, steel wheels appear

compared with average-quality alloy rims, but also to the lower

among the equipment options of most catalogues, with such a quality

consumption and lower CO2 emissions generated to produce a

level that they are sometimes difficult to distinguish from alloy rims.

steel wheel compared with an alloy one. In terms of aesthetics, steel

One example of this are the steel wheels of one of the Dacia Duster’s

rims still suffer from the objective limitations of their production

fittings, designed and manufactured by MW Romania, belonging

technology, but ongoing R&D in the field of steel stamping is leading

to Turin-based Group CLN. These rims have distinctive design and

to very positive results. Although in some markets steel rims are still

premium aesthetics and they are characterised by high production

the entry-level option in small and medium car purchases, other

complexity and a top-quality finish. How is this applied? Thanks to

markets value their longer service life, their better performance

the new coating system designed by Trasmetal (Milan, Italy) with an

degree on snowy roads thanks to less build-up, and their

automotive-derived application technology developed and provided

aerodynamic properties that reduce swirls and disturbances near the

by Verind (Milan), a company of the Dürr Group, which devised a

tyre. For all these reasons, MW has decided to invest in state-of-the-

bell-gun application system that is no longer fixed, but mounted on

art technology to finish them, purchasing a future-ready plant that

articulated robots. This applies waterborne paint, which is the top

could accommodate even larger wheels.”

coat of these rims, after cataphoresis.

Installed in December 2019 and fully operational since end 2020,

About MW Romania

this line incorporates the vast experience of well-established

The CLN Group, to which MW Romania belongs, is an Italian

manufacturers in the coating industry such as Trasmetal and Verind,

metalwork manufacturer of excellence. Founded by the Magnetto

© MW Romania

Overview of the new coating line for waterborne paints application, which has been developed and provided by Trasmetal from Milan.

international PAINT&COATING magazine - MAY/JUNE 2021 - N. 69

69

SPECIAL ISSUE ON AUTOMOTIVE

family in the early post-war

“Therefore, MW chose to switch

period as a flat steel trading

to horizontal coating systems

company, the CLN Group now

first at its French factory, then

presents itself as an innovative,

in the Russian one, and finally

high-quality, passionate partner

in the Romanian one. Here,

for the automotive industry, with

Trasmetal initially modified

two divisions: MA Automotive

the already existing system by

Components, which deals with

creating a “parasitic” chain link

the stamping, sheet metal

for the horizontal application of

working, and assembly of

waterborne paint. The logistics

bodywork components, and MW

flow included a double transfer

Steel Wheels, which designs,

of the wheels – first, from the

engineers, and produces steel

vertical hanging system of the

rims for passenger cars and light

cataphoresis station to the

commercial vehicles. The MW

horizontal one of the waterborne

division has its headquarters in

paint application booth and then,

Rivoli (Turin, Italy) and factories in

again, from the horizontal ring

France, Poland, Romania, Turkey,

to the vertical conveyor, before

South Africa, Russia, and Mexico.

entering the drying oven. This

The Romanian MW plant is located

second step took place when the

in Dragasani, about 200 km from

rims were still wet. Therefore,

Bucharest, between the Ford and

such technical adaptation

Dacia plants. This factory was

allowed managing small volumes,

created in the 1980s as Roti Auto

with some risk for the final

and it was acquired by the CLN Group in 2002. Currently, it has

quality of the coating. With the

© MW Romania

around 400 employees, it supplies the local OEM automotive market (mainly Dacia, Stellantis, and

increase in demand for high

Robots station with EcoRP 10, EcoBell 2, EcoBellCleanerD (this is the device for automatic cleaning of EcoBell 2’s exterior), and EcoGun during coating phase of the wheel’s edges.

Suzuki), and it produces its own line of aftermarket products.

aesthetic-quality steel wheels from its customers, however, MWR also chose to upgrade its

equipment by replacing the finishing plant following its cataphoresis station.”

The technological starting point

“The operational complexity of our factory in Romania and the lack

In the Dragasani plant, the project relating to the coating of steel

of adequate space delayed our investment in a new horizontal

rims stemmed from the need to replace the old system, with limited

coating line. However, in 2019, we decided to add a building to our

capacity and an outdated technological set-up. Indeed, one of the

factory that would enable, through a modification in the cataphoresis

evolutions that the steel wheel market has undergone is precisely

station’s conveyor, the installation of a new plant with a dedicated

related to its preferred finishing process, with a transition from

polymerisation oven and the design of a more logical coating

vertical to horizontal coating, as is typical of alloy wheels.

workflow,” says Marco De Andreis from MW Romania.

“Like most steel rim finishing lines, the Dragasani factory’s old coating

“Besides the technological upgrade to the state of the art of steel

plant included a single conveyor used for both the cataphoresis

rim coating, this project’s goals were related to sustainability (with a

and the top coat application systems, where the wheels were hung

switch from solvent-based to waterborne paint), production (with an

vertically,” explains Carlo Maria Caporale from Trasmetal. “This

increase in capacity and the streamlining of our internal workflows),

favoured the quality of the cataphoresis layer, but not that of the

and quality (with the transition from an application system with

waterborne paint one. When the demand for steel wheels with

tracking guns, effective but with a low refinement degree, to a bell-

aesthetic as well as functional finishes started to increase, the OEMs

gun system). The latter was made possible by Verind’s technological

of the automotive sector imposed an adaptation of the finishing

contribution, which provided us with a system that achieves the

technologies used to higher quality standards.

premium quality level typical of aluminium rims.”

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FOCUS ON TECHNOLOGY

The coating process

The inverted conveyor is an X45R type provided by CM Automazione

In the steel wheel market, the use of good paint products as top

(Giussano, Monza, Italy). Developed on three levels, the plant has a

coats enables to meet quality demands even in the absence of a

biplanar chain with four caterpillar drive units, with a design speed of

final clear coat. This is why MW Romania’s finishing process currently

7 m/min. CM Automazione’s conveyor is innovative because its plate

includes only cataphoresis and waterborne paint application –

acceleration system brings the wheels into the motorised device in

although the new plant supplied by Trasmetal is prearranged for a

the application booth, so that the rims transition from zero rotation

future expansion that includes a clear coat application station after

speed to the velocity required for the application process before

the base coat’s one, in order to accommodate any possible evolution

starting to be managed by the main roller.

of market demands.

“Another important step was the study made for prearranging

“The first challenge that Trasmetal faced in the design of this plant

the automatic transfer of the rims from one chain to another by

was related to the transfer of the wheels from the cataphoresis

means of robots, as already happens in MW’s French plant. After

system, located in the old building, to the new waterborne paint

cataphoresis, a robot that is currently being installed will pick up the

application line, installed in a newly built shed, not adjacent to

wheels and overturn them in order to hook them to the inverted

the first one but located across the street,” indicates Carlo Maria

conveyor’s spindles, thus completely automating this process phase.

Caporale. “MWR made a significant investment in terms of building,

In general, the coating process performed at MW Romania is difficult

whereas Trasmetal had to provide for the significant lengthening of

to control technologically, also because the company has chosen

the conveyor chain to cross the road and put the two lines in direct

to switch to waterborne paint, notoriously more sensitive to the

communication with each other. Furthermore, the waterborne paint

incoming workpieces’ surface temperature than solvent-based paint.

application line project also had to bring the coating workflow closer

The design of this waterborne paint application line was therefore

to MW’s new vision for this plant.”

focussed on the accuracy degree needed to obtain high-quality

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SPECIAL ISSUE ON AUTOMOTIVE

coating results with water-based paints,” notes Caporale.

booth’s envelope and suction system and its application system, still

“The rims reaching the waterborne paint application line actually

featuring conventional fixed tracking guns because, due to the rims’

come from several stations and not only from cataphoresis one, for

geometry, these guarantee maximum result repeatability.”

example from the storage warehouse or from the shift-end buffer: therefore, Trasmetal integrated a pre-coating surface stabilisation

The global market and the MW Group’s challenges

oven with gas catalytic infrared panels provided by Infragas (Turin),

In a production chain, the circularity and sustainability aspects are

which guarantees rapid heating of the parts’ surfaces before applying

integrated with an element common to every economic development:

the paint layer. Together with Infragas, we have designed a sound

energy, the very driving force of growth.

system featuring infrared panels with automatic lamp switch-on and

The main requests posed by MW to the group of companies in charge

off devices, depending on whether each rim is to be painted only on

of designing its new waterborne paint application line were as follows:

its visible side or on both sides. Afterwards, the parts reach the first

• Devising a green coating line thanks to the use of water-based

coating booth, applying waterborne paint on the rims’ visible side.

paints;

This booth is equipped with the technological devices supplied by

• Developing integrated control and automation systems able to

Verind, which, with the help of Trasmetal and by taking advantage of

monitor productivity information and any deviations from the pre-set

MW’s experience in other European plants, installed a bell and gun

standard and to make them available on a specific interface of the

application system instead of a traditional system with tracking guns.”

Line Master to enable any corrective actions;

“Until some time ago, the coating of the outer side of our steel wheels

• Guaranteeing high coating quality, consistency, and repeatability

was done with guns mounted

with automatic application stations

on a reciprocator: each gun

complete with robots;

painted a certain portion of the

• Guaranteeing general savings on

rim while this was being rotated,”

the application process, energy

explains Marco De Andreis from

consumption, and raw materials

MW. “Thanks to the evolution of

thanks to the right application

application products, we moved

technology.

towards the implementation of

“We can consider coating as a

fixed bell systems, currently in

surface treatment that calls for the

use in our Polish factory, and

aesthetic excellence of finishes and

then towards fixed bell and gun

the high chemical-physical quality

systems, as is the case in our

of films,” states Alessandro Soba,

Russian factory. The latest step of

the Senior Sales Manager di Verind

this evolution is the one seen here

(part of the international Dürr

in Romania, with bells and guns

group), to describe the technologies

mounted on articulated robots

supplied to MW Romania. “This

to ensure optimal uniformity and

phase is normally the final stage

distension of the applied film.”

of a production process and it has

“Trasmetal supplied the booth’s

an impact on the environment in

envelope and the suction system

terms of CO2 emissions, creation of

with dry filters, preferred over

special waste, and water pollution.

a water-veil one because the

With a view to this, meaningful

paint overspray that is created

engineering choices were made

with a bell and gun device is

on MW’s high-productivity, low-

really limited,” notes Carlo Maria

environmental impact coating line

Caporale. “After the flash-off

also in partnership with Trasmetal,

tunnel, if required, the rims reach a second booth for coating their inner sides. As for this station, Trasmetal provided both the

72

© MW Romania

The Verind-Dürr robot station. Application of clear metallic coating with EcoBell 2 with titanium cup.

N. 69 - MAY/JUNE 2021 - international PAINT&COATING magazine

with the following objectives: • Reducing the energy consumption of individual processes, the consumption of raw materials, the

FOCUS ON TECHNOLOGY

creation of liquid and gaseous waste, and the global CO2

emissions generated;

• Increasing efficiency and quality; • Optimising the cost per unit produced; • Integrating automation and digitalisation solutions; • Increasing efficiency through flexibility.

“From the development of the engineering concept to the completion of the Start Of Production (SOP) phase, the Verind-Dürr technology brought several significant advantages, including as follows: • Increase in the quality of the rims’ surface finishes thanks to the application of consistent, homogeneous thicknesses; • Increased transfer efficiency during application; • Paint savings per wheel produced and VOC reduction; • Reduction of the number of scrap rims; • Elimination of any downtime for cleaning the coating nozzles, thanks to the EcoCleaner technology installed and managed automatically by the robots;

In the foreground: two examples of steel wheels manufactured by MWR. In the background from left: Carlo Maria Caporale, Marco De Andreis, and Alessandro Soba.

• Integration of Industry 4.0-oriented automation solutions and interfaces.”

Say goodbye to masking Overspray-free paint application with EcoPaintJet Revolutionary precision in automatic application brings efficiency to product customization.

Dürr’s solution EcoPaintJet applies sharpedged paint lines on surfaces, pushing the limits for efficient and resource-saving coating: No overspray, no more masking of your product. www.verind.it

SPECIAL ISSUE ON AUTOMOTIVE

Details of Dürr’s application technology installed at MWR

rims in order to achieve optimal paint penetration. EcoBell guarantees

The booth is equipped with two robotised stations for the continuous-

precise atomisation pattern, in order to obtain an aesthetic effect

flow coating of steel wheels with different diameters and colours. Two

on the rims’ front faces that is as close as possible to the automotive

application technologies were installed to guarantee the automatic

one. Obviously, the implementation of such precise, high-repeatability

coating of the rims: EcoBell 2 and EcoGun. In particular, the following

coating programs has optimised the generation of overspray and,

technologies were integrated.

therefore, the company’s waste production and paint consumption,”

an application phase with a high transfer efficiency degree and a very

says Alessandro Soba. “Another advantage of this technology is the EcoRP 10 ATEX-certified 6-controlled axis robot

ability to perform inline automatic colour change operations (4 tints

Provides integrated automation in a high-production line with easy

from the remotely-controlled coating management unit designed by

point-to-point programming;

Trasmetal), selectable according to the programs requested by the

Automatic management of colour

queue management system to the

change operations, application

robotic stations and synchronised at

parameters, recipes, and interfaces;

the conveyor speed.”

Synchronisation at the conveyor speed;

Convergence of skills for a state-of-the-art line

EcoBell 2

“This project has pushed us to

Provides high-quality finishes while

combine different points of view,

guaranteeing paint savings in the

reflecting together with our partners

finishing process thanks to the

and plant and product suppliers to

Transfer Efficiency parameter;

find the best solutions, each with

High application performance

their own skills,” states De Andreis.

thanks to its bell and double-

“The result has been a customised

blade shaping air system made of

system with top-of-the-range

titanium.

technological elements for the treatment of steel wheels.”

EcoGun

“Such an experience is not very

Provides the ability to cover the

common in the coating industry,”

complex-shaped areas of the wheels

Caporale from Trasmetal and Soba

with the fine adjustment of the

from Verind agree, “because, in

atomisation air flow and pattern.

general, the average customers prefer not having to coordinate

EcoCleaner

two teams to get the best, but they

Integrated device managed by

rather require turnkey solutions

the robots, which provides the

because they think that it is simpler

ability to implement automatic,

and less expensive. Actually,

programmable external cleaning

however, a customer’s eye is always

cycles of the EcoBell and EcoGun

more attentive than an installer’s

systems, without any operator

eye and, therefore, the collaboration

intervention.

between the two can often lead to excellence.”

“The first EcoGun-equipped robot

© MW Romania

applies waterborne paint in the groove between the two parts of the

74

Coated wheels exiting the spray booth.

The floor conveyor, which develops on 3 levels, has been provided by CM Automazione from Giussano (Monza).

N. 69 - MAY/JUNE 2021 - international PAINT&COATING magazine

Your eco-friendly approach. 2/5

We care.

Water treatments specialities

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BRAND-NEW

A Pioneering Prototype E-bike Coated with Axalta’s ElectroLight Student engineering team from University of Oviedo has used ElectroLight to coat its prototype electric motorbike submitted to the MotoStudent Competition.

T

he Wolfast Uniovi team from the University of Oviedo, Spain,

advances in the quest for fully autonomous vehicles. It is a stand-out

has chosen ElectroLight, the 2021 Global Automotive Colour of

colour option in both trend and technology, and we’re delighted to

the Year from Axalta to coat its pioneering prototype electric

provide the students with our latest waterborne refinish paint in our

motorbike entry to the VI MotoStudent International Competition in

2021 Global Automotive Colour of the Year for this innovative e-bike”,

the MotoStudent Electric category.

says Elke Dirks, Axalta OEM Colour Designer for Europe, the Middle

The competition challenges students from all over the world to

East and Africa.

design, develop and manufacture motorbike prototypes in one of two

For the past six years, Axalta has supplied paint and provided

categories: MotoStudent Petrol (with internal combustion engine) or

technical expertise and guidance to the University of Oviedo’s

MotoStudent Electric (with a 100% electric propulsion system).

engineering teams. This year, the e-bike is coated in Axalta’s premium

“It is extremely fitting that this highly talented group of engineering

global refinish brand, Standox.

students chose ElectroLight for its very first electric motorbike.

The support for student competitions is part of one of the corporate

ElectroLight was developed to anticipate emerging technology

social programmes, Axalta Bright Futures. Its objectives include

© Axalta

© Axalta

76

N. 69 - MAY/JUNE 2021 - international PAINT&COATING magazine

SPECIAL ISSUE ON AUTOMOTIVE

forming long-standing relationships with students to encourage and to nurture active participation in the science, technology, engineering and math (STEM) subjects.

“We deeply appreciate the collaboration with Axalta. It is essential

Enduring.

Powerful.

Consistent.

for students to have access to the innovation, knowledge and expertise Axalta offers to be able to develop a project of this magnitude. ElectroLight was an easy choice for us! Not only is the colour outstanding and unique – an important consideration for us – but the fact it has been developed with mobility-sensing technology in mind is very much aligned with our goals to assess new solutions for improving motorbike safety”, says Álvaro Noriega González, Professor at the University of Oviedo and Team Principal.

The final MotoStudent International Competition event is scheduled for 15 to 18 July 2021 at the MotorLand Aragón Circuit in Spain.

For further information: www.axalta.it/color

© Axalta

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BRAND-NEW

SPECIAL ISSUE ON AUTOMOTIVE

AkzoNobel is Developing Advanced Technologies for Electric Vehicles AkzoNobel’s Powder Coatings has started to develop advanced technologies that will help to bring the automotive industry into the future. As e-mobility and the demand for electric vehicles is continuingly increasing all over the world, AkzoNobel is focusing its efforts on the growing needs of the customers within this industry.

F

ollowing the increasing global demand for electric vehicles,

as on alloy wheels. The rapid growth of e-mobility has led to the

manufacturers within the e-mobility industry are seeking world

emergence of new challenges but also opportunities for AkzoNobel,

class solutions that will help protect motors, battery systems

that will now help batteries last longer, thus allowing electric vehicles

and electrical storage of electrical cars and components. AkzoNobel

to drive even further. Market research suggests indeed that the

has therefore decided to offer its expertise to this new and

global electric vehicles industry will be worth around $700 billion by

innovative field, by creating a dedicated powder coating portfolio,

2026, up from $140 billion in 2019.

alongside a team of technical specialists providing expert assistance

That is why AkzoNobel has finally decided to help guide the

if needed.

industry on its way by continuing to innovate and providing more

“Thanks to our renowned Resicoat brand, we have more than 50

sustainable solutions for its customers. “We want to help transform

years of experience in offering tried, tested and proven performance

the e-mobility market through our pioneering approach and long-

for a wide range of electrical insulation and high temperature

standing commitment to technical excellence. We have all the

solutions,” commented Daniela Vlad, Director of AkzoNobel Powder

experience and expertise necessary to support the innovators of the

Coatings. “Building on that global track record, we’re now taking our

next generation technologies that will be used in the world’s most

innovation even further to help power up the next generation of

advanced electric vehicles. You could say we’re driving the current to

e-mobility through both our Resicoat and Interpon brands.”

power the future,” concluded Daniela Vlad.

The company has a strong experience in the coating industry, as its product are already used on car bodies and interiors, as well

For further information: www.interpon.com

© AkzoNobel

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SUCCESS STORIES

SPECIAL ISSUE ON AUTOMOTIVE

© MEILLER

www.cmautomazione.it

hi-tech

conveyors

MEILLER Relies on AGTOS and SLF to Equip its New Surface Pre-Treatment Division AGTOS and SLF Oberflächentechnik GmbH will work together in order to equip the new paintshop of MEILLER’s plant in Slaný (Czech Republic) with a cost-effective blasting system.

T

he MEILLER company was founded

The blasting system will be completed with

in 1850, and has always featured

lamella-type conveyors designed and installed

continuous growth, so much as that today

by SLF Oberflächentechnik GmbH.

it has become one of the leading groups in

These conveyors will be located in front of the

manufacturing waste disposal and commercial

blasting room and between the roller conveyors in

vehicles. The Munich-based firm has planned to

order to bring the abrasive back into the blasting

build a new surface treatment department in its

cycle, and ensure cost savings. AGTOS will provide

Czech plant in Slaný.

also the cartridge filter systems to extract and filter

It relied on AGTOS, specializing in blasting

out the exhaust air from the blasting machine and

technologies, in order to equip the new KTL

the blasting room. Providing one of the leading

coating line of the dump trucks designed by

surface treatment centres in Europe with these

MEGA-TEC s.r.o. with an automatic roller conveyor

important systems is a source of pride for AGTOS

shot blasting machine. AGTOS will provide MEILLER

and SLF.

with a RT 32-10 series shot blasting machine, which is able to blast welded pieces up to 2,550 mm width,

For further information:

950 mm height and 7,500 mm length.

www.agtos.com and www.slf.eu

CM AUTOMAZIONE srl - FA Ganci

Via Monte Bianco 20 - 20833 Giussano (MB) - IT p. +39.0362.314075 - f. +39.0362.861222 info@cmautomazione.it

© Avin

A coating system during the assembly phase.

HIGHLIGHT OF THE MONTH

SPECIAL ISSUE ON AUTOMOTIVE

Avin – A Strategic Partner for First Aid in Paintshops, Also in the Automotive Sector Francesco Stucchi ipcm

®

The assistance service for the systems maintenance and revamping is the core business of Avin, a company specialized in operations on the industrial coating lines.

I

n technical magazines such as ipcm®, success stories about

revamping, relocations, and recovery projects on a turnkey basis, with

the installation of new coating systems are always presented in

expertise and professionalism.

emphatic tones, often the result of large investments and company

It is even organised to guarantee a 24-hour first-aid assistance service,

expansion projects.

carried out by its highly trained, specialised technical staff. This service

Rarely, however, is another issue dealt with, which is very important

is offered on a European scale in many industrial sectors, including

not only for painting systems but for industrial plants in general:

the automotive industry, and it is mainly focused on restoring the

maintenance, modifications, and revamping – all aspects that, in the

functionality of elements such as overhead conveyors and handling

course of the service life of an industrial production line, sooner or

systems, for which Avin also provides spare parts.

later have to be coped with critically and competently.

Assembly and start-up services, another of Avin’s core businesses,

Since 2009, Avin Srl (San Martino al Tagliamento, Udine, Italy) has

are carried out by its subsidiary company, Met. Sp. Z.o.o (Limanowa,

been dealing with plant modernisations, upgrades, modifications,

Poland), specialised in providing complete assistance up to the

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HIGHLIGHT OF THE MONTH

turnkey delivery of the systems, including after-care and maintenance in agreement with each customer.

“Avin was established to fill a gap in the coating plant market, namely the provision of a range of services that are often underestimated, but actually essential for properly managing an industrial plant and extending its service life. I am referring to system modifications, which are necessary when production needs change but the existing plants are still functional and recently built; to complete revamps, when a company chooses to retain a few parts of its existing system (e.g. the spray paint booths or the conveyor) and replace all other components; and to maintenance, which is often underestimated but in fact strategic for the efficiency of production lines.

Finally, we also deal with upgrading projects, which, at present, are all related to digitalisation, remote control, and the Industry 4.0 in general,” says Morgan Infanti, the General Manager of Avin. “Another very complex task is plant relocation: at the moment, for example, we are working on a major relocation project of a wheel coating line. We operate mainly at the European level, but we also have active customers in China, India, Russia, the Arab States, North Africa, the United States, and South America.”

“Avin also supplies a range of components that are essential for plant optimisation, such as diaphragms and cells for cataphoresis, oil separators,

© Avin

A cataphoresis tank during the maintenance phase. Avin provides with membranes, cells and any kind of spare parts.

SPECIAL ISSUE ON AUTOMOTIVE

© Avin

The pre-treatment tunnel is the heart of the coating plant, and it requires frequent maintenance and revamping.

and water purification and demineralisation plants,” indicates

requirements. Avin offers an all-round plant first-aid service.

Infanti. “While gradually training our skilled, knowledgeable staff

“Our customers are firms looking for a good solution without investing in

at the mechanical and electrical levels, we first concentrated on

new equipment – although some revamps can cost more than a million

maintenance and assembly activities, thus building a portfolio

Euros,” explains Infanti. “Since the beginning of the year, we have seen a

of customers that are not interested in buying new systems but

big increase in demand, especially for part replacement, expansion, and

simply in renewing and optimising their already existing ones. Avin,

optimisation tasks. Its drivers are digitalisation, increased production

therefore, is not a competitor of coating plant engineering and

rates, and higher product quality requirements. The latter aspect, in

manufacturing firms, but it can act as a strategic partner for them,

particular, frequently calls for changes to pre-treatment tunnels, which

able to support them with professionalism, expertise, precision, and

are often designed for treatment cycles with a few stages, unsuitable to

accuracy and with highly trained teams of fitters and professionals.”

meet the new requirements in terms of quality degree and outdoor and

Many markets, especially the Italian one, are currently in a recovery

corrosion resistance. In these cases, we often suggest the application of

phase and several manufacturers find themselves with machines

nanotechnology-based pre-treatment products, which involve the use of

that need to be adjusted to meet new quality and production

demineralised or osmosis water or of atomising systems.”

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New 2021 The new frontier for the mass painting

Luca Floreanini designer

The perfect solution For painting and/or coating automatically and quickly small parts (metals and not) in batch, for example: buttons, bolts, screws, springs, O-rings and much more.

The new process An automatic control of air and paint flow allows you to obtain a perfect wettability of the pieces in any cycle phase.

New temperature control Reliable, accurate, economic.

The Data Management The new control SW stores all process data, for a precise consumption and production costs control, and supports you proposing a plan of preventive maintenance operations.

4.0 Rotover MES Easy and interactive production planning system for one or more machines.

A data-base of working cycles accessible from every machine and easy to be updated: 4.0 interconnection.

Multifunctionality Interchangeable drums of various shapes, sizes and geometries, designed for different possible types of items and for different materials.

Customer Service Send a test batch and Imel will prepare for you the optimized cycle for your production.

All machines are connected to Imel Service Center for a real time support On the side of the operator Easy and immediate control software.

New design Ergonomic, user friendly with no exposed cables and pipes.

Find out more, Scan the QR code to add the contact of our product manager to your device.

IMEL SpA – Via Divisione Julia 10 – 33033 Codroipo, UD – Italy – T +39 0432 908578 – info@imelspa.com – www.imelspa.com

FOCUS ON TECHNOLOGY

SPECIAL ISSUE ON AUTOMOTIVE

First Coating Line for Agricultural Trailers with Cutting Edge E-Coat and Powder Coating System Dietmar Jost Kansai Helios Coatings GmbH – Vienna, Austria

dietmar.jost@helios-group.eu

The Austrian company Brantner, specializing in manufacturing agricultural trailers, worked in cooperation with the coatings specialist HELIOS to install a state-of-the-art e-coat + powder coating system.

E

nvironmentally friendly and efficient coatings are on the cutting

adopts an environmentally friendly process technology. The plant

edge of today’s technology. Especially products permanently

is also designed to provide toll coating services. Let us take a look

exposed to extreme conditions require a top coating quality

behind the scenes of a cutting-edge surface technology plant and the

with excellent corrosion protection. The Austrian company Brantner, a pioneer of the industry, uses state-of-the-art e-coat and powder

perfectly adjusted coating systems.

coating technologies to protect its vehicles. In cooperation with

Brantner: 100% of products manufactured by itself

coatings specialist HELIOS, a modern surface technology plant was

For more than 75 years, Brantner has been counting on local

installed directly on the Brantner site. With this modernisation,

production and top product quality. Years of experience and the

Brantner enhances its product quality further and, at the same time,

success led to the Brantner Group become the European market

The Austrian company Brantner is specialized in manufacturing agricultural trailers.

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FOCUS ON TECHNOLOGY

leader in the production of agricultural

and powder coating, Brantner has chosen a

trailers (three-side tippers, dumpers, push-off

system which meets all quality requirements

trailers, manure spreaders) and be active in

for coatings for trailers and other agricultural

steel and industrial building construction, toll

and construction machinery and provides the

manufacturing, surface technology, and the

best protection from corrosion.

car trade. Up to the present, the company has

The conversion to the new coating system

produced more than 128,000 trailers (tippers, push-off trailers, manure spreaders).

“You can only ensure outstanding quality if you make a product yourself. Following this motto, we manufacture 100% of our products in our own plant. Our vehicles are exposed to

Being an innovative company and market

© Brantner

leader in manufacturing agricultural trailers,

Aerial view of the Brantner site in Laa an der Thaya, Austria.

Brantner focuses on constant optimisation of production processes combined with

extreme stress such as abrasion, weathering,

high-quality coatings technologies. Brantner

and UV radiation and therefore require,

components and units with modern laser and

is the first company in the sector to convert

above all, an optimum corrosion protection

robotic technology, coating and assembly

the coating process to e-coat and powder

to ensure their durability. Accordingly, we

of the vehicles as well as quality control. In

coating technology with the aim of achieving

choose our coatings technologies with

addition to excellent corrosion protection,

a stronger technological performance, higher

greatest care”, Hans Brantner, Managing

the final products provide extreme weather

robustness, and reduced production costs,

Director of Brantner, said.

and UV resistance as well as a premium finish

and the company can share the experience

The entire manufacturing process takes place

in the Brantner Design – features which can

with others in the sector: high product quality

on the Brantner site in Laa an der Thaya

only be created with an optimum coating

and the environmentally friendly process

including cutting, moulding, and welding

system. With the combination of e-coating

technology also convince other manufacturers

© Brantner

© Brantner

Parts up to 16 m long and 4 tons of weight run through the state-of the-art surface technology plant on the Brantner site.

international PAINT&COATING magazine - MAY/JUNE 2021 - N. 69

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SPECIAL ISSUE ON AUTOMOTIVE

© HELIOS

The e-coat baths.

© HELIOS

The coated piece exiting the coating booth.

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© HELIOS

The powder coating booth.

FOCUS ON TECHNOLOGY

Efficient and reliable

who use the toll coating services at the Brantner site for their agricultural equipment and trailer parts some of which are up to 16 meters long and weigh up to 4 tons.

“The conversion to the new plant was a huge project. We worked closely together with our long-standing partners and specialists to develop the technical equipment as well as the coatings. Without close coordination, services, and expert know-how, a successful

solutions for surface coating since 1988.

implementation would not have been possible”, Hans Brantner said. “We are proud to share this success with other companies who use the coating services on our site.”

Pre-treatment and coating perfectly aligned In cooperation with HELIOS, the modern surface technology plant was designed specifically for e-coating and powder coating applications and aligned with surface pre-treatment. Coating specialists and industrial engineers cooperated closely to develop the best solution for Brantner.

The individual steps are coordinated to ensure that the process runs as fast and as efficient as possible. After spray or dip degreasing, the pickling or grit blasting surface pre-treatment

electrostatic systems for liquid painting

can be flexibly adjusted which is then followed by wet chemical cleaning. Before the coating is applied, a tri-cationic zinc phosphating is carried out by immersion. Then, a waterborne 2K epoxy anti-corrosion primer is applied for the e-coat. This is the

electrostatic systems and spraying booths for powder coating

first organic coat on Brantner production parts. When the e-coat is cured, the parts move on into the powder booth.

This process is cost-effective and meets the highest industry standards in the field of corrosion protection because of the

pneumatic systems for high-, medium-, and low-pressure painting

optimum combination of e-coating and powder coating systems of the system supplier HELIOS. Both, powder coatings and e-coats are highly environment-friendly.

Powder coatings are solvent-free, e-coats have an extremely

IR and UV drying systems

low solvent content (in the case of Elecron 1.5%). The low curing temperatures of this product result in remarkable energy savings.

The product provides an excellent corrosion protection, perfect surface coverage, and high colour retention – particularly when

robot and reciprocators

combined with powder coatings which are perfectly adjusted by system suppliers such as HELIOS with regard to colour shade, gloss level, and durability.

CM SPRAY s.r.l. eosmarketing.it

www.cmspray.it

© Hegyi Zsolt

Agrikon manufactures cabins for construction and agricultural machinery.

FOCUS ON TECHNOLOGY

SPECIAL ISSUE ON AUTOMOTIVE

Agrikon’s Paintshop Goes Electrostatic Philippe Godbil Graco, Maasmechelen - Belgium

philippe.godbil@graco.com

Hungarian heavy machinery cabin manufacturer selects Graco’s electrostatic sprayers to increase efficiency in its paintshop.

A

grikon, based in Kiskunmajsa, Hungary is a manufacturer of

To meet the increasing quality demands of these customers, Agrikon

cabins for construction and agricultural machinery. Its portfolio

was keen to improve the final quality of its surface painting processes.

includes cabins for wheel loaders, excavators, road rollers, lifts,

At the same time, in these challenging economic conditions and in

tractors, harvesters, and balers, as well as doors and sub-assemblies.

a highly competitive market, the company was seeking to improve

Customers include multinational companies such as CLAAS, JLG,

the efficiency of its painting processes in order to improve cost-

ZETOR, and Liebherr.

effectiveness and reduce costs.

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FOCUS ON TECHNOLOGY

Cooperating with Paint Service Kft For a number of years, the Agrikon paintshop had been equipped with a two-component polyurethane mixing and spraying system.

Unfortunately, due to its age, the system was frequently breaking down, leading to frustrating downtime and expensive repairs.

Looking around for advice, Agrikon turned to Paint Service Kft, which has been distributing Graco products in Hungary since 2006.

“Paint Service has a very good reputation on the Hungarian market, especially for 2K plastic and metal paint spraying solutions and Gelcoat applications,” explains Sandor Varga, Managing Director, Paint Service. “We run a large demonstration lab with all Graco products and a Fanuc robot for automation tests. We were happy to talk to Agrikon and see if we could solve their challenges.”

After visiting the Agrikon plant and carefully analysing their specific requirements, Varga © Graco

recommended the Graco ProMix 2KE Plural Component Mixing System. “This is a compact,

The Agrikon’s paintshop.

entry-level proportioner that is available in pump and metered versions for all spray technologies. We suggested the pump version with a mobile trolley.”

The ProMix 2KE is designed for single-colour, two-component, in-booth applications, and offers predefined tolerance limits that help to stay on ratio within 2%. Maintenance is quick and easy, and it comes with an easy-to-use, icon-driven LCD display. Agrikon started off with one ProMix 2KE, but were so delighted with it that they soon purchased a second unit. Two years later, they purchased another two ProMix 2KE units, as well as two ProMix M2K units. The M2K is a basic mechanical plural component mixing system that increases mix material accuracy and reduces material waste compared to hand mixing.

Electrostatic air-assisted spray guns Most recently, Agrikon returned to Paint Service with another question. How might it be

© Graco

possible to reduce paint consumption while maintaining the same high-quality levels? “To

The two ProMix 2KE units.

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SPECIAL ISSUE ON AUTOMOTIVE

© Graco

© Graco

The inside of the coating booth.

A coating phase with a Graco’s Pro XP manual booster air spray gun.

meet this challenge, we looked closely at the spray guns that Agrikon

25% reduced paint consumption

were using, and we recommended they change to Graco’s Pro XP

Today the Agrikon paint shop is set up with 10 ProMix 2KE units. Each

manual booster air spray guns. These are designed for low-pressure

one feeds one or two Pro XP electrostatic spray guns, which means

spraying where they deliver a high-quality finish with excellent transfer

that at any one time up to 16 spray guns are in operation.

efficiency.”

“Agrikon is now totally prepared for the increasing orders that

In addition, Pro XP spray guns are small and light so are easy to

are coming our way. We have a fully up-to-date and streamlined

operate. They have a round spray option for a bell-shaped pattern,

paintshop, with reliable plural component mixing systems and top-

and a high conductivity version to handle low-resistivity material. They

quality electrostatic spray guns,” says János Tóth, paint shop manager

are available in 40, 60 and 85 kV models.

at Agrikon. “We are delighted with Graco’s products. The final quality

A trial was set up and Agrikon was delighted with the results. They

of the painted surface of our cabins is exceptionally high, and overall,

purchased 12 Pro XP spray guns (and a further five ProMix 2KE units).

we are experiencing a 25% reduction in paint consumption.”

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Future-proof and reliable overhead

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

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

SUCCESS STORIES

SPECIAL ISSUE ON AUTOMOTIVE

© Dürr

Dürr Delivers One of the Biggest Paint Shops to SAIC Volkswagen Despite all the restrictions caused by the coronavirus pandemic, Dürr handed over one of the biggest paint shops in China to SAIC Volkswagen right on schedule.

D

ürr has supplied to SAIC Volkswagen joint venture (SVW) plant

How the project came to be

near Shanghai all of the plant engineering as well as the most

In order to bring this project to life, mechanical engineering and the

comprehensive portfolio yet of its proprietary DXQ software

IT department worked in synergy right from the beginning: the digital

products.

solutions were developed in parallel with planning and implementing

The new plant in Anting, which produces various electric models and

the comprehensive plant engineering – from the RoDip® dip coating

conventionally powered vehicles, has a production capacity of 120

system through paint booths with EcoDryScrubber dry separation to the

bodies per hour – twice that of a standard paint shop – and features

oven and the air pollution control. Over the 18-month project duration,

a smart painting line that records around 3,500 digital data points for

six international product development teams from Dürr worked with up

every individual body alone. Moreover, sensors supply many gigabytes

to ten developers in each case on the new technologies.

of data in the form of process values for, i.e., temperature, pressure,

To ensure a smooth IT installation in China, all the software functions

and humidity – information that is useful to increase the overall

were first tested in the Dürr headquarters in Bietigheim-Bissingen in a

equipment effectiveness (OEE) of a paint shop.

test environment that faithfully replicated the conditions in Anting.

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DXQcontrol: one software to control the paint shop

paint shop, and as a mobile version as well. The software has

SVW uses nearly all modules from the DXQcontrol software solution

interfaces to the plant equipment’s almost 130 controllers, and uses

for higher-level plant control. It enables the life cycle of each body

them to determine each piece of equipment’s need for maintenance

to be tracked from beginning to end. This starts with receipt of a

based on up-to-date information like operating hours or counter

production order, whereby the order information is translated into

readings. SVW can also incorporate plant components from other

concrete production steps. In addition to order data management, the

suppliers here.

DXQbusiness.intelligence module is also used in a new form: for the

Several terabytes of digital data per year are collected, saved, and

first time, consumption data such as energy, water, or air usage can

evaluated by the algorithms of the DXQplant.analytics application.

be evaluated historically over long periods. This lays the foundation

If, for example, an employee detects an irregularity on the paint

for sustainable plant operation.

surface during the quality inspection, he enters it into the tablet.

A further innovation is the use of mobile apps provided by various

DXQplant.analytics correlates recorded quality results with order

DXQ products. For example, employees can manage and filter alarm

data (production number, derivative, color, etc.) and process data on

functions directly at the point of origin in the plant using tablets if the

the basis of artificial intelligence to identify patterns. A broad base

line comes to a stop.

of data makes it possible to track the fault causes in a targeted way

Maintenance data, as well, can be accessed by employees using

and define measures. In this way, the system can be permanently

tablets by scanning QR codes on plant components. In this way,

optimized. For the first time, process data from other suppliers’

information can be called up directly at the point of origin. This

components and systems is also evaluated at SVW in Anting using

enables the employees to work more flexibly than is possible with

DXQplant.analytics, for example in Application Technology.

stationary PCs. At SVW in Anting, the DXQequipment.maintenance maintenance software is being used for the first time for a complete

For further information: www.durr.com

© PPG Industries Inc

HIGHLIGHT OF THE MONTH

SPECIAL ISSUE ON AUTOMOTIVE

Covid-19 Might Increase Sales of Blue Cars, According to PPG 2020 Automotive Color Popularity Report Andrew Wood PPG Industries – Amsterdam, Netherlands

awood@ppg.com

PPG 2020 Automotive Color Popularity Report shows that blue hues – which convey optimism, confidence, recovery and hope – have increased their popularity.

P

PG has recently released its 2020 Automotive Color Popularity

expected to further fuel the preference for the colour blue.

Report, which shows that blue continues to increase in

“COVID-19 has consumers focusing on their desires and priorities.

popularity. The hue symbolizing optimism has reached 9%

Blue is an optimistic, comforting colour that conveys trust,

of global colour share (increasing by 1% from 2019). In Europe, it

dependability, confidence, healing and hope. It’s also associated with

performs even better, at 11%, and the sales of blue luxury, mid-

nature, cleanliness and future-forward technology”, explains Misty

sized and small vehicles also grew by 1%, as anticipated by PPG’s

Yeomans, PPG’s colour styling manager, who also expects the colour

2019 automotive colour forecast. The global COVID-19 pandemic is

to merge into more vivid or desaturated shades.

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“Digital-inspired aqua-blues combine versatility with a sense of

and versatility in turbulent times,” Yeomans adds.

youthfulness and a fresh spirit. Emergence of the electric vehicle (EV)

“In addition to the pearl and metallic whites that are already widely

market also will drive growth in vibrant tones and interesting effects,

popular, we anticipate a new dimension of white stylings in the

such as colour-shifting colours. We’re also seeing blue used more

automotive market that create a warm, sophisticated feel+, such

extensively in trim lines, logos and other accessorizing applications”.

as creamy shades of ivory or bone-coloured tints and ceramic

White is still the world’s most popular colour for the automobile

effects. White colours are also highly compatible with emerging

sector with 34% of the market share, even if it fell by 1%, while black

radar and LiDAR technologies that enable self-driving vehicles.

and red remained respectively at 18% and 8%.

Red is consistent and an important colour space in the automotive

Silver instead has faced a slight decrease, dropping to 12%, but grey

market, holding steady at 8% globally. This colour will get a new

has risen to 12%. PPG forecasts that it will remain an important core

push with EV start-ups due to its stand-out nature and association

colour, as concrete and stone materials as well as ceramic and metal

with sports car models. Year after year, we see high chromatic reds

tones are increasing their popularity.

growing in interest. Effects and finishes that incorporate black tones

Nature will also play a pivotal role: warmer and more organic tones,

allow for artistic reveals in the way colour shifts, highlighting hidden

which reflect consumer tastes, will align with light tones, including

undertones and adding a dramatic flair to the possibilities provided

white and silver.

by the new pigments and finishes being developed within this colour

“White colours also reflect consumers’ desire for refined simplicity

family.”

© AdobeStock

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BRAND-NEW

© SAMES KREMLIN

The Innovative Sames Kremlin’s PaintSave Halves the Paint Lost to Colour Changes 40 cubic centimetres: that’s about the volume of paint lost on a car line with each colour change.

PaintSave reduces it to 18 cc and allows to save tens of thousands of euros per year.

E

very time a robot applicator of a car line changes its colour

In order to solve this issue, Sames Kremlin developed an innovative

and cleans its tools, it loses 40 cubic centimetres of paint, or

device called PaintSave, which has already been installed in a car

about € 0,48.

factory in the United States. It allows to reduce losses from 40 to 18 cc.

However, colour changes are very frequent on an industrial line, because car manufacturers prefer to manufacture in order of order

How it works

rather than in colour batches, so as to reduce lead times and limit

PaintSave is based on the pig system: a cylindrical part pushed by

stocks. They change colour every 5 cars on average, or even every 2

compressed air that circulates between the colour changer and the

or 3 cars.

sprayer. It scrapes the inner edges of the hose and thus recovers the

After a year, the paint lost amounts to tens of thousands of euros.

majority of the paint.

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SPECIAL ISSUE ON AUTOMOTIVE

However, since the pig rubs and its seals wear out, gradually losing its effectiveness, and can also pick up particles from the inner coating, increasing the risk of stopping during the application and even arresting the manufacturing line, Sames Kremlin has developed a new solution that replaces the pig with a “shuttle”.

Being cylindrical, with a diameter slightly smaller than the hose, it runs without friction or risk of blockage. It recovers a little less paint, but with an inestimable gain in reliability.

Endurance tested over 600,000 cycles According to laboratory endurance tests, the PaintSave’s shuttle can withstand 600,000 cycles without damage, the equivalent of 7 to 12 years of industrial operation.

PaintSave ensures a return on the investment within 6 to 12 months, depending on the frequency of colour changes and the cost of the paint. It can be installed as a retrofit to existing equipment or as a complete system, and it is available immediately.

For further information: www.sames-kremlin.com

© SAMES KREMLIN

● ● ● ●

Conveyors Conveyor chains Special components Automations

© SAMES KREMLIN

Se.Po. di Pozzi Sergio Via Concordia 43 23854 Olginate (LC) T.+39 0341605056 info@sepoitalia.it www.sepoitalia.it

INNOVATIONS: PRESENT&FUTURE

SPECIAL ISSUE ON AUTOMOTIVE

PVD Sputtering Approved for Car Interior and Exterior Components: A Great Achievement of Italian-Made Excellence Stefano Lazzerini Kolzer Srl, Cologno Monzese, Milan, Italy

stefano.lazzerini@kolzer.com

Over the last ten years, vacuum metallisation and, in particular, PVD sputtering, which allows depositing a thin film of different metals to guarantee high aesthetic and mechanical properties, have expanded horizontally in the industry, thus conquering very different market sectors. Not only cosmetic and glass packages, but also aluminium profiles for interior design1, 3D printed (or AM) components2, fashion accessories3, and automotive interior and decorative components can now exploit the advantages of vacuum metallisation to achieve glossy, shiny, and durable finishes in a wide range of colours and through an environmentally friendly process.

Alessia Venturi, “Rose Gold Finishes for the Bathroom Accessories of the Future: Now It Is Possible, Thanks to Italian startup Almain’s Metallisation Sputtering Process for Aluminium Profiles over 2 Metres” (ipcm® no. 65, Vol. XI, September/October 2020, pp. 58-64) 1

2 3

Monica Fumagalli, “The Perfect Combination of 3D Printing and PVD Sputtering: From Prototyping to the New Frontiers of Additive Manufacturing” (ipcm® no. 67, Vol XII, January/February 2021, pp. 38-44) Monica Fumagalli, “Creativity at the Service of Technology to Design a Highly Versatile, Compact System for the PVD Coating of Fashion Accessories” (ipcm® no. 66, Vol XI, November/December 2020, pp. 66-74)

© Kolzer

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INNOVATIONS: PRESENT&FUTURE

V

acuum PVD thin-film metal coatings can be created by a sputtering process that is fast, low-temperature, environmentally friendly, easy to use (it has no gas or liquid

emissions and it produces no waste or by-products for disposal), repeatable, and versatile (it can be applied to any type of substrate, including heat-sensitive ones, without embrittlement). Sputtering is also highly economical, because it consumes little energy, it enables loading and unloading operations to be automated, and it is carried out in user-friendly machines that do not require skilled labour to run them.

Thanks to these characteristics, PVD sputtering coatings have emerged as a sustainable, economically viable, versatile, and highquality alternative to galvanic metallisation, whose industrial future is uncertain due to increasingly stringent environmental regulations on its processes and on waste water disposal, as well as the phasing out of many chemicals widely used in galvanic operations, such as hexavalent chromium, under the European REACH regulation. As proof of the very high level of technology, quality, and durability reached by the coatings deposited with this vacuum technology, the latest achievement of PVD sputtering have been car exterior components. Building on seventy years of experience in vacuum metallisation and, in particular, PVD sputtering processes, Kolzer has just become the first company to receive approval from several OEMs for the PVD sputtering decoration of exterior components for cars produced in Europe.

Technological background In a sputtering process, the coating material is inserted into the vacuum chamber as a cathode in the form of a metal plate. Once vacuum has been created in the treatment chamber, a process gas is added (argon is normally used due to its high atomic weight) and plasma is generated. The plasma stream, formed by positive argon ions, undergoes an acceleration process on the negative cathode, which ejects atoms from the metal plate (evaporating material). The impact of ions on the evaporating material produces a “sputtering” effect because of the acceleration transmitted by the incoming particles. As a result, the components loaded in the treatment chamber are coated by the sputtering of the evaporating material.

Unlike many other vacuum deposition techniques, there is no melting of material, so all metals and alloys can be deposited with high efficiency and control.

If, in addition to the process gas, a reactive gas (e.g. nitrogen or acetylene) is introduced into the chamber, carbide-reactive nitride develops on the substrates. It is possible to change the combination of individual layers by varying the combination of reactive gases.

In order to produce multi-layer systems, several cathodes made of different materials can be inserted into the vacuum coating system. As regards sputtering coatings with metallic effects, which

© Kolzer

Interior and exterior parts processed by PVD Sputtering.

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© Kolzer

The high automation MK63’’ system for large volumes.

feature high abrasion and chemical resistance properties, sputtering

of Kolzer’s sputtering method. Numerous tests were also carried out

depositions of chromium and stainless steel or carbides and nitrides

at a customer that operates in the automotive world, SITIM (Cassino,

of transition metals (e.g. titanium and zirconium) are mainly used.

Italy), which was the first to believe in this finishing process for exterior

Process approval: an obstacle course

components and agreed to participate in the approval process together with Kolzer.

Kolzer’s new PVD sputtering process has now been approved for the

The first OEM with which Kolzer worked, also due to geographical

finishing of car mouldings, trim parts, door handles, bumpers, and

reasons, was the Stellantis Group. To date, Kolzer’s PVD sputtering

alloy wheels. The path to achieve this goal was long and complex and

process has been already approved both by Stellantis for OE interior

it implied an increase in the quality level of the PVD sputtering process

and exterior components and by other European and Japanese OEMs.

– a mature technology that however, until the approval of Kolzer

The company is also working with the Audi group and it is positively

machines, was not suitable yet to meet the decorative and functional

testing its innovative solution for various components of Ferrari,

performance requirements of the automotive sector, which are much

VW group, Hyundai, and many other global brands. Also on alloy

higher than those imposed to decorative sputtering processes in

wheels, sputtering coatings can be applied with an ad hoc multi-layer

traditional application fields such as cosmetic packaging. The approval

system, which can be easily integrated in the coating plants currently

was finally obtained thanks to the fine-tuning of the sputtering

operating in this sector.

process in combination with base coats and protective coatings guarantee the durability and resistance of the treated parts and thus

The drivers of the development of PVD for car exterior components

meet the most stringent specifications.

Although not approved, the PVD sputtering process was already well

Therefore, in order to complete this approval process, Kolzer started

known to the automotive industry, because its use for decorating the

a profitable, dynamic collaboration with the world of coatings by

interiors of cars was necessary to offer lighter, cleaner, and recyclable

scouting for the most suitable products on the market, until finding

materials thanks to the above-mentioned process advantages over

the winning combination of base coats and top coats to be integrated

other technologies available on the market. However, PVD’s use

with a rather complex multi-stage PVD process. Another key to the

potential was still underestimated, due to a lack of awareness and

success of the project was the choice to offer OEMs an in-depth,

knowledge, also in terms of the wide colour options offered by this

secretless analysis of the technological and process characteristics

process. For decades, the automotive industry has been stuck on the

appropriately developed by Kolzer and its specialised partners, which

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© Kolzer

Maximum efficiency in powder coating

The DGK36’’ user-friendly system with a space-saving design.

use of satin-finished or polished chrome plating. PVD sputtering now offers to the automotive world a very wide spectrum of

Nordson HDLV dense-phase technology – everything under control

finishing colours and effects, superior to what can be achieved with galvanic processing.

The development drivers that led to PVD sputtering coatings also being approved for car exterior components have been as follows: • Flexibility of shades, effects, and materials (plastics, extruded or

The heart of Nordson HDLV® technology is patented High Density, Low Velocity (HDLV) pumps delivering exceptional powder coating results.

die-cast aluminium, carbon fibres, fabric, leather, etc.) on which the metal coating can be deposited; • High quality: with the use of PVD sputtering, it is possible to achieve lightweight, strong, durable finishes with perfect colour matching between different car parts, even made of different materials. The latter is a key issue for the automotive industry,

Significant powder savings and productivity gains from: higher application efficiency, uniform coating thickness, faster color change and minimum maintenance downtime.

especially in the sports and luxury car segments.

• Environmental sustainability: the absence of emissions and waste water to be treated and its low energy consumption make PVD sputtering a truly “green” technology.

• Economical: the batch process is user-friendly and optimal for small, medium, and large batches (unlike in-line machines, which are only cost-effective with the very high volumes and standard

Explore the unique features of our powder coating systems online or get in contact with us today for more information!

finishes typical of the packaging industry). Moreover, this process

Scan me

does not generate any scraps because, unlike galvanic processes that are very aggressive on substrates and lead to embrittlement, which generates a high scrap rate, PVD is gentle on base materials. ics.eu@nordson.com www.nordson.com/hdlv

SPECIAL ISSUE ON AUTOMOTIVE

A new generation of car components

conscious and PVD sputtering can ensure sustainability and safety for

Two of the mega trends of the automotive industry are lightweight

operators, without the risk of the supply chain halting due to any ban

construction (also called lightweighting, i.e. the lightening of all car

on chemicals within a few years. In the light of these considerations

components using state-of-the-art materials) and electric mobility.

and the technological possibilities of PVD sputtering, the future looks

The latter, in particular, will call for the redesign of many components

bright. PVD will no longer be used to imitate finishes designed for

on which sputtering will also be employed for non-decorative purposes,

a different technology, but the OEMs’ style departments will design

as well as for decorative ones, starting with wheels, but also for a new

colours for new car models to be obtained with the exclusive use of

focus on a range of colours recalling electric power (greens and blues).

this process.

In the light of these mega trends, PVD sputtering coatings are very

In Kolzer, OEMs have found already the expertise, experience, and

advantageous. First of all, with their thin films, they contribute to the

knowledge degree required to achieve the difficult task of having its

lightening of vehicles. Secondly, they can meet a growing demand that

process approved for car exteriors. A lot has been achieved since the

the galvanic industry is increasingly struggling to meet, as environmental

first use of the sputtering technology for decorating newly invented

limitations have reduced the number of players in the sector, thus

blown or injected plastic Christmas balls – Kolzer’s first patent, back

leading to a drop in productivity and an increase in plating prices.

in the 1950s. And this achievement is only the starting point of an

Finally, automotive OEMs are becoming increasingly environmentally

evolution of the PVD technology that seemed impossible to many.

Kolzer PVD chrome process on aluminium and plastic.

PROPERTY

TEST

RESULT

Squaring adhesion

ISO 2409

GTO 0% of removal

Bucholz hardness

UNI EN ISO 2815 08/05

BH 167

Impact resistance, direct

ASTM 2794-93

1 kg - 20 mm / 2 cm No cracking

Resistance to UV – QUV rays

ASTM G154-04

No defects to report

Resistance wet room static (1056 h a 40 °C)

Visual inspection Adhesion + Tear Comb 1 mm after 2h

No loss of brilliance 2h = GT1

Resistance to corrosion (salt spray test for 1300 h)

Visual inspection Adhesion + Tear Comb 1 mm after 2h

No loss of brilliance Detachment at some points (on the edges where the thickness of paint is lower). 2h = GT1

Sodium hydroxide 0.01N 4h at 50 °C

Perform the evaluation after rinsing with water.

The covering must not be soft, swollen or resistance to rubbing. No indelible stain.

No defects to report

Sulfuric acid 0.01 N 24h / RT

Perform the evaluation after rinsing with water.

The covering must not be soft, swollen or resistance to rubbing. No indelible stain.

No defects to report

Resistance to solvents-denatured ethyl alcohol 99.9%

10 double passes

Pass

Resistance to solvents-acetone

10 double passes

Pass

Resistance to essences - GT1

10 double passes

Pass

Drop test

EN12373-4

No loss of adhesion

Loss of weight

EN12373-7

No defects to report

Resistance to abrasion

Sand paper at degree 00

No defects to report

Resistance to chemical agents

pH 1 … and pH 13,5

No defects to report

Resistance to temperature

200 °C for 2h

No defects to report

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A X A LTA C O AT I N G S Y S T E M S

? s s o l G ? t c e ff E Colour? helping you find the perfectr pyoowu.der

asy by ers nea e n t e r c a i p o r h c u o r ou t one of i s i V .

We make y t c e j your pro r o f selector g r n u i t lo a o c / co m o w.axalta.c w w : o f in e Mor

INNOVATIONS: PRESENT&FUTURE

Long-lasting Corrosion Protection for Large Vehicle Parts Hendrik Narjes Dörken Coatings GmbH & Co. KG - Herdecke, Germany

hnarjes@doerken.de

Effective corrosion protection can deliver long-term functionality and operational safety of large parts and components throughout the lifetime of the vehicle as a whole.

Protection in accordance with specifications

stresses in daily use and are required to continuously withstand

Many of the large parts and components installed in and on cars

potholes, cracks or uneven road surfaces. In addition, they are in

are subjected to extensive stress and environmental influences on

continuous contact with moisture, cold, heat, salt, grime and air.

the road. As a result, both chassis parts and safety-relevant parts

Long-term, effective corrosion protection is urgently required to avoid

such as axle carriers or wishbones/trailing arms require long-lasting

rust and malfunction. The situation is a similar one for the wishbones,

surface and corrosion protection. A good example for this is axle

trailing arms and twist beams fitted to the chassis, which are made

carriers made from aluminium or steel. The pivot points of the wheel

from steel or aluminium, depending on the class of vehicle. These

suspensions are secured to these - on the front axle carrier typically

are exposed to diverse environmental influences on a daily basis.

also the engine, gearbox and steering gear. As safety-relevant and

Corrosion damage to any of these components would have fatal

load-bearing components, the axle carriers are exposed to extreme

consequences for car passengers and bystanders. To ensure the

© Dörken

Large components such as mounts, axle parts or triangular control arms can be protected against corrosion with a zinc flake coating.

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lifetime and function of the components, and therefore the vehicle, especially resistant coating systems are required.

Coating options to combat corrosion Passive corrosion protection such as KTL coating is often used to prevent corrosive impact on the aforementioned components.

KTL - cathodic dip coating - is an electro-chemical coating process in which the component is coated via direct current in a tank filled

GLOBAL SOLUTIONS FOR WATER TREATMENT

with an aqueous, electrically-separable dip coating. The thickness of the deposited coat is typically between 10–40 μm. An annealing process cross-links the coating layer to form a homogeneous, cohesive film. This cross-linking and the resultant barrier effect largely protect the component. As the KTL paint also penetrates the smallest hollow spaces and is deposited there (engulfing), it is also possible to evenly coat larger components with complex structures. A second topcoat - typically a powder coating - enables further properties such as individual colouring or chemical resistance to be achieved. A problem with this: the KTL coating

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

does not achieve a cathodic corrosion protection effect. If the coating is damaged, rust can soon form. This problem can be resolved via an innovative system from Dörken, which combines cathodic dip coating with a zinc or zinc flake basecoat, thereby achieving highly capable cathodic corrosion protection.

Proven corrosion protection through zinc flake coating Tried and tested for many years in the car industry for bolts and fasteners, high-performance zinc flake coatings are also highly advantageous for large parts subjected to high levels of stress.

The distinctive feature: with coats as thin as 8–20 μm – usually a combination of base and topcoat – a protective effect of more than 1,000 hours can be achieved against base metal corrosion (red rust) in salt spray testing in accordance with DIN EN ISO 9227. In combination with a topcoat to match the respective requirements, a high degree of cathodic corrosion protection is provided, including after stone impact. This means: in the event of damage to the coating the ignoble zinc in the basecoat sacrifices itself on contact with water and oxygen in favour of the more noble steel base material. A further advantage: no hydrogen is generated in the coating process, with the result that no application-

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

related, hydrogen-induced stress corrosion cracking occurs. As a consequence, the zinc flake technology is also suitable for coating high-tensile steel (classes 10.9 and higher). The low cross-linking temperature of 220 °C also avoids damaging the steel through excessive heat.

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

SPECIAL ISSUE ON AUTOMOTIVE

© Dörken

Triangular control arm after stone impact test in accordance with DIN EN ISO 20567-1 and salt spray test in accordance with DIN EN ISO 9227 Left: No Dörken coat and no cathodic corrosion protection results in red rust after 144 hours; right: Min. 720 hours without red rust with Dörken coat and cathodic corrosion protection.

Effective corrosion protection for large car components

Conclusion

(Large) components fitted in and to cars require surface protection

If large components in and on cars are to be given enduring and

tailored to their requirements and area of use. Zinc flake systems are

effective protection against the effects of corrosion, a zinc flake

not only ideal for large components such as wishbones, trailing arms

coating comprising basecoat and topcoat and tailored to the

and twist beams. Even parts with complicated or intricate geometry

respective requirements is the recommended choice. This achieves

can be coated without any problem. The internal coating of tube

outstanding long-term performance even with extremely thin

constructions or the coating of cavities and weld nuts is therefore

coats, whilst also satisfying the strict requirements of the latest

also no problem. This thin coating also means that weight savings

manufacturer quality tests.

can be made - an aspect that is not only of significance in the field of lightweight construction, but also that of climate protection.

Characteristics of the Dörken zinc flake systems at a glance • High cathodic corrosion protection

• No risk of application-related, hydrogen-induced stress corrosion cracking

• Tailored system of base and topcoat

• Attractive appearance thanks to coloured topcoats

• Extremely thin layers of 8–20 μm

• Setting of co-efficients of friction and fastening characteristics

• Threaded parts without reworking / recutting • Low cross-linking temperature (to max. 240 °C)

• High chemical resistance • Chromium VI-free and resource saving

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booths

ovens

cataphoresis

tunnels

complete plants

eosmarketing.it

conveyors

IDEAS NEED TALENT C.M.V. srl - Via dell’industria, 2 - 61036 Tavernelle di Colli al Metauro, PU - Italy - T +39 0721 892274 - info.cmv@cmvimpianti.it - www.cmvimpianti.it

The series of shoots to celebrate the 40th birthday of the BMW M1 designed by Andy Warhol.

ART WITHIN SURFACES

SPECIAL ISSUE ON AUTOMOTIVE

Beauty and Speed: when the Automotive Industry Meets the Art It is a pop art icon, one of the most expensive cars in the world, but also one of the most extraordinary: the BMW M1 Art Car was painted by Andy Warhol in 1979. ipcm® has chosen to talk about it in this section because it represents the perfect match between industry and art.

T

hey race, are traded as works of art and are practically

American sculptor Alexander Calder. A few months later, Poulain

priceless: the BMW Art Cars. For more than 40 years, they have

unveiled the powerful multi-colour lightweight coupé at Le Mans

been the highlights of the BMW Art Car Collection. The French

– the first instance of BMW performance art. Since then, the BMW

auctioneer and hobby race car driver, Hervé Poulain, invented the

M Art Cars have been hot-selling exhibits. And some of the most

BMW Art Cars. In 1975, he dreamed of competing in the 24-hour

spectacular combinations of speed and beauty.

race at Le Mans in an artist-designed racing car. His biggest wish: a

To date, a total of 19 BMW Art Cars, based on both racing and

super sports car. His greatest happiness: BMW Motorsport GmbH,

regular production vehicles, have been created by artists like David

founded three years previously. They recognised the potential of

Hockney, Jenny Holzer, Roy Lichtenstein, Robert Rauschenberg, Frank

this seemingly crazy idea, and had a BMW 3.0 CSL painted by the

Stella, and Andy Warhol. The most recent artist to the join BMW Art

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© Stephan Bauer

© Stephan Bauer

© Stephan Bauer

Car program is Cao Fei in 2017 with her M6.

40 years later, enthusiasm for the mid-

regard his Art Car as the highlight of the entire

One of the BMW Art Cars most popular is

engined sports car remains unabated. Already

collection. It’s therefore hardly surprising that

the BMW M1 created by the pop artist Andy

world-famous at that time, the US icon of

Munich-based automobile photographer

Warhol in 1979. Showcased in some of most

Pop Art shared the same passion with many

Stephan Bauer spontaneously opted for

important cities in the world, today its value is

automobile fans of that bygone era. And the

the BMW M1 finished in the Warhol design

priceless.

fascination of the unique special created

when he was selecting his dream subject on

“I love this car. It’s more successful than the

by Warhol has indeed increased. Many fans

four wheels. Bauer emerged as the victor in

artwork,” was the opinion of Warhol after

the Social Media Contest “Shootout 2018”

his sweeping brush strokes with 6 kilograms

organised by BMW Group Classic and he

of paints had transformed the BMW M1. It

was given the opportunity for an exclusive

marked the starting point of M GmbH in 1978,

photo shoot with BMW Art Car Number Four.

and is still regarded as the ultimate super

A series of photos was created to mark the

sports car. So it’s no surprise that none other

40th birthday of the BMW M1 designed by

than Andy Warhol should have designed

Andy Warhol. They provide a completely new

the car. The sleek inline 6-cylinder with gull

perspective on one of the most legendary

wing doors and pop-up headlights was an

vehicles from the history of BMW. 40 years

absolute novelty in the history of racing with

ago, this automobile both celebrated its

470 hp. When the BMW M1 is in full throttle,

sporting debut in the Procar Series and

all lines and colours blur into a regular colour

entered the annals of Pop Art history.

Against the backdrop of an old factory

explosion. Speed has never been depicted so beautifully. Supposedly, Andy Warhol finished his painting in just over 28 minutes.

© BMW

Andy Warhol painting the BMW M1.

building in Cologne, Stephan Butler choreographed a spectacular contrast

international PAINT&COATING magazine - MAY/JUNE 2021 - N. 69

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SPECIAL ISSUE ON AUTOMOTIVE

between the brightly coloured Art Car and

© BMW

the dour grey of the abandoned industrial structure. At a subsequent outdoor session, laser search lights shrouded the BMW M1 in a positively mystical atmosphere. In both settings, the Art Car kept emerging from a completely new perspective – and always to perfection.

Andy Warhol’s Art Car proved to be a dream subject for the recent photo shoot in Cologne. The artist himself made things much more difficult for the photographers.

40 years ago, the cameras had hardly been set up when Warhol had already finished painting the bodywork in all the colours of the rainbow. As the artist explained later, his speed was a reflection of the statement made by his work of art: “I attempted to show speed as a visual image. When an automobile is really travelling fast, all the lines and colours are transformed into a The BMW 3.0 CSL painted by Alexander Calder.

blur.”

Very soon after the last brush stroke had been applied, the BMW M1 styled by Warhol demonstrated just how fast an artwork can

© BMW

be. In June 1979, the BMW M1 emblazoned with start number 76 competed in the 24 Hour Race of Le Mans. German driver Manfred Winkelhock, and Frenchmen Hervé Poulain and Marcel Mignot drove the Art Car to second place in its class and achieved a ranking of six in the overall standings.

The dreams of a race car driver, an artist and a photographer revolved around this fabulous vehicle which, thanks to colours and artistic touch, doesn’t ever lose its newness.

Scan the code to watch Andy Warhol painting the BMW Art Car The first digital BMW Art Car created by Cao Fei.

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© ipcm

FOCUS ON TECHNOLOGY

Fluiver Combines Long-Standing Expertise and Innovation for the Optimal Coating of Large-Sized Plastic Parts Monica Fumagalli ipcm

®

The strength of Fluiver, a company specialising in the top-quality finishing of plastic, is its ability to reconcile the craftsmanship of manual application processes, the result of thirty year of experience in the sector, with innovative ideas, implemented to optimise its coating process.

F

ibreglass (or Sheet Moulding Compound, SMC) is one of the plastics that, thanks to their excellent mechanical and chemical-physical performance degree, have experienced

rapid development in the automotive and ACE sectors in particular.

Specifically, this is a thermosetting sheet material consisting of glass fibres, mineral fillers, pigments, and unsaturated polyester resins.

One of the advantages that make it such a sought-after material is the possibility of modifying its components, e.g. the orientation or type of fibres, in order to obtain appreciable variations in the chemical-physical characteristics of end products and thus achieve the performance level required for different applications.

This guarantees smooth, homogeneous surfaces (achieved by hot polymerisation following thermoforming in steel moulds), reduced weight, ease of transport (thanks to which it can replace more conventional materials such as steel to reduce vehicle weight by 15-20%), simple installation, long service life, and no need for maintenance.

“However, it is also one of the most difficult materials to coat due to its extreme porosity,” explains Franco Bertolotti, the Production Manager of Fluiver (Albano S. Alessandro, Bergamo, Italy). “Specialising in the coating of this and other plastics used in the automotive and ACE Fluiver specialises in the coating of plastic components for the ACE and automotive sectors.

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industries was our first objective when we founded our company last year.”

FOCUS ON TECHNOLOGY

© ipcm

The compact coating plant installed by MI Due.

Fluiver is a young business that, however, was born from the thirty-

treat large-sized parts, another aspect that is becoming crucial to

year experience of a group of car refinish specialists. “Each of us

Fluiver’s success.”

brought their own work experience into Fluiver, thus combining the car part coating. Our speciality is the manual coating of plastic and

Fluiver’s strategy conquers even the most difficult markets

ferrous materials, provided that they have been previously treated

“Currently, we especially serve the earth-moving machinery sector,”

and made ready to be painted. Thanks to the design and installation

adds Bertolotti, “for which we handle parts up to 3.5 x 2.5 m in size.

of a system specifically tailored to our production needs by MI Due

What makes us competitive in this market is precisely the large size

(Besana Brianza, Monza e Brianza, Italy), we apply top-quality finishes

of our coating booth, which enables us to treat huge components,

that are appreciated in the industry – especially because we can also

such as those of earthmoving machines that no other coater in the

different skills we had acquired in the fields of plastic moulding and

© ipcm

Components with different shapes and large dimensions painted by Fluiver.

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SPECIAL ISSUE ON AUTOMOTIVE

area is able to handle. This is also why we are in the process of being

flame-hardened. “Subsequently,” adds Bertolotti, “we apply different

recognised as approved applicators by some of the most important

systems depending on the material to be treated. We may use either

players in the ACE sector.”

two-coat systems, in high demand in the earth-moving machinery

This choice might have seemed risky, but it has also enabled the

sector, consisting of water-based primer + top coat or base coat/

firm to establish itself in another extremely competitive market, the

top coat + clear coat for ABS, or three-coat system including primer

automotive one. “It would have been difficult for a newly founded

+ base coat + clear coat. The flexibility of Fluiver is also guaranteed

company such as ours to enter the already-saturated market of

by the possibility of managing batches of up to 10 workpieces with

the automotive supply industry. Therefore, we chose to provide

different shapes requiring the same colour. We apply up to 10

customers in this sector with the top-quality manual finishing of small

different tints.”

batch parts, including for instance vehicle front panels, which are

The painting process continues with the drying of the applied film.

difficult to coat with an automatic operation. The large size of our

“In the case of SMC, we also proceed with grouting any imperfections

coating booth even enables two operators to work at the same time,

because the material can “degas” during the drying process: this is

thus speeding up our painting process.”

why the flash-off of the primer takes place at a temperature about 6

The variety of the plastics treated is also one of the reasons why

degrees higher than that of the top coat.”

Fluiver is appreciated by the market. “We coat all plastics and, in particular, SMC, EMC, and injection-moulded and rotomoulded

A pioneering coating plant

materials that need to be prepared from the raw, out-of-mould state,

The concept of the plant combines the expertise gained from the

as well as all injection-moulded polymers, such as polypropylene,

previous work experience of the Fluiver team with the technical

polyethylene, polycarbonate, ABS, and many others, for which we

know-how of the MI Due staff. “I personally designed and drew the

guarantee the total elimination of any joint lines, porosity, blow-holes,

layout of this coating system. I then submitted it to Carlo Casiraghi,

and any other defects related to the moulding process, thanks to the

the owner of MI Due, which was one of the few plant engineering

manual sanding operation we carry out on all components.”

firms to make themselves available for its construction. That further confirmed the professionalism of this company, with which I had

The flexibility of the coating cycle

already collaborated while working for other firms in the past.”

After sanding, the coating preparation phase continues with a manual

In addition to the large size of its booth, one of the original technical

cleaning phase with water; in the case of polypropylene, the parts are

aspects of Fluiver’s coating line is its workpiece handling system:

© ipcm

© ipcm

The manual sanding station.

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The customised trolleys designed for Fluiver’s handling needs.

FOCUS ON TECHNOLOGY

© ipcm

© ipcm

The inside of the dry coating booth.

The edrizzi® cubes.

“I avoided installing a conventional line with a traditional inverted

water-curtain one; I immediately endorsed this solution, too, because

conveyor, which would not have been functional due to the large

it is both easier to clean and more fitting to the type of application

dimensions of the parts we intended to treat. We therefore

process we carry out. However, dry coating certainly also means

created a handling system consisting of trolleys with supports

more frequent filter changes. In addition to the filters supplied to

designed specifically for this type of workpieces. At the same time, a

us by MI Due and the pre-filtering clothes developed by Valspray

conventionally-sized booth would also not have been appropriate:

(Brembate Sopra, Bergamo), we have recently installed 70 edrizzi®

this is why we opted for a solution with a considerable size of 6.5 x

cubes. This paint mist separation system developed by Austrian

5 m and a height of 4.5 m, which will help it remain clean for longer

company Brainflash should enable us to replace our filters only once

time.”

a year.”

Characteristics of the tailor-made system

Valspray also provided the coating application system. “Together with Valspray’s technicians, we built a coating management unit including

The plant went into operation on 15 December 2020 and it is

5 pumps: one for base coats, one for pigmented top coats, one for

prearranged to accommodate a larger oven and a second booth in

metallic top coats, one for water-based primers, and one for clear

future, in order to further expand the company’s production capacity.

coats. At the moment, the system is operated manually, but we plan

“One of the aspects I most appreciate about this system,” states

to integrate gear pumps and solenoid valves. The next step will be

Bertolotti, “is its compact design, thanks to which we were able to

choosing an automatic mixer.”

install the booth in an area of the factory with limited space, despite

The line continues with a flash-off tunnel and a drying oven featuring

its large size.”

a heat exchanger that reaches a maximum temperature of 95 °C.

The line includes a pressurised cleaning chamber and a static booth

“In this case, too, we relied on the experience of MI Due, which, on

with a dry filtration system, which enables Fluiver to fall well within

the basis of the maximum temperatures reached for our processes,

the permitted parameters for particulate emissions (3 mg/m3). “On

recommended the use of a heat exchanger instead of air vein

the advice of MI Due’s staff, we preferred a dry booth rather than a

burners.”

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117

SPECIAL ISSUE ON AUTOMOTIVE

Manual and automatic coating: the two cores of Fluiver’s future paintshop “At Fluiver, we have opted for manual application both because of the characteristics of the parts we handle and because it ensures high quality finishes,” says Bertolotti. “However, this does not exclude that we may rely on automation for our second coating booth: we do not want to distort one of our main characteristics, but we certainly aim at further diversifying our production and applying our top-notch skills to automatic coating, too. I have a project in mind for a new coating line © ipcm

with an inverted conveyor that moves our workpiece-handling trolleys as if they were skids: another original concept that I am sure MI Due will be able to develop. Our intention is to continue on the path of innovation with new ideas and insights, but without losing sight of the quality level guaranteed by manual application processes. These will continue to characterise our work and our care for all our operational phases, which is fundamental to deal with the most difficultto-coat materials.”

© ipcm

From top to bottom: - The coating management unit developed by Valspray.

- The flash-off tunnel. © ipcm

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- The inside of the drying oven.

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www.infragas.com

INFRARED RADIANT GAS SYSTEMS FOR THERMAL TREATMENTS

uffi

© Arz

Metal packaging for the cosmetic industry.

INNOVATIONS: PRESENT&FUTURE

Arzuffi’s Line-Met System Conquers the Decorative Industry by Offering Maximum Automation at Reduced Costs Mara Arzuffi Arzuffi Srl – Bernareggio (Monza e Brianza), Italy

mara.arzuffi@arzuffisrl.it

Arzuffi’s Line-Met metallising plant family expands into the cosmetic and glass packaging sectors to offer maximum automation at a reduced investment cost.

D

espite the global health crisis, the figures recorded at

These plants guarantee full automation, continuity with the existing

the end of 2020 show that the packaging industry in Italy

line and reduction in investments costs: in fact, the expensive robots

reached a turnover of around 34 billion Euros, with the

used in conventional lines are replaced by a single cartesian arm.

glass packaging sector showing one of the most positive values (+8% compared to 2018 data)1. In this particular sector, production lines

The new line for cosmetic packaging: Line-Met V5

are characterised by high volumes and automation technologies

The new Line-Met V5 system consists of a workpiece loading station,

of the highest level. The automation of the coating processes, from

3 process chambers, and a final unloading station integrated with an

basecoat to metallization up to topcoat, is among the plant solutions

automatic device for returning the tray to the beginning of the line.

that weigh most heavily on companies’ costs, precisely because of the

In order to meet the needs of the cosmetics industry, the traditional

high robotisation and mechanisation level required. In order to meet

static sputtering process has been replaced by the new dynamic

its customers’ needs, which have become even more urgent at this

sputtering technique, guaranteeing a significant reduction in costs.

difficult time, when the cosmetics sector has experienced a setback

The productivity of Line-Met V5 is unprecedented: with a cycle time

for the first time in its history, Arzuffi Srl has developed a new series of

of less than 45 seconds, it achieves a line speed of 20 meters per

systems called Line-Met V5 and Line-Met V6.

minute, exceeding the one achieved by the majority of the painting lines. With reference to a 16 mm-diameter mascara tube, this plant

https://www.italiaimballaggio.network/it/il-settore-del-packaging-2020-2-istituto-italiano-imballaggio

1

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is capable of metallising 1200 bars (standard length of 900 mm) per

INNOVATIONS: PRESENT&FUTURE

hour, equivalent to approximately 25,200 mascara tubes per hour.

Another key aspect is the complete automation of the burdensome loading and unloading of trays or bars from the existing coating line, which can be easily integrated into the system. The tray has a useful coating area of 900 x 600 cm, but it can be adapted to customer needs and even allow loading different kinds of workpiece fixtures/ support.

How the new line works The operation of Line-Met V5 is similar to that of traditional Line-Met systems, developed and created for the automotive industry and now chosen for years by the world’s leading manufacturers of car interiors, exteriors, and headlights. The line operates continuously and runs 24/7 without any interruption between base coat application, metallising, and top coat application. Its three chambers perform a loading and plasma etching phase for surface activation, a dynamic sputtering phase, and a ventilation phase. The metal layer is deposited evenly and uniformly on all products placed in each tray thanks to the transverse positioning of the cathode in the upper part of the chamber and the underneath transition of the trays.

The unloading station includes a device for lowering each tray and returning it to the first station, where the Cartesian robot’s mechanical arm picks it up and brings it back along the coating chain to unload the metallised components and load new ones to be treated, thus starting a new cycle. Having a single loading/ unloading station allows installing only one arm, as opposed to the two robots typically required for loading and unloading parts at the beginning and end of a cycle, thereby optimising time management and the efficiency of the entire system and dramatically reducing its automation costs.

© Arzuffi

Example of a Line-Met V5’s tray with mascara tubes.

©A

rzu ffi

The advantages of Line-Met V5 at a glance

The V6 system maintains the same technological processes as the V5, but it

• Very high productivity thanks to a line speed

differs in the structure of the chambers,

of 20 m/min.: compared with conventional

which are higher and narrower. In the

systems, production throughput is almost

dynamic sputtering chamber, using the same

three times higher;

technology used to coat bottles, the parts

• compact and flexible layout;

undergo a double movement, sliding in front

• the system can be easily integrated into

of the cathode positioned vertically on the wall

existing lines;

of the chamber and simultaneously rotating

• the automation system means less handling

on their axis.

of components, resulting in higher coating

The added value of Line-Met V6 is the fact

quality and reduced rejected pieces, as well

Glass bottles with metallic effect.

as lower labour costs; • prearranged for integration into Industry

that, by changing its speed and dispensing power parameters, it is possible to obtain different effects, from semi-transparent to

4.0-oriented company systems;

containers, from cosmetics to beverages, from

coloured or backlit, thus offering incredible

• reduced plant cost, roughly corresponding

pharmaceuticals to food, their production is

consistency on a wide range of products, from

to that of a batch sputtering system;

characterised by difficult handling operations.

magnum bottles to vials.

• investment affordability within the reach of

Arzuffi has decided to lend its technological

any company.

expertise to this field as well, choosing to

Conclusions

exploit the same fixtures coming from the

Meeting customer needs is the goal of all

base coat (where applicable) and headed

companies. Surprising them with solutions

Line-Met V6: a tailor-made concept for glass packaging

to the top coat for a twofold advantage:

that exceed their expectations in terms of

One of the critical issues faced by the

reduction of rejected pieces due to excessive

both technological innovation and cost is a

glass packaging industry is the fragility of

handling of glass and elimination of additional

mission shared by many but achieved by few.

components. Whatever the intended use of

costs for the purchase of metallising tools.

Arzuffi is one of them.

© Arzuffi

Line-Met V5 with the cartesian arm for loading/unloading.

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Partners for the successful renovation, implementation and commissioning of your coating plant.

Revamping, implementation, renovation, modification, recovery, and relocation of painting installations

info@avin.it professionality

know-how

punctuality

www.avinsrl.com

© CBV Blechbearbeitung GmbH

FOCUS ON TECHNOLOGY

CBV Blechbearbeitung Improves its Production Depth, Flexibility, and Energy Efficiency with the Help of Italian-Made Technology Sven Kraus ipcm

®

An increased loss of time in surface treatment by external contract coaters and the resulting delays in delivery to its customers prompted CBV Blechverarbeitung to realise the coating of its sheet metal components itself. The components have therefore already been coated in our own factory since October 2020.

I

n spring 2019, CBV Blechbearbeitung GmbH decided to insource the coating of its sheet metal components, which until then had been carried out by a few local coating contractors. In fact, due to increased demand and the

simultaneous shortage of skilled workers within these firms, the lead time for the surface treatment of its parts was becoming longer and longer, up to time-to-market delays of four weeks. For CBV, this was no longer sustainable.

That is why, since October 2020, it has carried out the coating of its sheet metal components in-house, at its headquarters in Laasdorf (Germany). With the help of Eurotherm’s Italian-made technology, CBV is thus almost self-sufficient in terms of its production depth, it has been able to increase its flexibility, and it has now full control over the coating process as well as the lead time of its parts.

Reasons for the investment As a specialist in sheet metal processing, CBV has been manufacturing large and small mechanical building parts in all industrially relevant metals for almost three decades, with particularly wide expertise in lightweight constructions with stainless steel, aluminium, and their alloys. Its portfolio also includes design and programming services, as well as the production of individual, small, and mediumsized series, thanks to its know-how in the laser cutting, CNC punching, forming, edge breaking, welding, and surface treatment of thin sheets with thicknesses Some coated items during the curing phase in the Eurotherm’s oven.

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ranging from 0.1 to 25 mm, mainly in steel, stainless steel, non-ferrous metal, and aluminium.

FOCUS ON TECHNOLOGY

Together with company founder Werner

© CBV Blechbearbeitung GmbH

Neumann, the firm’s management decided to invest in its own coating installation for a variety of reasons. One of the decisive factors, however, were the increasingly long process times resulting from the outsourcing of its coating operations. “Due to the increased lead times at our coating contractors, we were experiencing more and more delays in the delivery to our customers. We could no longer accept these losses of time, in the interest of both our company and our customers,” says Enrico Liebold, the surface treatment department manager of CBV. A special, challenging requirement for the new coating plant technology was the installation of a C50 MGT micro gas turbine. Contributing to the company’s electricity and heat supply through its in-house photovoltaic system, it had to be integrated into the system as an energy and heat source, especially as the oven’s heat source. Indeed, energy efficiency has always been one of the most important aspects in the corporate philosophy of CBV Blechbearbeitung GmbH, also with a view to the savings potential achievable through the optimisation and implementation of different

The plate sheet pre-treatment department.

coordinated, individual measures into one overall concept.

© CBV Blechbearbeitung GmbH

During the tender process, it quickly became clear that Eurotherm, an Italian coating systems manufacturer based in Turin, was the right partner for the development and installation of this system: right from the start, it proved to be flexible and solution-oriented with regard to the complex requirements posed by the integration of the micro turbine in the process flow.

The genesis of the plant The planning phase for the coating plant began in spring 2019. After completion of the tender process, construction work began in June 2020. In October 2020, CBV Blechbearbeitung GmbH could start its inhouse surface treatment operations on an area of about 1,200 square metres, including office and staff areas. Five people are currently

The pieces preparation to the coating process.

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125

© CBV Blechbearbeitung GmbH

© CBV Blechbearbeitung GmbH

The cleaned pieces are carried out at the coating department.

The coating department.

employed in the surface treatment department.

integration of the micro turbine in the process flow. The decisive factor

The plant technology supplied by Eurotherm consists of both manual and

here was the ability to cool down the hot air coming from the micro gas

automatic stations. The system includes the following individual stations:

turbine (about 278 °C) to a maximum temperature of 200 to 210 °C, at

a dryer, a manual powder coating booth, two paint extraction walls

which the oven is operated. And, from CBV’s point of view, Eurotherm

(Euro 3H and Euro 3.2), and an oven. The sheet metal components go

presented the most coherent concept for this.

through the pre-treatment, rinsing, drying, and powder coating processes

In addition to its excellent technology and skilled service, Enrico Liebold

and then reach the oven, the core of the plant. This was designed and

is very pleased with Eurotherm’s cooperation. “The cooperation with

manufactured by Eurotherm.

them was always easy, fast, targeted, and professional. In particular,

The oven booth has a size of 4 x 2 x 2.5 metres (L x W x H); it is loaded

their assistance during the construction phase was excellent. The

manually and it can accommodate components with a maximum size of 4

coordination between Eurotherm and the other companies involved was

x 1.2 metres (L x W).

also perfectly smooth, despite the language barrier, as all exchanges

As mentioned, the integration of its micro gas turbine as an energy

occurred in English.”

and heat source was a basic requirement for CBV, especially in the oven station. During the tender process, it quickly became clear that

About CBV Blechbearbeitung

Eurotherm was the right partner for the development and installation

After almost thirty years spent operating with passion and competence

of this system: right from the start, it proved to be flexible and solution-

in the sheet metal processing industry, success has proved company

oriented with regard to the complex requirements posed by the

founder Werner Neumann right, as have the numerous awards

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FOCUS ON TECHNOLOGY

Custom-built painting installations Macchine e impianti realizzati su misura

Shot blasting booths Cabine di sabbiatura

Washing tunnels Tunnel di lavaggio

Liquid painting installations

Impianti di verniciatura a liquido

© CBV Blechbearbeitung GmbH

The manual coating of the items.

Powder painting booths

Cabine di verniciatura a polvere

received by his firm. The last one was awarded by the Oskar Patzelt Foundation in October 2019, for its outstanding entrepreneurial Founded in October 1992 as an owner-managed company, it began production in February 1993 in a former pig farm in Mörsdorf (Germany). The management put together the necessary machinery from parts of the formerly nationally-owned Carl Zeiss factory.

Curing ovens

Forni di cottura

Three years later, fifteen employees were already working for CBV Blechbearbeitung GmbH. In 1999, the production area in Mörsdorf reached its maximum capacity. The company’s new headquarters in Laasdorf were inaugurated in April 2001. After nine months of construction, production could already be moved to the new location and the newly gained space was used to expand the firm’s plant equipment.

The economic crisis in 2008 hit CBV hard. The company’s turnover collapsed, resulting in layoffs and redundancies. One of the

Eurotherm S.p.A. T +39 011 98 23 500 | M info@eurotherm.eu Eurotherm Oberflächentechnik GmbH T +49-7571-92795-10 | M contact@eurotherm.eu

managing directors also left the company: Ronny Neumann, the son Eurotherm France S.A.S. T +33 (0) 4 90 55 20 75 | M france@eurotherm.eu

www.eurotherm.eu

Made with passion in Italy

achievements, high economic commitment, and social engagement.

of the company’s founder, succeeded him and thus turned CBV into a purely family-run business. All in all, the firm managed to take advantage of the crisis as an opportunity and a chance to rethink its business. All economic and technical factors were reviewed and new concepts developed. In 2010, LED lamps replaced all lightning systems in order to reduce energy costs by 25%. In 2011, a photovoltaic system was also installed on an area of about 1,300 square metres. All these changes helped the company improve its position and gain new strength in the market.

In May 2012, the production area was expanded and an inhouse apprenticeship workshop including a seminar room was inaugurated, in order to secure the company’s future and counteract the shortage of skilled workers. This also reflects CBV’s corporate mission statement, considering people as the firm’s biggest asset. Staff turnover at CBV is very limited and a large number of employees have been with the company for years. The firm currently employs more than fifty people and it has about 1,000 regular customers and a database of about 100,000 parts and assembly groups.

Increasing competitiveness through ecofriendliness All of CBV’s measures for plant expansion and technological upgrade have managed not only to contribute to systematic energy efficiency and to savings in energy, resources, and costs, but also to improve the company’s competitiveness. In particular, CBV Blechbearbeitung GmbH is highly pleased with © CBV Blechbearbeitung GmbH

the investment in its own coating plant. Because of the new system, CBV is now almost self-sufficient in its production and CO² neutral. Moreover, the pre-treatment employs almost no drinking water, as collected rainwater is used. “We can adjust our production process’ flexibility, thus increasing throughput, depending on our needs. This was a very successful project, which will prove highly beneficial in the long term for our customers as well,” Enrico Liebold sums up in conclusion.

Above: Exterior of the curing oven designed by Eurotherm.

© CBV Blechbearbeitung GmbH

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Below: The integration of its micro gas turbine in the oven station as an energy and heat source was a basic requirement for CBV.

SUCCESS STORIES

© Tecnofirma

The Tecnofirma’s coating system with the Futura’s conveyor installed at ISA’s plant.

At ISA’s Plant, a New Coating System 4.0 Proves Strategic for the Efficient Use of Energy Resources In the manufacturing industry, there are increasing demands for environmentally friendly production processes. Designing and manufacturing surface treatment equipment, Tecnofirma Spa has made this its mission. In ISA Spa, specialising in the production of refrigerated display cabinets and furniture for public premises, it found a customer that shares its same vocation so much so that it has decided to invest in a new Industry 4.0-oriented coating plant guaranteeing maximum efficiency of energy resources.

I

n the HVACR sector, the focus on saving energy sources has become

“ISA was founded in 1963 in the Umbria region,” says Roberto Mela,

ingrained in the research and development of increasingly high-

Business System Manager of the company based in Bastia Umbra

performance products. This is why, when it started designing its

(Perugia, Italy). “It represents the excellence of an area internationally

new factory five years ago, ISA Spa, one of the most important Italian

recognised for its high standards in the fields of fashion and design.

manufacturers of refrigerated display cabinets and furniture for public

With our 5 brands (ISA, COF, TASSELLI, ABACO, and HIZONE), we

premises, laid the foundations for a path aimed at maximising the

currently export to 110 countries quality products with a high level of

efficiency of energy resources in a completely Industry 4.0-oriented

technology and innovation, also in terms of sustainability through the

structure.

use of natural refrigerants. ISA is one of the world’s most important

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SUCCESS STORIES

players in the field of furnishings for public premises, refrigerated display cases and cabinets for ice cream parlours and pastry shops, and professional furniture.”

In order to meet the new challenges of the global market, in 2017 the firm inaugurated a new 65,000 m2 factory, perfectly integrated with its surrounding environment and applying innovative production and logistics methods, with a significant space reserved for the R&D division. “Our new factory,” adds Mela, “was designed and built with a view to environmental sustainability and the safety and liveability of its working environment. One of the focal points of the project was integrating increased productivity with greater control over our quality levels and material flows, without forgetting the energy impact of our production processes. The same principle was applied to our paintshop,

© Tecnofirma

which was built by a team coordinated by

Interior of the coating booth.

Tecnofirma (Monza, Italy) and composed as follows: Futura Convogliatori Aerei for the conveyor, DN Chemicals for the pre-treatment chemicals, and Siver for the coating application booths.”

Perfect teamwork ISA’s research study to choose the supplier of its new coating line took almost two years. “Given the importance of the coating process for our products,” notes Mela, “we wanted to carefully select our partner. After thorough analysis of the proposals made by more than fifteen suppliers, our choice fell on Tecnofirma: we visited and certified its design division and workshops and we checked the operation of some of its old and new systems installed at other companies.

We were thus able to confirm its technical and construction skills and verify the robustness of its technological solutions. In Tecnofirma’s staff, we found the same expertise level and the same desire to innovate that has distinguished our company for almost sixty years.”

“Compared to their previous coating line, now dismantled,” says Alex Buzzi, Project Manager at Tecnofirma, “the new system features a

© Tecnofirma

A phase of the coating application.

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131

SUCCESS STORIES

higher-performance conveyor, combined with a multi-stage pre-

parameters in a paintshop means optimising its process and making it

treatment process developed by DN Chemicals to increase the range

as lean as possible by eliminating unnecessary activities and reducing

of products and thicknesses that can be handled. Lastly, the oven was

waste, in order to achieve a tense or semi-tense production flow even in

fitted with an energy recovery system that reuses the extracted hot air

such a complex production phase.”

to pre-heat the new one, so as to reduce methane gas consumption

“The use of an advanced coating process management system such

and increase overall energy efficiency.”

as the one developed for ISA,” points out Buzzi, “guarantees constant workflow control and production optimisation, from the received

The multi metal pre-treatment process

orders to the end products. In particular, in this system, a barcode

“The pre-treatment process developed by DN Chemicals,” explains

reader enables the loading operator to scan a production order that

DN Chemicals Sales Director André Bernasconi. “is an alkaline pre-

contains all the information needed to start a process, including the pre-

treatment phase guaranteeing good salt spray resistance properties

treatment cycle and paint colour required. The multimedia system that

on hot dip galvanised sheet metal, aluminium, and cold rolled steel.

manages the plant keeps the information acquired throughout the cycle,

The process does not produce any sludge at all, thus extending both

while at the same time integrating it with the main process parameters.

the replacement interval and the maintenance interval of tanks, bars,

Thus, the data string reaching the coating line is further enriched with

nozzles, and the heat exchanger.”

a series of information that, once the end product is unloaded, can be

If the line is stopped, no oxidation phenomena occur for a sufficiently

sent back to the management system to guarantee workflow control

long time and this makes it possible to avoid programming empty

and data analysis.”

racks, thereby increasing production efficiency. “The surfactants package,” says Bernasconi, “was designed both to ensure the

Conclusions

almost total absence of foam even during rinses up to almost room

“Numerous key elements characterised the design of our new

temperature and to facilitate the de-emulsion of oils in the alkaline

paintshop,” states Mela. “First and foremost, we wanted it to respond to

pre-treatment tank and their subsequent elimination. Finally, the plant

the pressing demands for safety, quality, and sustainability that should

was prearranged for any future upgrade of the current process, with

now be on the agenda of any company. In order to achieve these three

the possibility of integrating a final passivation stage, with or without

objectives, we first had to achieve maximum energy efficiency, reduced

atomisation.”

consumption of raw materials, and good production flexibility combined

Lean production in the paintshop

with high plant and process reliability and, last but not least, a reduction in the size of the coating system. By optimising the management of

“The line provided by

energy resources, this new

Tecnofirma,” notes Mela,

coating line has enabled us

“consists of two separate

to achieve the results we

loading stations, three coating

had set ourselves during

booths, and two unloading

the proposal analysis phase.

stations connected to software

Tecnofirma has long been

interfaced to ISA’s management

feeling the same market

system, thus guaranteeing

‘pressure’ for production

maximum flexibility and speed

processes with minimal

in the handling of orders. We

environmental impact and

are able to meet any request

it has been and is able to

from our partners thanks to

keep up with such requests

a colour catalogue of more

by investing its technical

than 100 RAL tints, applied

resources and expertise to

with about sixty colour-

meet the demands of its

change operations per day.

customers, just like ISA is doing.”

Implementing the Industry 4.0 © Tecnofirma

Some coated items.

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Salcomix è il marchio di AkzoNobel per un sistema di prodotti vernicianti industriali dal design modulare, che può essere utilizzato per fornire vernici per una grande varietà di applicazioni per l‘industria leggera, in modo rapido e flessibile. Questo è possibile grazie a un sistema di miscelazione che offre una superiore precisione del colore con la massima varietà di prodotto.

Salcomix is AkzoNobel's brand for a modularly designed industrial coatings system that can be used to provide paints for a variety of small-industry applications, quickly and flexibly. This is possible thanks to a mixing system that offers superior color accuracy with maximum product diversity.

www.akzonobel.com infosalcomix@akzonobel.com

0087–04019

www.salcomix.com

© Comau

The MATE-TX exoskeleton developed by Comau.

INNOVATIONS: PRESENT&FUTURE

Comau’s New MATE-XT: A Robust, Lightweight Exoskeleton to Support Coating Operators and Reduce Muscle Strain Stefania Bernabeo Comau, Grugliasco (Turin) – Italy

stefania.bernabeo@comau.com

Finishing operations require considerable physical effort from operators. Comau’s MATE-XT reduces the fatigue experienced by coating line workers even in less than ideal conditions and environments, without sacrificing convenience and safety. Certified EAWS by the Ergo Foundation, the MATE-XT exoskeleton effectively reduces the biomechanical risks encountered by coating operators, typically involved in loading/unloading or manual painting activities. It is now available in a more light and slim, and highly breathable version, offering more adjustment options and providing an excellent, measurable improvement in ergonomics.

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INNOVATIONS: PRESENT&FUTURE

T

he work performed on a coating line subjects operators to

exoskeleton reduces the effort required, thus making operations

continuous muscular and bone strain, which can lead to health

less burdensome and improving operators’ health. Thanks to its very

problems, mainly in the back area, and general fatigue. Both

thin, lightweight carbon fibre structure and its extremely intuitive

while hanging parts on frames and during manual coating activities,

adjustment system, MATE-XT can be quickly adapted to any body type,

the physical effort and repetitive movements required of workers are

from the slimmest to the largest ones. By replicating the physiological

high and constant. At the beginning of December last year, Comau

movements of human operators and providing optimal upper body

presented MATE-XT, a revised and updated version of its wearable

support, it facilitates any coating operation while greatly reducing the

exoskeleton, which is particularly suitable for supporting operators

effort required.

during finishing processes.

In addition, the MATE-XT exoskeleton does not require batteries,

Reducing physical effort

motors, or other devices to operate, which could hinder the workers’ movement and make the equipment heavier. There are currently

Comau has been developing industrial automation systems and

8 different levels of support available, which can be set or changed

products for almost half a century, specialising also in wearable and

quickly even while the activity is in progress, thus guaranteeing a

collaborative robotics solutions that reduce operator fatigue during

high degree of convenience during use. An exoskeleton of this type,

coating operations. With the aim of helping companies, whatever

therefore, facilitates the day-to-day operations carried out during

their size or sector, to improve the quality and productivity of their

finishing and coating processes, which require ever-higher quality and

processes and at the same time the wellbeing of their workers, the

effort levels. Finally, Comau’s global sales network enables it to quickly

development of this type of product has been an absolute priority for

meet any user needs and solve any issues that operators may face

this company. By providing support during physical activities, Comau’s

when using its exoskeletons, wherever they may be.

COATING PLASTIC PARTS? Coating systems and application technology from one supplier Your expert for automatic coating machines for coating metal parts, plastic parts, glass and many more will be happy to advise you!

www.sprimag.com

© Comau

© Comau

With the new product of Comau the muscular activity of shoulders decreases by 30%, and a considerable back support is guaranteed.

Certified, measurable physical wellbeing of coating operators

also reduces the risk of painting defects due to operator fatigue. In

MATE-XT is currently the only exoskeleton available on the market to

precision, quality, and performance. Customers can easily calculate

be included in the ergonomic risk evaluation index of EAWS (Ergonomic

their return on investment (ROI) through measurable ergonomic

Assessment Work-Sheet) issued by the Ergo Foundation, which attests

performance factors. Comau itself carried out studies with its

to a system’s ability to reduce biomechanical loads while carrying out

customers using the EAWS calculation method and it found that its

particularly demanding work. More than half of the workers who wore

MATE-XT exoskeleton can help to increase work precision during

this exoskeleton said that they felt a much lower level of exertion – the

activities involving continuous arm lifting by 27% and speed of

muscular activity of shoulders decreased by 30%, and a considerable

execution by 10%. Moreover, cycle times are reduced by at least 5%.

back support is guaranteed – which led to positive improvements in the

Resistant to water, dust, ultraviolet rays, and high temperatures,

quality of their working day.

MATE-XT is particularly suitable for industrial, non-industrial,

Improved efficiency: a positive side effect In addition to the health benefits for workers, Comau’s new product

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fact, from an operational point of view, MATE-XT promotes higher

and outdoor use in finishing and coating operations, but also for carpentry, construction, agriculture, assembly, and logistics applications.

Fully Automated In-Line Equipment

SPECIFICALLY DESIGNED FOR COSMETICS AND OTHER DECORATIVE INDUSTRIES • Easy prompt integration into existing painting line • Dynamic sputtering technology • Highest productivity at the most competitive price in the market

Arzuffi high vacuum systems Leader company in PVD and PECVD processes with over 30 years of experience Bernareggio (MB) • Italy • Phone +39 039 6012626 • info@arzuffisrl.it MADE IN ITALY

ITALIAN INNOVATION WORLDWIDE EXCELLENCE

INNOVATIONS: PRESENT&FUTURE

Alit’s Fastrip AP System for Sustainable Paint Stripping of Aluminium Profiles Claudio Burato Alit Technologies, San Bonifacio (VR) – Italy

info@alit-tech.com

The paint stripping of defective products is an essential step of a manufacturing process, and being able to carry out it in complete autonomy means bringing important benefits to the production chain. The new Fastrip AP system developed by Alit (San Bonifacio, Verona, Italy) now enables aluminium coating contractors to strip profiles themselves: in about three hours, defective profiles can be stripped, rinsed, and delivered ready to be reprocessed again.

A

luminium is considered the material of the future as it is light,

integrated with other Alit paint stripping technologies. This makes AP

versatile, sustainable, and fully recyclable, but it needs to be

a paint stripping system suitable for all aluminium manufacturers,

returned to its raw state in order to obtain an optimal product

extruders, converters, or coaters that need to restore badly painted

to reprocess. Alit Technologies is a company headquartered in the

profiles efficiently, cost-effectively, quickly, and without burdensome

province of Verona (Italy), specialising in products and machines

logistics.

for the chemical paint stripping of aluminium, zinc, and alloys. It

The genesis of the new plant

off-line plant that enables small batches of aluminium profiles to be

Fastrip AP’s development been a natural progression of the R&D

stripped quickly. This technological solution will especially enable

activity of Alit, which already has an extensive range of plant and

coating contractors to recover defective profiles without any loss

chemical stripping solutions for quickly removing powder coatings

of productivity. Like in-line chemical paint stripping plants devoted

(including Qualicoat 1 and 2) from hooks, frames, and metal structures

to hooks and using high-performance, low-environmental impact

in different sizes. In some markets, especially abroad, there is a lack of

formulations, the new AP system can be integrated into already

paint stripping contractors capable of restoring defective profiles in a

existing processing lines or installed as a stand-alone system, possibly

timely manner; this has an impact on companies’ process times and

© Alit Technologies

has recently developed a new system called Fastrip AP, a compact

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INNOVATIONS: PRESENT&FUTURE

flows. The AP system thus enables aluminium coating contractors, as well as extruders needing to strip profiles before re-melting them, to take immediate action on defective materials without excessive processing or logistical operations. AP is also available as a multi-tank plant (with larger tanks and an overhead crane), designed for paint stripping contractors requiring a system than can handle higher, more constant workloads.

Functionality and convenience of the Fastrip AP system This new off-line paint stripping system can

© Alit Technologies

accommodate 30 to 70 aluminium profiles up to 8 metres long. It enables the material to be stripped and ready for reprocessing in about 3 hours, thus significantly reducing the time required by the production chain. This compact system has two tanks, a stripping one and a static or dynamic rinsing one (with a usable cross-sectional area of 50 cm x 50 cm), and a loading and unloading station. The operator can approach the plant with a wheeled basket containing the material to be stripped, similarly to what is done with immersion pre-treatment plants.

The machine automatically hooks up the basket, lifts it, and starts the first cycle in

© Alit Technologies

the paint stripping tank, which contains Alit’s environmentally friendly alkaline paint stripper Metastrip 1333/1. The plant’s handling system allows continuous “swinging” (i.e. a quiet vertical movement of the basket), which increases the performance level of the paint stripping bath. At the end of the cycle, the operator can assess the parts’ cleanliness degree and decide whether to continue with the paint stripping process. The system then automatically transfers the basket to the rinsing tank, where the swinging movement continues. Finally, the basket is transferred to the unloading station, which also includes a drip tray.

The paint stripping tank has a variable temperature (between 45 and 60 °C) and it is equipped with a lid. Its heating system

© Alit Technologies

From top to bottom: The two tanks and the coated aluminium profiles, the profiles exiting the stripping tank and the profiles entering the rinsing tank.

international PAINT&COATING magazine - MAY/JUNE 2021 - N. 69

139

© Alit Technologies

The profiles exiting the rinsing tank.

is electric and the heating elements are fixed to the outer wall to

high-performance, and the fresh paint stripper’s replenishment is

prevent contact between the heat source and the liquids, in order

reduced to the minimum. Considering that a cycle lasts an average

to guarantee maximum safety against any form of risk of fire. The

of three and a half hours, the machine can handle two baskets at the

tank is also set up for suction at low hertz if the lid is closed, but able

same time, thus guaranteeing a working autonomy of around 8 hours

to increase frequency once it is opened; emissions must then be

without human supervision.

channelled into a fume abatement system.

Paint stripping and the recovery of defective workpieces will become

The tank is ready to connect to a suction system which can be either

increasingly important in future.

already existing at the customer’s factory or supplied separately by

Therefore, coating contractors too will need an efficient and fast

Alit.

system to recover metal products, which will reduce costs and speed

Investment optimisation

up the production chain.

Although such an investment might initially seem expensive, the active

Soon on the market

chemical paint stripping bath can potentially last indefinitely if kept

Alit is currently concluding the latest internal tests of Fastrip AP’s

in good condition. Decanting and filtering of the stripping bath – AP

prototype system. After fine-tuning, the system will be made available

is connected to an ALIT’s filter press system – must be carried out

to the customers, who personally can see and evaluate it at the San

correctly. Thanks to these operations the product remains active and

Bonifacio site.

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BRAND-NEW

Europolveri 5L4 Matt Paints: 207 Hues of Peculiar Aesthetic Value The 207 elegant and sophisticated hues of the 5L4 Matt series by Europolveri have been developed in order to best enhance architectural and design elements. © Europolveri

T

he 5L4 Matt powder coatings made by Europolveri are ideal for granting a peculiar aesthetic value

to treated metal surfaces.

It is therefore possible to perceive directly from the surfaces not only the colour but also the type of coating that has been used, which has an opaque, elegant and sophisticated effect that is in highly requested, as it allows to enhance architectural and design components.

The 5L4 Matt series includes 207 RAL colours - all in accordance with the C.E.P.E directives (05-05-2004) - with a brilliance of 25 ± 5 Gloss.

It can also reach C5M-H corrosion protection (meeting EN ISO 129442 standards) according to the Qualisteelcoat (QSC) specifications, through the application of appropriate © Europolveri

painting cycles. 5L4 Matt paints are included in the Pural 5L series, so they are TGIC-free Qualicoat polyester products realised in accordance with Qualicoat class 1 technical specifications, thus guaranteeing a high degree of protection and durability. Consequently, these paints are suitable for the application on aluminium or steel frames in the architectural sector and, more broadly, wherever high resistance to atmospheric agents is required.

Warehouse storage of over 1,000 products 5L4 Matt paints are fully available in stock, starting from a minimum order quantity of 25 kg, together with other

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750 Europolveri products immediately available. It is therefore easy to guarantee fast delivery times. Technical support is also available, in order to recommend application cycles that use specific primers approved for QSC cycles.

The catalogue of the 5L4 Matt series can be consulted and downloaded from Europolveri website. It contains 12 folders depicting the reproduction of all 207 hues, their codes and characteristics.

For further information: www.europolveri.it

© Europolveri

INNOVATIONS: PRESENT&FUTURE

New Perspectives for the Quality Control in Industrial Coatings Carola Konitzer PhoenixTM GmbH - Bad Oeynhausen, Germany

carola.konitzer@phoenixtm.de

The quality control plays an increasingly important role in every phase of the manufacturing process.

In paintshops it is essential to guarantee a suitable monitoring operation and, consequently, perfect coatings.

Here is an overview of the solutions developed by PhoenixTM for measuring temperatures.

R

eliable production without effective quality control is

safely in the hazardous areas of the paint shop, legally complying

impossible. The demands are constantly increasing. Customer

to the working environmental classifications. In addition, there is a

specifications must be met and verified, as well as the

completely revised user software that has been specially optimised

specifications of the paint manufacturers. Especially in the coating industry, there are also more and more standards and certifications,

for the paint shop monitoring operation.

to which compliance is essential. But how can all these specifications

Phoenix’s TS04 Finishing System

and decrees be integrated into the operating processes as effectively,

The TS04 Finishing System is a complete solution for monitoring

economically and simply as possible?

temperature data, especially in coating processes. The system is

PhoenixTM has been very successful in the design and development

easy to operate and records the temperature data of the product

of temperature measuring systems for 10 years now. In addition

during the oven cycle. By attaching the thermocouples directly to

to the well-known systems, there are always new products that are

the product, such as a car test body, it is possible to introduce the

added to the product range and further developments. In addition

monitoring system onto the coating line at any time. There, the actual

to the new and innovative optical systems, there is the Epsilon-x

product temperatures are recorded.

system, which has been approved for ATEX zones and can be used

The data obtained in this way is stored in the data logger. This

Standard FIS04 temperature measuring system. © PhoenixTM

INNOVATIONS: PRESENT&FUTURE

© PhoenixTM

is protected from the

supplier cure specification.

temperatures prevailing in the

Profile comparisons with

oven by a thermal barrier. At

other measurements are also

the end of the process, the

possible. A standard report

data logger is removed and

shows all relevant information

temperature data downloaded.

and a graph. Subsequently,

With the help of the

various detailed evaluation

ThermalView finishing software,

reports can be created.

the raw data is converted into meaningful process data.

Phoenix Factor

With this information, quick

The Phoenix Factor is a curing

and well-founded decisions

index, a numerical factor that

can be made to solve baking problems. The measurement

Figure 1: New ThermalView Finishing Software.

results are available as a

accurately quantifies, from the complete temperature profile, how well the paint/

complete temperature profile at a glance and can be used, for

powder cure conditions match the paint supplier’s specification

example, for process or product optimisation, customer audits,

(activation temperatures, cures schedules, Fig. 1). The curing of the

reduction of operating costs, saving of resources and much more.

coating (polymerisation = cross-linking) is dependent on both time and temperature. For this reason, paint and powder manufacturers specify

ThermalView Finishing Software

“recipes” or curing charts according to which the paint should be

This software has been specially developed for the coating industry

“baked” in order to achieve a good quality result. This “recipe” is stored

and is an easy-to-use tool. The entire oven process is displayed

in the software as a “time at a certain temperature” curve.

using detailed graphical data. For example, the heat source and

If we look at these curves taking into account different cure/oven

fan positions can be stored so that problem areas can be located

conditions as shown in Figure 2, we find that the time at 180°C is

quickly. The ability to apply library paint cure parameters allows

identical for both curves, although the curves are in fact very different.

accurate, efficient analysis of profile data directly against the coating

If we take these curves and analyse them as they are against the

© PhoenixTM

Figure 2: Simple setpoint/actual temperature curve.

international PAINT&COATING magazine - MAY/JUNE 2021 - N. 69

145

specifications, we must conclude that undercuring has occurred here. Time at 180°C for only 7 min instead of the specified 12 min.

But how to analyse the holistic nature of the results? The application of mathematics allows the exact calculation of the curing of paints or powders including all curves in the temperature profile. The Arrhenius equation, named after its inventor Svante Arrhenius, describes approximately a quantitative temperature dependence in physical and chemical processes in which an activation © PhoenixTM

energy (here the transition to cross-linking) Figure 3: Arrhenius equation - Phoenix factor.

must be overcome at the molecular level (Fig. 3). For coating, it is assumed that the frequency factor (k) refers to the reaction temperature at which A and E both constants of the cross-linking reaction.

In relation to the temperature curve in Figure 2, this means that a reference curve is created using three temperature points specified by the coating manufacturer in order to determine the values between the points by interpolation (Fig. 4). In this way, the required curing time at any temperature is calculated for each measuring point. Then, taking into account the total curing time, the total equivalent of the curve at a given temperature (here 180°C) is determined (Fig. 5).

© PhoenixTM

The ThermalView software compares these Figure 4: Constant curve - reference curve of three points.

values and determines the curing index, the so-called Phoenix factor (Fig. 6). This is clearly and simply displayed in a graph and, as shown in Figure 6, provides an immediate overview of the measurement taken and its result. Despite the (supposedly) measured underbake in Figure 2, it becomes clear after a close look at all curves and the holistic inclusion of the process times and temperatures that the component was in fact theoretically overcured. The evaluation in Figure 6 shows (thermocouple 2) an equivalent time at 180°C of 27:28 min instead of the manufacturer’s optimum specification of 12 min. This is over twice the optimum bake time as shown with the Phoenix Factor being <2. A precise and holistic observation of the curing process,

© PhoenixTM

Figure 5: Calculation of the Phoenix factor.

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with the possibility of direct comparison of the

INNOVATIONS: PRESENT&FUTURE

© PhoenixTM

Figure 6: Evaluation of the Phoenix factor.

parameters specified by the manufacturer, is thus the more accurate

checks usually take place after the drying process. Defective products

alternative to “time @ temperature analysis”.

are then sorted out or reworked at great expense. PhoenixTM has

Focus on operational safety

now expanded its existing portfolio for in-process temperature monitoring in paint dryers with the new optical monitoring system.

The focus of the considerations was to create a device that meets

This is used by the technician to view the interior of the oven as well

the strict requirements of explosion protection at the workplace

as the product under production conditions. Like the temperature

according to the latest EU standards. The basis for further

measurement system, the system travels directly through the process

development here is the proven PTM1-200 data logger. The resulting

and captures a video as it passes through the oven, providing a

Epsilon series is intended to meet the requirements of the ATEX

complete picture of the paint drying process.

regulations (ATmosphere EXplosive = Explosive Atmospheres,

In paint drying processes, so-called paint drips, sags or curtains can

Fig. 7). PhoenixTM has further developed the data logger and the

occur from time to time, which represent a quality defect. The causes

associated components so that they comply with the valid ATEX

are known, for example, fans or burners generate air currents that

approvals according to Directive 99/92/EC (or ATEX 137). It has been

can disrupt the uncured paint or the melted powder. But it is not

certified accordingly and is approved for Ex zone 2. This is particularly

always easy to find out where and when these arise in the dryer. The

important for wet painting systems, as the paints are outgassed

new optical system now makes this possible directly in the process, in

during the curing process and, depending on the recipe, explosive

which a camera travels through the oven and records what happens

gases can be produced.

to the paint at the relevant points. In this way, problems can be

The benefits of the Optic system

detected and rectified without having to interrupt production. Oven revisions can also be better controlled in this way. The recorded

With the Optic system, PhoenixTM has added another effective tool

videos also provide information on whether there is any wear or

to optimise process control to the product family (Fig. 8). Visual

tear, for example, on the oven cladding, the insulation material or

international PAINT&COATING magazine - MAY/JUNE 2021 - N. 69

147

the racks. Defective fans or heating elements can also be detected,

Conclusion

as well as deposits and dirt. In this way, the user knows at any time

Precise knowledge of the various oven parameters is essential to

what condition the dryer is in and whether maintenance or repairs

optimise the product quality, productivity and efficiency of the coating

are necessary. The Optic System is available in different versions. It is

lines. This is a very important criterion, especially in the current

possible to use both an independent system and a combined system

situation, as it helps to reduce costs, increase productivity and thus be

that combines temperature and optical recording.

able to act more economically.

© PhoenixTM

Figure 7: Optical system with data logger. © PhoenixTM

Figure 8: ATEX-compliant Epsilon system.

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eosmarketing.it

SPECIALIZED TRAINING

ipcm® Academy: Ten Years of Specialised Vocational Training for Over 130 Companies Gabriele Lazzari ipcm

®

Our in-depth presentation of the training courses organised by ipcm® Academy continues with an interview with its co-founder Paola Giraldo. We find out with her why the need for a specific training course for coating technicians arose and, looking back over ten years of activity in which more than 130 companies have been trained, we try to understand what developments await the new profession of Industrial Surface Finishing Process Technologist, recently included in the Framework of Professional Standards of the Lombardy region.

Paolo Rami has already expressed his views

he immediately started working as a trainer,

on the current situation and the future of

teaching at various professional institutes. In

vocational education and training . For this

1980, he founded Cierrepi, a consultancy firm

issue, we have chosen to interview Paola

set up to make his thirty years of experience

Giraldo, the co-founder and soul of the

available to the entire coating industry.

Academy. It was thanks to her insight that a

Author of the book “Verniciatura e controllo

school was born, that has developed rapidly

qualità”, published by Hoepli in 2004, since

and quickly become a point of reference in

2011 he has played a key role in the design

the industrial metal coating sector.

and implementation of the vocational training

1

courses of ipcm® Academy. Under his Ten years ago, you inspired the

leadership, this has become a reference point

creation of ipcm® Academy. Apart from

for all Italian companies needing to train

specialised degree courses or specific

industrial coating technicians and operators.

corrosion inspector trainings, there was

When he passed away in 2016, the coating

no training course focused on coating

industry lost one of its most important

and involving all the players of this

figures.

complex process: those who wanted to © ipcm

learn could only do so in the field. How

Over these ten years, many aspects

did your idea come about?

have changed: from the course venue to

Paola Giraldo, co-founder of ipcm® Academy.

Founding a “coating school” had always been

the teaching staff to the actual course

U

one of my personal and professional dreams.

structure. Can you describe the most

ntil recently, there was no form of

That dream finally came true in 2011, when

important steps that characterised this

certification available to industrial

the ipcm® magazine started to organise its

transformation?

coating process experts. However,

first training courses with the collaboration

ipcm® Academy has always provided top-level

the collaboration between ipcm Academy,

of Ivano Pastorelli. Acknowledged as one of

training, which, over the years, has been able

the training division of the ipcm magazine

the leading experts in the coating industry, he

to keep up with the innovations brought to

with more than ten years’ experience, and

has served as a manager and consultant for

the industry. Its first courses covered powder

the ASP Mazzini Institute (Cinisello Balsamo,

the technical and commercial departments

and liquid coating application techniques,

Milan, Italy) has led to the creation of a Surface

of several major companies in the sector

anaphoresis and cataphoresis anti-corrosion

Finishing Process Technologist certification,

since 1970; in addition to his consulting work,

processes, and systems and methods for

®

®

testing finished products. Three years later,

which is now recognised at the national and European levels. ipcm Academy director ®

150

1

IPCM no. 66, Vol. XI, 2020

N. 69 - MAY/JUNE 2021 - international PAINT&COATING magazine

in 2014, a module was added focussing on

SPECIALIZED TRAINING

© ipcm

Ivano Pastorelli with the ipcm® Academy’s students in Rome.

pre-treatment. Then, cooperation began

Thanks to his coordination, a specialised

Thanks to the collaboration of ipcm®

with Prof. Ivan Davoli, the coordinator of

teaching team was formed consisting of

Academy with the ASP Mazzini

the Materials Science degree course at the

Pasquale Roberti, an expert in quality

Institute, last year the new profession

Tor Vergata University of Rome, and Prof.

control solutions for coatings and plastics,

of Industrial Surface Finishing Process

Claudio Goletti, in order to offer companies

Anastasios Vergani, an expert in waste

Technologist was officially recognised

from Central and Southern Italy the

water treatment and ZLD systems for metal

by the Lombardy region. What will this

opportunity to attend our trainings. In Milan,

finishing lines, and Franco Falcone, an expert

certification mean for the preparation of

we moved from the Polytechnic University,

in aluminium surface treatments. Finally,

trainees?

our first venue, to Innovhub - Experimental

we have further expanded our training

ASP/CFP Mazzini is a training body accredited

Stations for Industry, equipped with an

offer with modules on ‘Failure Analysis and

by the Lombardy region for guidance,

advanced testing laboratory that students

Maintenance’, ‘Plants and Equipment and

vocational training, and job placement

visit during the practical lessons held by

Safety’, and ‘Process Control Documentation

activities and services. Together with them,

Gianmaria Gasperini, the head of Innovhub’s

and Investment Management’, which

we outlined a new professional role to fill

Oils and Greases Business Area and another

includes a practical activity session.

a training gap that the category of surface

long-standing lecturer in ipcm® Academy

The final key step in chronological order was

treatment technicians and operators had

courses.

the beginning of our collaboration with ASP

always suffered from. We therefore designed

Since 2016, the Academy has been managed

Mazzini in 2019.

a course of 100 hours divided into 12 days

by Paolo Rami, a Master of Labour and an

To date, more than 130 companies from a

with a final written and oral examination, after

expert in the design and approval of anti-

wide range of sectors have invested in the

which, if successfully passed, a certificate is

corrosion processes and analyses of specific

ipcm® Academy courses to train their coating

issued attesting to the acquisition of the skills

problems and defects in coating processes.

operators.

required to organise and manage an entire

international PAINT&COATING magazine - MAY/JUNE 2021 - N. 69

151

industrial coating process, with the aim of

for the first session this year. However, the

There is a lack of technical graduates in all

ensuring the correct execution of surface

surface control lessons that are part of

sectors: it is important to focus on the revival

finishing operations.

the practical activities offered take place in

of technical education, which serves the

The ipcm® Academy provides students with

presence. Given the success of the online

whole productive system.

a comprehensive handbook in printed and

mode, we have even decided to maintain

The difficulties that companies find when

digital formats, which helps the trainees while

this format when the classes resume in

selecting new candidates are precisely related

both attending the lessons and studying for

person, in order to facilitate companies from

to skills shortages and this is very damaging

the exam, but which can also be used as a

other regions.

to our country, which is losing productivity,

source of information for later reference during work.

competitiveness, and innovation.

What are the main future projects of

The task of ipcm® Academy is to continue

ipcm Academy?

on the path of training coating technicians

Due to the impossibility of conducting

Our short-term goals are to include new

in order to fill this worrying cultural gap and

lectures in person for reasons that

lessons on technical aspects related to new

to contribute to the relaunch of production

are well known to all, this year’s first

products and technologies and to further

activities, while still meeting the needs of

session is taking place online. Can you

expand our teaching staff.

those who already work in the sector for

describe the structure of the course and

For the future, we have an ambitious project:

in-depth study and refresher courses.

what are the most important changes

creating a full training course in a new

brought by distance learning compared

vocational school open to young people

with face-to-face training?

after middle school. We will create synergies

Unfortunately, following last year’s health

with companies from our industry in order

emergency, we were forced to activate an

to get these boys and girls into the world of

online attendance mode, which continued

work.

®

© ipcm

Paolo Rami during one of the ipcm® Academy training courses in Milan.

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B2B Marketing: How to Set Up an Effective Multichannel Strategy Ilaria Paolomelo eos Mktg&Communication Srl

info@eosmarketing.it

Cross-media marketing has always been considered a key factor in ensuring the effectiveness of a corporate communication strategy. But how to set up a multichannel marketing strategy, especially in a sector like B2B, which is dominated by more complex promotion, sales and purchasing dynamics? How to choose the online and offline channels that best suit our needs? Here are the steps to put this into practice.

T

he digital transformation has completely revolutionized consumer

1. Define the goals

habits and the ways in which companies manage their marketing

The first step to take to set up any marketing strategy aimed at the

and sales activities.

business development of a company is to define the goals to be

And if this revolution has swept over the B2C sector, made of companies

achieved. To be effective, these objectives should be SMART – an

that sell products or services directly to the end user, B2B, which instead

acronym that encompasses the five fundamental qualities that a goal

refers to the commercial relationships that exist between companies located in different points of the production chain, stood by and watched, perhaps due to its very technical and specialized nature, which often requires a more conventional approach to selling and buying.

But digital transformation was not (nor will it be) the only event that changed the way we communicate.

In fact, the spread of the Covid-19 pandemic has led us to an almost paradoxical reflection: if on the one hand digital transformation is the future, on the other digital and non-traditional means of communication are actually still essential today1 and the desire for a return to the past and to forms of communication capable of filling the informational gap perceived online and widened with the pandemic, prevails.

From newsletters to podcasts, from technical and specialized magazines up to trade fairs and events: what we thought we could easily replace with increasingly advanced, almost futuristic forms of digitisation, still plays a very important role and it is destined to continue to do so in the future, as we have already discussed when we analysed the 2021 social trends.

What to do then? How to set up a marketing strategy in such a particular sector as B2B by combining digital transformation with more traditional forms?

The answer is simpler than one would think: by setting up a multi-channel strategy, that is, by identifying the tools necessary to achieve the goals we have set ourselves and creating a synergy between digital and conventional marketing.

So, let’s see what are the steps to take to define and manage a successful cross-media marketing strategy.

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THE MARKETING CORNER

should have:

what their needs are, then let’s ask ourselves how our company can

• SPECIFIC: the goal must be well defined and tangible and should

meet these needs. To do this, we can create Buyer Personas: fictional

answer the questions what, how and why we want to achieve it;

but realistic figures through which we can identify the needs, even

• MEASURABLE: in order to verify the achievement of the goal - in the

unexpressed, of our potential customers. In a nutshell, let’s identify with

long or short term - it must be measurable. For example, we could

our potential customers and ask ourselves who they are, what needs

express it numerically: “I will respond to requests from my customers in

and desires they have. Let’s give them a name, a face, a personal and

less than 48 hours” or “I will end a task tomorrow at 10.00”;

work experience to make them as realistic as possible.

• ACHIEVABLE: the goal must be realistic and appropriate to the

Creating these identikits allows us to understand our customers better

resources we have;

and get closer to their mentality: the more we know our target, the more

• RELEVANT: before spending time, money and resources, we must

we have the opportunity to tell them the right thing.

carefully evaluate the benefits we will get from our project, to make sure • TIME-BASED: foresee a deadline for each goal in order to define all the

3. Identify the channels on which to set up your marketing strategy

necessary steps to be carried out in a predefined time frame.

The website

it’s worth it;

2. Define the target through the buyer personas

Although there are some companies (a few, fortunately) that have not yet landed on the web, most B2B companies communicate through

A good marketing strategy should put the customer and his needs at

their website: whether you get there through search engines, a

the centre.

business card or social profiles, the website is one of the fundamental

Firstly, let’s think about who our potential customers could be and

touchpoints for any business, and in all likelihood the first source of information about a company, its products and services.

However, simply having a website is not enough: we have to make it functional for both users and search engines. Therefore, organizing and structuring the contents, also from an SEO (Search Engine Optimization) perspective, is essential not only to offer users who browse the site all the information they need in a clear and direct way, but also to position ourselves better on the SERP (Search Engine Results Page), both against our competitors and for the most relevant keywords to our business.

Once we have created a website that is effective in terms website navigation of both visitors and search engine crawlers, the benefits we can obtain are numerous. Here are the main ones.

Brand awareness Reputation and authority, primarily of the brand, are two fundamental factors both offline and online. A well-structured and positioned website can help us increase awareness of the brand and all the values associated with it. This will not only encourage interaction with our audience but can also significantly affect purchasing choices.

Lead generation Both in the online and offline world, it is increasingly difficult to collect high quality leads: we have to optimize communication activities on all our channels - from the website to email marketing, up to social media - to attract contacts who are really interested in our company, products and services. Lead magnets can also come to our rescue. They can be free, useful content or incentives that attract the attention of the public with the aim of convincing our audience to leave the email or any other personal information necessary to create a contact list.

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© socialbakers

Example of a Buyer Persona.

Positioning ourselves as an authoritative source

Social media

Regularly publishing valuable content that can help our customers

Although social media weren’t created as a business promotion channel,

deepen the potential of our products and services - perhaps through

over time companies have been able to obtain an increasingly functional

a blog - or sharing customer success stories can help us engage our

and complete space on most platforms.

audience and cultivate a solid and long lasting relationships with our

This has helped to make social media an essential tool for any company,

target.

a new touchpoint, like a website or a booth at the fair. In fact, 75% (https://business.linkedin.com/content) of B2B buyers, early on their

The newsletters

buying journey, use social media to find the ideal supplier. Therefore,

One of the most effective, popular and cheapest digital tools for

these channels represent an excellent showcase for companies, as well

staying in touch with your audience is email marketing, which is one

as a way to get in touch with potential customers and maintain direct

of the most traditional digital tools. Creating a marketing strategy

contact with existing ones.

that includes periodic newsletters allows us to retain our target and

However, not all social networks are right for us in terms of target and

constantly communicate with our customers/suppliers, keeping them

type of content.

up-to-date on new products, offers, initiatives and activities carried out by our company. It also allows us to generate traffic on the website and

How to choose the right platforms

promote our brand at the same time.

The most popular and widely used social network in the B2B industry is

Consistency and quality are the main success factors: we must not

LinkedIn. With over 675 million professionals, LinkedIn was created with

overwhelm our audience, especially if our communications do not offer

the aim of connecting professionals from all over the world.

added value. However, neither can we send out a newsletter every 2

During the registration phase, each user can enter their background

months: with 2.9 billion emails (www.campaignmonitor.com/blog) sent

and career experience, and connect with other professionals in order to

every day, our audience could forget about us, not open the newsletter

build a highly specialized network of contacts. Furthermore, on LinkedIn

or, even worse, decide to unsubscribe. Creating a calendar and

it is possible to create a company page through which presenting our

identifying possible topics to be discussed is the first step for setting up

products and services to all the social network users.

an effective email marketing strategy. To learn more, read our complete

In second place among the most used social networks in B2B we find

guide on how to create a successful newsletter2.

Twitter, the social media known for the brevity of the messages that can be posted (max. 280 characters) and which boasts 330 million active

2

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THE MARKETING CORNER

users and 500 million Tweets per day (www.dsayce.com/socialmedia/tweets-day). Many B2B companies have decided to use this platform to speed up the Customer Care service and provide users with quick answers to solve problems and doubts.

In third place, we find Facebook, used by about two sevenths of the world population and which strength is represented by the possibility of favouring direct interaction and strengthening the sense of community through textual posts, images, videos, links, chatbots and instant messaging.

In fourth place there is YouTube, Google’s social network that best responds to the need to communicate in depth the characteristics and uses of products and services through explanatory videos, guides or tutorials of any duration.

Finally, we find Instagram, perhaps the social media with the highest visual impact, which allows us to share photos and videos and take

 

advantage of very trendy formats such as Stories, Reels and Live.

Technical press Another conventional but highly effective mean of communication, especially in B2B, is technical press, which has evolved over time, implementing both more traditional forms, such as printed copies, and digital tools and channels.

Just as LinkedIn is the social network on which it is easier to meet a professional target because it was created with this purpose, technical magazines are the most direct mean to reach a highly specialized target, precisely because they are created to represent a particular sector, they “speak the language” of that industry (often very technical and specialized) and are perceived as authoritative within the sector.

For a company, relying on the technical press at an editorial and advertising level can be an opportunity to really reach its target, promote its brand and present its technologies and products in an in-depth way, certain that those who read that content will be able to fully understand and appreciate it.

Being present in sector magazines allows us to exploit the editorial material not only to create content for digital platforms (social media, newsletters, website) but also for direct meeting contexts such as fairs and events, during which editorial material can be used as a tangible and comprehensive promotional tool.

Fairs and events Event marketing, which includes all the activities of planning, organization and participation in an event (both in person and online) in order to promote a brand, a service or a product, played and still plays a fundamental role.

Despite the difficulties of the period, which caused many cancellations and a completely different approach to events, being





© CMI

The most popular social media used in the B2B industry.

present in conventions, seminars or conferences is still one of the

and target, choosing the right channels up to the monitoring of the

most effective ways for B2B companies to get in touch and build

performance.

a direct relationship with potential buyers, create greater brand

The message that I hope you have grasped by reading this article is

awareness and generate leads and sales.

the following: if we want to create a truly effective marketing strategy,

Therefore, we must take events into consideration to create an

we cannot think of communication as a dichotomy between old and

effective cross-marketing strategy: it is on this very occasion, when

new, between conventional and innovative.

we shake the hand of our potential customer, that everything that we

In marketing, not only are there no certain formulas, but also what

have built in terms of communication converges.

we label as outdated can rise again, just as what is trendy does not

4. Monitor the performance

necessarily entail a good return on investment.

This happened with podcasts, which disappeared ten years ago only

The last step to take when it comes to multichannel marketing is the

to rise again now, so much so that the number of podcast listeners on

constant monitoring of the performance.

Spotify has doubled since the start of 2019 (https://podcasters.spotify.

To do that, we can use monitoring platforms such as Google Analytics,

com). It happens with Twitter, which is often declared dead or in

analyse the data offered by social networks and the various newsletter

decline but that is still today one of the most used platforms together

tools but, above all, we have to listen3 to our audience, both online

with Facebook and Instagram. It happens with TikTok, an innovative,

and offline.

fun and absolutely trendy platform to which many have subscribed without so much as a second thought but also without getting the

One does not exclude the other

desired results, especially in terms of business opportunities and ROI.

In this article we talked about four fundamental steps to develop

It is therefore good to pause and carefully analyse the situation so as

a B2B marketing strategy, starting from the analysis of the goals

not to make the mistake of excluding some communication channels in favour of others and in order to identify those that best suit our

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communication and sales objectives.

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STANDARD & LEGISLATION - UCIF Informs

Cleaning Processes Are Now Even More Important Marcello Zinno UCIF – Italian Surface Treatment Equipment Manufacturers’ Association, Milan, Italy

N

info@ucif.net

ow that we are beginning to glimpse the return to normal life,

environmental disasters, extreme weather events, and climate change.

it is time to start to get going and look to the future again. As

In recent years, in fact, there has also been a growing realisation

after all major disasters, a period of great commitment awaits

that sustainable growth brings considerable economic, ethical, and

us in order to regain full control of our lives and our work. Historically,

environmental benefits. The circular economy approach, based on the

it is precisely in moments like these that the most ambitious and best

principle that someone’s waste can become a resource for others, has

projects have come to life: thanks to their spirit of survival, human

begun to take shape. The philosophy behind this new economic model

beings are driven to invest more in the future, using their innate ability

is that objects never reach the end of their life, but they are “reborn”

to internalise and exploit past experiences. Will it be a new Renaissance?

for other uses. This means saving money (e.g. extraction, production,

Certainly, there is an unprecedented factor: for the first time, all states,

and disposal costs), consuming fewer raw materials, and reducing one’s

all governments, all men have had to face and fight the same enemy.

own polluting impact on the environment. It is therefore necessary to

In this global battle, we have realised how important it is to take care

rethink production cycles right from the design stage. The use of smart

of ourselves and clean the surfaces we come into contact with. UCIF

technologies in manufacturing processes is of the essence, as well as

member companies have always dealt with surface treatments and

the production of energy from renewable sources and the large-scale

finishes, for which adequate preparation of the substrate to be treated,

adoption of separate waste collection processes.

including cleaning, is essential. In the last thirty to forty years, great

The question now arises: is it possible to design “environmentally

strides have been made in the industrial cleaning sector in particular.

friendly” industrial plants without sacrificing efficiency? The answer

Increasingly complex and efficient technologies have been applied to

is definitely positive. Our companies have already succeeded in

achieve more and more effective results. At the same time, however,

creating high-performance, environmentally friendly finishing systems

a huge amount of pollutants has been produced, controversial water

and treatments while also meeting the other requirements of their

purification issues have arisen, and enormous quantities of resources

customers. With a view to the circular economy principles, several

have been used. In short, cleaning has definitely improved the quality

manufacturers have started to look for solutions to reduce the amount

and performance levels of products, but it has also had a negative

of processing and energy waste, implement industrial recycling

impact on the environment.

operations, and make new resources available. “Zero discharge” is no

This is no longer tolerable. There is a need to invest more and more in

longer a mirage but an attainable goal.

research and to introduce new treatment and production processes

We can therefore say that it is now possible to clean effectively, without

with an ever-decreasing environmental impact, as it is now recognised

necessarily making the world dirty. Actually, we have found that doing so

that the current economic development model is among the causes of

even provides a significant added value!

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COVERED by ipcm®

“Alluminio & Acque” Conference - 14 April 2021 Gabriele Lazzari ipcm

®

The digital conference “Alluminio & Acque” on the management of aluminium and water, organised by CIE and MST Chemicals in collaboration with AITAL (Italian Association for Aluminium Surface Treatments) and the ipcm® magazine, was held in Italy on 14 April 2021. It was divided into four sessions in which various topics were addressed, such as the increasingly variable and strict discharge limits, the shortage of adequate supplies and discharge systems, and the environmental protection policies in force.

I

n the introductory session, AITAL

also make it possible to stay in touch with

and energy consumption, as well as being

general secretary Giampaolo Barbarossa

the market and gain visibility, not only for

virtually sludge-free.

provided useful information about the

promotional purposes but also to allow for

Lodovico Palladini from Henkel compared

greater dissemination of innovations.

acid satin finishing with conventional alkaline

regulations on nickel and the toxicological limits set by the European Commission. He

satin finishing through anodising. Acid satin

trioxide must be authorised by an upstream

1st SESSION: treatment processes and chemicals

player and that the review of the list of

BASF Chemetall sales manager Cristiano

the US, guarantees a substantial reduction

restrictions by the European Commission

Laurita’s speech focussed on new

in sludge and treatment time. However,

could be postponed; by 2024, however, a list

technologies. The aim is to design chemical

it also presents some critical issues, such

of materials that are allowed for contact with

pre-treatment solutions to ensure that

as the presence of a few specific plant

drinking water should be published.

surfaces have the right electrochemical

requirements and some waste water

also emphasised that the use of chromium

finishing, which is not widely used in the European market but is often employed in

Afterwards, ipcm editor-in-chief Alessia

resistance against environmental factors that

treatment problems. The report then

Venturi described the role of an international

promote corrosion. Laurita then presented

continued with a presentation of a new way

technical magazine in fostering dialogue

Oxsilan , an eco-friendly technology for

of applying chrome-free conversion products

between suppliers and users and thus

chromium replacement that allows working

(Adhesion Promoter No Rinse, APNR) in

promoting industrial innovation. Magazines

at room temperature and reduces water

vertical coating systems for aluminium

®

®

© CIE

The Conference’s speakers. From the left: Franco Falcone, Rosario Patricelli, Anastasios Vergani and Angelo Quaini.

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© CIE

The CIE’s fully automated chemical physical waste water treatment system at TALEX plant, Abu Dhabi.

profiles. Advantages include the elimination of conversion bath

best technologies to be implemented in order to limit the use of

controls, of any pollution problems due to dragging, and of the final

water while guaranteeing good cleaning quality and compliance with

cleaning phase.

environmental parameters. Although evaporator water is generally

2 SESSION: plants and tools nd

The second session was opened by Alessandro Corrà from SAT (Surface Aluminium Tech), who described the advantages of

used in closed-loop systems, she suggested using mains water in the cleaning stages after the soda tank and between the cold sealing and hot process stations.

mechanical profile brush-off systems in vertical coating lines. The

3rd SESSION: purification plants and technologies

vertical brush-off machine called “The Brusher”, to be installed

Rosario Patricelli from CIE pointed out that the increasingly stringent

before the chemical pre-treatment tunnel, performs a mechanical

European restrictions on the discharge of sulphates, fluorides, and

surface preparation of profiles by removing any defects that prevent

aluminium require state-of-the-art plant and chemical solutions. In the

chemicals from reaching the inside of the aluminium parts. This

aluminium sector, although they have been on the market for more

improves the profiles’ quality, as well as reducing chemicals and water

than thirty years, ZLD (Zero Liquid Discharge) solutions are used in

consumption and waste rates.

less than 5% of existing plants. According to the speaker, the reasons

Then, it was the turn of Irene Marcolungo, external consultant of CIE,

are mainly economic, although he expects that the technologies for

who clarified that the management of cleaning operations is a crucial

reducing (or even eliminating) the final evaporation phase will become

aspect in any anodising plant. It is necessary to carefully assess the

increasingly popular.

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Afterwards, Angelo Quaini from MST presented the PUR-ALL® technology, which makes it easy to keep sulphates below 300 ppm (as per the regulations on discharges into rivers, lakes, and surface water). He also noted that, with the right equipment, it is possible to achieve a value of less than 100 ppm, virtually allowing the liquid to be reused in the same line.

4° SESSION: ZLD waste water treatment In conclusion, Anastasios Vergani from CIE further clarified the functionality of the PUR-ALL® technology: it is a ZLD solution that guarantees zero energy costs and 100% reuse of water without the use of UF, RO, or evaporator systems. With a few modifications, it can also be adapted to already existing water treatment plants.

© CIE

Chemical-physical treatment tanks.

Around fifty people attended the conference and the debate that ensued was very constructive, generating – despite the limitations posed by the global pandemic – interesting food for thought. The organisers looked forward to future initiatives, to be found on the CIE Group and MST Chemicals’ websites and YouTube channels.

CONVEGNO ALLUMINIO & ACQUE 14 APRILE 2021

© CIE

A waste water treatment system developed by CIE Srl.

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Agenda Released for the 2021 Powder Coating Summit The Powder Coating Summit will be held in Columbus (Ohio, US) on 22-23 September 2021.

P

aint & Coatings Industry magazine and the Powder Coating

powder coating formulation techniques. This live, hands-on course will

Research Group announce the agenda for the 2021 PC

be held in the PCR Group lab on 20-21 September.

Summit. This year’s Summit includes a keynote by Kevin Hales,

“Back by popular demand and expanded to include an advanced

AkzoNobel’s Automotive Innovation Manager – Powder Coatings.

formulator’s course, the 2021 PC Summit has something for every

He will be providing an update of the rapid growth of powder coating

powder coating technologist,” says Kevin Biller, aka Joe Powder, and

technology in the automotive industry with a particular focus on EV

the founder of the Summit.

(electric vehicles) applications. In addition, Alessia Venturi, IPCM’s

“We have a wide-ranging agenda that spans a spectrum of recent

Editor-in-Chief and co-founder of EOS Mktg&Communication Srl, will

innovations in powder coating materials, processes and industry

present a talk on how smart coatings are impacting the industry.

trends.”

This year’s event will be hosted at the Columbus (Ohio) Polaris Hilton on 22-23 September and includes a short course on advanced

For further information: www.powdersummit.com

© Powder Coating Research Group

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The New Concept for IAA 2021 The IAA exhibition will take place in Munich (Germany) from September 7 to 12, 2021.

T

he mobility and technology sectors will meet for the first IAA in Munich (Germany) from September 7 to 12, 2021. A new venue and a new concept: the IAA 2021 will become an exhibition, a forward-looking

mobility platform and a dialog forum all at the same time.

The new IAA is a triad: • The Summit on the trade show grounds will be the venue for brand and product presentations, and conferences for professionals.

• The Open Space will turn Munich’s most beautiful inner-city locations into interaction forums on mobility concepts for the future and stages showcasing technologies as experiences.

• The Blue Lane will connect the city centre and the trade show with a test track where forward-looking mobility becomes a real experience.

And the IAA will be compact and even more intensive: the entire program can be

© VDA

experienced on six days.

“Individual mobility is a basic human need – and satisfying it in all its facets is an ever-growing challenge for our society, which business and policy-makers have to address. The new IAA will point up solutions for connecting these mobility demands in ways that are efficient, economical, and socially and environmentally acceptable,” announced Hildegard Müller, President of the German Association of the Automotive Industry (VDA), during the “IAA Concept Release” at Messe München.

“This new IAA in Munich is intended to stimulate and drive forward solutions for the mobility of the future,” stressed Hildegard Müller and Klaus Dittrich, Chairman and CEO of Messe München, at the presentation of the concept for the new IAA, with Bavarian Minister-President Markus Söder and Munich’s Lord Mayor Dieter Reiter.

“Mobility is frequently presented as an ‘either-or’ choice – pleasure versus © VDA

sustainability, urban versus rural, individual versus public. But mobility is always a diverse AND,” Hildegard Müller underscored. “What is more, mobility and climate protection do not contradict each other, there is no ‘either-or,’ only an AND. The latest technologies and fascinating vehicles developed by the German automotive industry form the basis for a new sustainability. This IAA will demonstrate that in all its diversity,” Hildegard Müller said, adding: “We’re looking forward to Munich and the IAA 2021.”

“The new IAA in Munich will have a totally novel event concept. Content, exhibits, experiences and discussions will be accessible to everyone – that is, residents of Munich and guests from all over the world,” said Klaus Dittrich, Chairman and CEO of Messe München, describing the show of the future. “Repositioning the IAA is one of the most challenging tasks in the international trade show business and a unique opportunity for Munich.”

© VDA

For further information: www.iaa.de/en/mobility

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Chemistry and Automotive: that is, the World After Pandemic The “Chemistry and Automotive” conference will be held in Warsaw (Poland) from 7 to 8 September 2021.

A

lthough the pandemic has limited

powder systems, including solutions that

conventional materials, and new methods to

access to knowledge and news for

could soon significantly shorten the painting

effectively control their visual properties will

most of us, the world has not stopped.

process and reduce its costs.

also be presented.

New solutions are being developed, with

The second subject discussed will include

The conference will conclude with

laboratories working at full capacity and

a series of presentations on paint application,

a discussion between experts and industry

customer expectations evolving every day.

including powder coating application. The

professionals on the future of coatings

The “Chemistry and Automotive” conference,

new technology presented will include paint

systems. This will be an opportunity to

scheduled for 7 and 8 September 2021

printing, production automation, possible

resume the discussions that began during

in Warsaw (Poland), is an excellent

cost reduction, productivity improvements

the previous Chemistry and Automotive

opportunity to supplement knowledge and

and so on.

conference.

learn about new developments. Especially

There will also be a how-to segment on

In short, this year’s Chemistry and

since many prominent specialists have

dealing with problems that sometimes prove

Automotive is bound to be an interesting

confirmed their participation. Speeches by

to be unavoidable. The topics discussed

meeting with plenty of professional

paint producers that will largely focus on

during this section will, among others, include

development and learning opportunities.

ecology and environmental issues, as well

eliminating irregularities on the E-Coat

After such a long break, taking advantage of

as new products not yet presented at the

process and adhesive joints.

it is certainly worth it.

conference, are likely to be both important

Additionally, the role of plastics in

and interesting.

development of the automotive industry, as

For further information:

This time there will be a broader focus on

well as their characteristics in comparison to

www.chemiaimotoryzacja.pl

© Chemistry and Automotive

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WELCOME TO THE INDUSTRY’S LEADING TRADE SHOW NUREMBERG // GERMANY European Coatings Show: 14 – 16 September 2021 European Coatings Show Conference: 13 –14 September 2021

ECS 2021 – innovative, modern and safe!

Accompanied by Europe’s largest and most important industry conference  Plan your visit online: european-coatings-show.com/shownavigator Organisation: NürnbergMesse european-coatings-show.com

Organiser: Vincentz Network european-coatings.com

ZOOM ON EVENTS

Construction Players to Reconnect in Person at the Big 5 Construct Egypt The Big 5 Construct Egypt will take place in person from 26 - 29 June at the Cairo International Convention Centre (CICC).

T

he construction industry is preparing to reconnect in person

and trade sectors, and we believe events such as The Big 5 Egypt

at The Big 5 Construct Egypt from 26 - 29 June at the Cairo

Leadership Conference provide a good forum to kickstart vital talks on

International Convention Centre (CICC).

the matter,” he says.

A Thriving Market

Celebrating Industry Excellence

Commenting on a report released in partnership with MEED projects,

A new platform to recognise project excellence in Egypt’s booming

Vice President at organiser dmg events, Muhammed Kazi shares

construction industry, The Big 5 Egypt Impact Awards are being

that Egypt has presented as a top performer in the MENA region.

launched to honour the people, organisations and projects driving

“With nearly $15bn worth of contracts awarded in 2020, and contract

sustainable development, innovation, and transformation in Egypt’s

awards showing the lowest decline year-on-year in the last decade,

construction industry.

Egypt’s construction sector has shown formidable resilience,” he says.

MENA Regional Manager at The Chartered Institute of Building (CIOB),

Heavyweights signed up to exhibit include the likes of Hassan Allam

and awards judge Matt Doran has shared congratulations to finalists

Holding, Orascom Construction, El Soadaa, ASGC, Hanimex, Al Zamil,

of The Big 5 Egypt Impact Awards, disclosing that “submissions

Al Ahram, Wellbond, Al Amal and more.

have shown great feats of industry collaboration and innovation,

Driving Transformative Leadership

while reflecting a strong focus on digitalisation, contribution to the Sustainable Development Goals, and a diversified portfolio of projects

The Big 5 Egypt Leadership Conference is scheduled to gather

in Egypt.” The event is supported by Strategic Partner, Hassan Allam

Ministers and International Leaders from the region and is one of the

Holding, Platinum Partner, Orascom Construction, Construction

most anticipated additions to this year’s event.

Partner, The Arab Contractors, Banking Partner, Banque du Caire,

H.E Otunda Richard Adeniyi Adebayo, Honorable Minister, Federal

Gold Sponsors, ABB, CRC Dorra and Samcrete, Silver Sponsor, Keller,

Ministry of Industry, Trade and Investment in Nigeria looks forward

Stone Sponsor, Gremic, Supporting Association, The Chartered

to the inaugural conference, particularly the emphasis it will give to

Institute of Building (CIOB), Research Partner -ABiQ, and VIP Lounge

Egypt’s transformation into Africa’s trade hub.

Partner Hanimex.

“We look forward to increased collaboration between our two nations, with a focus on enhancing bilateral trade relations in the economic

© dmg events

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For further information: www.thebig5constructegypt.com

© dmg events

Supplemento a IPCM n° 69 - Maggio/Giugno 2021

ICT digital on www.myipcm.com

water-based met al cleaning m achin es, hydrokin etic v acuum m achin es, cabins, tunn els

Hydrokin etic v acuum water-based cleaning m achin e RH series

Máquin a de lav ado hidrocin ética al v acío serie RH

plant as de lav ado mediante detergentes, cabin as hidrocin éticas, al v acío y tún eles en contínuo

Met al degreasing system using chlorin ated solvents under v acuum hermetically sealed met al degreasing m achin es using chlorin ated solvents, hydrocarbons and modifi fie ed alcohols

Plant a hermética de desengrase de met ales al vacío por disolventes clorados

plant as hérmeticas de lav ado de m e t a l e s m e d i a n t e d i s o l ve n t e s c l o r a d o s , hidrocarburos y alcoholes modifi ficcados

Water-based high pressure cleaning m achin e RHS series

Máquin a de lav ado de alt a presión a base de agua serie RHS

SMART SOLUTIONS FOR METAL CLEANING w w w. u n i o n m e t a l c l e a n i n g . c o m

Tunnel washer for continuous or step by step cleaning TN series

Tún el de lav ado en continuo o “paso a paso” serie TN

CONTENTS

May/June 2021

178 175 EDITOR’S LETTER

176 INDUSTRY NEWS © Unitech

178 TECHNOLOGY OVERVIEW The TiTAKO 3 series generators and the new TiTAKO WAVE transducers: the successful partnership between Unitech and Every Wave continues

182 TECHNOLOGY OVERVIEW Electronic Grade Coating: an effective, efficient tropicalisation process for automotive electronics

186 CASE STUDY The importance of proper cleaning for the production of automotive components: Benevenuta’s project

182

© meconline.it

© Ecoclean GmbH

192 TECHNOLOGY OVERVIEW Cleaning weld seams on outer and inner surfaces in a targeted, sustainable and efficient manner

196 ZOOM ON EVENTS

192

Impianti di lavaggio Washing machines

Novità aquasealer® Impianto di impregnazione Impregnation plant Soluzione in resina per le porosità Resin solution for porosity

aquaroll® EE40 con Rulliera Motorizzata per un’alta ed efficiente produttività for high and efficient productivity

aquaroll® MR9 – Macchina Rotativa a 9 stadi per un’eccellente qualità di lavaggio nel rispetto delle specifiche piu restrittive for excellent washing quality in compliance with the most restrictive specifications

STS Srl - Sede legale e operativa: Via L. Galvani, 8 - 48123 Ravenna RA (Italia) Sede amministrativa e magazzino: Via G. Ferraris, 7 - 48123 Ravenna RA (Italia) Tel. +39 0544 456731 - Fax +39 0544 456733 - www.stsitaly.it - sts@stsitaly.it

ICT | EDITOR’S LETTER

A

long time has passed since industrial part cleaning was considered the “Cinderella” of production processes, more of a hassle than a real added value in terms of the service life and operational reliability of components.

Regardless of whether solvent-based or water and detergent-based cleaning technologies are implemented, what all the systems, lines, and machines we have witnessed in action over the last two years have in common is their high level of automation (especially in the loading and unloading phases) and their resulting seamless integration into production lines. Nowadays, in many applications, cleaning plants have come to become actual work centres, meeting stringent design requirements and requiring no human supervision.

Moreover, several Industry 4.0-oriented investments have been made in the cleaning field, where, similarly to other manufacturing sectors, these have been driven not only

Francesco Stucchi Editor

by production needs but also by government funding for plant digitalisation.

The industrial cleaning sector is thus becoming increasingly technological and the debate on low environmental impact chemicals has now been superseded by far more complex technical issues.

ICT – Industrial Cleaning Technologies has remained the last magazine to speak exclusively, organically, and purposefully about workpiece cleaning and washing applications. In this issue which, as is also the case in November, is an insert of the ipcm® magazine, we deal with some very interesting topics, particularly related to the automotive world.

A cleaning process with robotic loading and unloading phases that replaces sandblasting in the cleaning of welding joints for electric vehicle subframes; a rotarytable cleaning machine integrated in an automatic car components production line; the brand new electronic grade coating (tropicalisation) process developed for car electronic devices and applied by a system traditionally devoted to cleaning.

These are just some of the insights that, over the next few pages, will give you an idea of what industrial cleaning has really become.

international PAINT&COATING magazine - MAY/JUNE 2021 - N. 69

175

NEWS

ICT | INDUSTRY NEWS

Monitoring of the concentration of sulfuric acid and oleum by means of sonic velocity The LiquiSonic® measuring system from SensoTech GmbH guarantees automatic identification and optimal inline monitoring.

C

onventional monitoring of sulfuric acid and oleum is carried

desired, passed on to a process control system. Compared to the

out in many production facilities with manual sampling. These

separate inline measurement of both components, the simultaneous

samples are then analysed in the laboratory and a result

inline measurement has clear advantages. While the respective

is available a few hours later. In production, fast and accurate

calculation model must be selected for individual measurements,

monitoring of the concentration is of great importance, as this

this work step is completely omitted. This has the advantage that

influences the quality. It is precisely this determination of the

the concentrations, especially around the switchover point, can be

concentration that can be ideally realized by means of sonic velocity

determined exactly at any time and in a matter of seconds. Manual

with very high measuring accuracy.

identification and switching are no longer necessary.

It is a challenge for many users that although sulfuric acid and oleum

If necessary, the maintenance-free measuring system

occur in the same part of the plant, identification with a physical

LiquiSonic® offers the possibility of adjusting the calculation model to

quantity alone is not possible. Therefore, empirical values have to be

emerging additional components, gas bubbles and other disturbing

used, which can lead to major problems in case of a wrong decision.

factors. The device can thus be used very flexibly and adapted to

For this reason, the combination of two physical measurands for

changing process conditions.

product identification has proven to be advantageous.

The simultaneous monitoring of sulfuric acid and oleum with LiquiSonic® thus revolutionizes the workflow in production plants.

LiquiSonic® - The smart process monitoring system

By saving time-consuming and inaccurate sampling with the help

By using a feature specially developed for this requirement, switching

of simultaneous inline measurement, an increase in efficiency is

between the areas is fully automated with the LiquiSonic measuring

possible immediately after installation of the measuring system.

®

system from SensoTech GmbH. The concentrations are determined with a specially developed calculation model, displayed and, if

For further information: www.sensotech.com

© Sensotech

The controller reliably displays both concentration values - sulfuric acid and oleum.

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NEWS

ICT | INDUSTRY NEWS by

SAFECHEM ensures cleaning process stability with DUALENE™ 1601 S

MODlFIED ALCOHOL

SAFECHEM released the new generation of modified alcohol DUALENE 1601™ S, which is able to clean off lubricant greases, polar oil additives, corrosion inhibitors, just as effectively as moist emulsion residues.

S

AFECHEM, the pioneer of modified alcohols, has introduced the next generation modified alcohol DUALENE 1601™ S that sets a new benchmark for ensuring process stability in high precision

metal cleaning. DUALENE™ 1601 S is the first pre-stabilized, pure and virgin-grade modified alcohol ever developed in the market for a wide

High performance modified alcohol cleaning machines

range of metal cleaning applications. With a built-in alkalinity buffer, DUALENE™ 1601 S has the distinct ability to bolster process stability right at the start of the cleaning process compared to other modified alcohols. It can improve the process safety for all applications and is especially recommended for demanding operations with high stability

High pressure waterjet deburring and cleaning systems

requirements, including when: • Chlorinated oils are cleaned off. This helps prevent the formation of hydrochloric acids which could lead to corrosion of critical machine parts.

• High amount of particles are present, primarily aluminium, iron, copper, zinc. The particles of such reactive metals can increase the formation of acids in the machine.

• Unknown contaminations are cleaned off (e.g. contract cleaning).

Due to its polar and non-polar properties, DUALENE™ 1601 S can clean off lubricant greases, polar oil additives, corrosion inhibitors, just as effectively as moist emulsion residues. Its outstanding cleaning result is comparable with DOWCLENE™ 1601, SAFECHEM’s long-

Complete integrated in-house build automation

standing reference product in the metal cleaning industry with a wide range of approvals and validations.

For further information: www.safechem.com

DIVISIONS: CLEANING

BLASTING

AUTOMATION

Automation! © Shutterstock

Tel. +39 02 97289696

info@itfwashers.com www.itf.it

ICT | TECHNOLOGY OVERVIEW

GABRIELE LAZZARI ipcm

The TiTAKO 3 series generators and the new TiTAKO WAVE transducers: The successful partnership between Unitech and Every Wave continues The continuous and rapid technological evolution that the market is experiencing and the need to achieve ever-higher performance call for a constant search for new solutions. In order to meet these needs, Unitech Srl, which has been successfully operating in the field of ultrasound systems for industrial use for several years now, has combined its experience with the innovative skills of its start-up company Every Wave with the aim of designing a new generation of ultrasound generators and a new transducer that promise to achieve very high efficiency levels.

TiTAKO 3 series ultrasound generators

precision for any type of treatment.

The new TiTAKO 3 series ultrasound generators are very flexible

The TiTAKO 3 ultrasound generators do not place any limits on the

and they feature a multi-tasking control system that manages

type of power supply – they cover the entire range from 110 to 500

several frequencies simultaneously thanks to a 64-bit Quad-Core

Volt Hz, both single-phase and three-phase (even without neutral) –

Arm processor, with a range between 20 and 135 KHz, in order to

decreasing thermal dissipation and thus being able to be potentially

achieve the required cleanliness degree. They are available in three

installed anywhere. As they are also equipped with a smart indirect

different models, all with single-frequency, dual-frequency, and

cooling control that minimises ventilation, they can even be installed

multi-frequency versions and common basic features, but differing in

in harsh environments.

some specific functions and possible fields of use. The combination

The S.I.A. (Smart Impedance Analyser) control system algorithm

of the pulsed cyclic Step Mode modulation together with the Sweep

continuously scans and analyses the impedance value in order

Mode modulation generates a uniform ultrasonic field with optimised

to enable the working conditions to be adapted to the changing

TiTAKO 3 TOP allows to program and manage all the parameters with extreme ease. © Unitech

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®

ICT | TECHNOLOGY OVERVIEW

physical conditions of the system. The continuous transformations

are immediately recognised and interconnected, thus enabling

that the market is experiencing have prompted UNITECH to provide

remote assistance – a significant feature, given the travel restrictions

its TiTAKO 3 generators with Ethernet Modbus TCP-IP remote

still into force, although more limited than they were a few months

connection, thus enabling data exchange and control and falling

ago. Unitech’s technicians can check the various parameters and,

within the parameters of Industry 4.0.

if necessary, actively change the device’s configuration no matter where it is located. If it is necessary to display all the parameters of

Differences between the three available models

all connected generators, this can simply be done by connecting an

TiTAKO LIGHT is the most basic, but functional model. Its user

HDMI cable to a monitor. Software can be updated via one of the two

interface with an illuminated keypad allows managing the main

USB ports on the device.

functions manually. Various parameters can also be customised

The TiTAKO TOP model is slightly more complex, suitable for

using an optional Ti.PROG handheld programmer.

example for research and development laboratories thanks to

The centralised Ti.Link interface enables to cascade several TiTAKO

its Wi-Fi and Bluetooth connection and a multilingual online user

LIGHT generators (up to a maximum of 12). Using the ModBus

guide. All parameters can be managed on the device’s touch-screen.

TCP-IP Ethernet communication network, the available generators

This model is therefore also ideal for the surface treatment and

can be interconnected to automated production controls. Being

sonochemistry industries.

equipped with a Plug&Play system, once connected the generators

The third and last model available, TiTAKO BLACK, offers a remote-

© Unitech

The ultrasonic generator TiTAKO LIGHT.

© Unitech

TiTAKO BLACK is the third and last model available of ultrasonic generators designed by Unitech.

international PAINT&COATING magazine - MAY/JUNE 2021 - N. 69

179

ICT | TECHNOLOGY OVERVIEW

only interactive user interface, both at the local and global network levels. Compared with the other two, this model is therefore more suitable for automatic plants that require full h

nitec

©U

control of system parameters through remote management.

TiTAKO WAVE ultrasonic transducers Built in titanium, the TiTAKO WAVE transducers are designed to deliver high power with a small footprint.

Solid titanium waveguide guarantees long-

© Unitech

standing resistance to high pressures and temperatures, whereas this product’s compact size favours its use in both multi-chamber and vacuum cleaning systems and machines.

The radial sound uniformity generated by this brand-new transducer guarantees maximum cavitation and cleaning performance. The S.I.A. control system ensures that the TiTAKO WAVE transducers, which are controlled by TiTAKO Generators, are in constant operation and it protects them against no-load operation.

Having been designed to high FEM (Finite Element Method) levels, these new transducers almost completely minimise any vibration propagation losses at the fixing point.

Four working frequencies are available (20-25-3040 KHz), up to a maximum power of 2000 W. In addition, the Wave-Stop suspension distributes all the ultrasound waves in the sonotrode, thus achieving a yield of over 95% according to Every Wave, which defined itself as “a spin-off of Unitech” in a recent interview with ipcm1. As for fixing and installation, the new Plug&Play system allows immediate implementation of these transducers.

The transducers can also be supplied with a mounting system compatible with other transducers currently on the market.

The TiTAKO WAVE transducer and an application of the transducers.

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1

ICT n. 19, Vol. XII, 2021

ICT | TECHNOLOGY OVERVIEW

Electronic Grade Coating: an effective, efficient tropicalisation process for automotive electronics The combination of the electronic grade coating technique with MEG’s plant technology has proved effective for coating electronic components intended for the automotive sector.

C

ar electronic devices are fundamental and, at the same time,

engines and self-driving cars. In this field, as in many other high-

ever-expanding components. Automotive electronics manages

technology sectors (military, aerospace, medical, nautical, railway,

multiple aspects, including as follows:

telecommunications, industrial control, automation, etc.), the reliability of

• it determines performance, fuel consumption, and the overall

electronic components is therefore of the essence. Modern companies

efficiency of the vehicles’ operation;

can no longer afford the economic and image damage resulting from

• it reduces road accidents by optimising braking, road holding, and

any malfunctioning or premature obsolescence of their products, all the

headlight illumination and compensating for the drivers’ errors and

more so when these might affect people’s health or lives.

distractions;

It is therefore necessary that electronic devices and sensors are able to

• it guarantees the safety of passengers by protecting them in the event

withstand any usage and environmental condition to which they may be

of an accident;

exposed on a daily basis, including the most adverse and unfavourable

• it optimises the driving experience through driver assistance,

ones. Vibrations, dust, humidity, vapours, corrosive agents or other

entertainment, and comfort systems;

chemical/physical contaminants, thermal and electrical fluctuations, and

• it protects the environment by contributing to the reduction of harmful

electromagnetic fields can seriously damage circuit boards and lead to

emissions.

serious malfunctions. At the same time, however, the manufacturers

Looking to the future, the technological evolution of the automotive

of electronic components must also find effective, efficient solutions

industry is increasingly ambitious, moving towards fully electrified

to protect electronics without jeopardising business productivity and

The MEG’s cleaning and electronic grade coating system installed at MEC s.r.l. Electronics Tomorrow. ©meconline.it

ALBERTO GNOATO - MEG Srl and MARCELLO NEBBIA - Chem Solutions Srl info@meg.it - info@chemsolutions.it

Your Leaders in Zero Liquid Discharge significantly increasing process costs and/or any risks

of process times. The resin is applied by total or

to operators and the environment.

selective immersion of the circuit board, with no need for prior masking (which is only necessary in

The electronic grade coating (ECG) process

rare cases) and its polymerisation is very rapid. This

The response to all these market needs is the

allows moving from cycle times of several minutes

electronic grade coating process, which is a viable

for the application of acrylic or silicone resins – and,

alternative to conventional conformal coating. It

in many cases, several tens of minutes, depending

is a tropicalisation technique, already validated

on the conformal coating product used – to a cycle

and approved by major players in the electronics

time of just one minute for the application and

industry, ensuring long-lasting performance, lower

polymerisation of the 3M product.

application costs, reduced production times and

This is made possible by the formulation of 3M

labour costs, improved quality, and greater safety for

Novec™ ECG, which contains a latest-generation

the environment and workers. Similarly to conformal

solvent that is non-flammable, non-toxic, and

coating, circuit boards are coated with a thin layer of

ODP-free and has a low surface tension value.

synthetic resin that creates a barrier against external

This solvent does not require any heat treatment

agents, thus improving electrical insulation and

to dry, but only a rapid passage of the treated

preventing dendrite growth and oxide formation.

board through the cold coils of the automatic MEG

Industrial Wastewater Treatment

machine, which even allows it to be recovered and

Electronic coatings applied with MEG technology

reused through condensation. In essence, the

The 3M coating product, distributed by Chem

avoided and the dispersion of hazardous solvents

Solutions (Novara, Italy) and applied with the

into the working environment and the atmosphere

technology developed by MEG (San Martino

is significantly reduced, as is the case with some

di Lupari, Padua, Italy) for its 1S series plants,

conformal coating products that still contain

guarantees indisputable advantages. First of all,

substances such as benzene, toluene, ethylbenzene,

this solution guarantees a reduction, if not zeroing,

and xylene.

use of tunnel ovens for cross-linking the resin is

Simple Principle

© MEG

Effective Result

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

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

The electronic devices and sensors should be able to withstand any usage and environmental condition to which they may be exposed on a daily basis, including the most adverse and unfavourable ones.

www.h2o-de.com

ICT | TECHNOLOGY OVERVIEW

CHARACTERISTIC

EPOXY

SILICONE

URETHANE

ACRYLIC

PARYLENE

EGC-1700

THICKNESS (µm)

50 - 125

125 - 260

75 - 150

75 - 150

15 - 30

1

REWORKABILITY

Poor

Fair

Fair

Good

Poor

Excellent

MASKING

Yes

Yes

Yes

Yes

Yes

Not always

COVERAGE

Poor

Poor

Fair

Fair

Excellent

Excellent

<10 - 120

60 - 240

30 - 200

15 - 60

45 - 120

<5

3.3 - 4.0

2.6

4.2 - 5.2

4.0 - 5.5

2.8

2.1

Good

Excellent

Good

Poor

Excellent

Good

Excellent

Fair

Good

Good

Excellent

Poor

Poor

Excellent

Fair

Poor

Excellent

Excellent

PROCESS TIME (min) DIELECTRIC CONSTANT (1MHz) CHEMICAL RESISTANCE MECHANICAL DURABILITY STRESS/CRACKING Source: 3M™

The advantages of this combined system

Integrating the two processes

Compared with the spray application method normally used for acrylic

A further advantage of the technology developed by MEG is the ability to

and silicone resins, automatic immersion guarantees as follows:

integrate the coating application tank into a solvent cleaning machine,

• process repeatability;

thus making it possible to combine and automate the two processes to

• further reduction of cycle times due to faster handling;

the benefit of results and productivity. The selective immersion process

• lower product consumption;

also makes it possible to further reduce the consumption of the 3M

• better application of the product over the entire surface of the

product, which has a yield of approximately 34 m2/litre, equivalent to

component to be treated, as it penetrates even below the surface

23 m2/kg. In fact, once dried, the product leaves a 1µ transparent film

thanks to 3M’s low surface tension property.

on the circuit board, which has excellent hydrophobic, anti-adhesion,

In particular, immersion guarantees homogeneous coverage of the

and anti-dust properties and which, thanks to its molecular structure,

circuit board and it eliminates any shadow effect that can potentially

reduces the surface tension of silicone oils (Table 1). Application costs

be created when spraying in the presence of obstacles or different,

are therefore extremely low – they are estimated to be less than half or

large components, thus proving particularly suitable when treating

two-thirds of the alternatives on the market. Finally, the 3M product can

miniaturised components.

be easily removed from the boards already treated with this process,

The combination of MEG’s application technology and 3M’s properties

thus allowing any repair or reworking operation.

also prevents the formation of air bubbles underneath the coating or it guarantees the formation of a homogeneous film. In order to achieve

Minimum thickness: one of 3M electronic coatings’ strengths

these results, MEG’s system has been designed to maintain constant

A negative remark that is sometimes made about electronic grade coating

level and temperature of the product in the immersion tank. This

concerns the thinness of its film compared with that created by other

guarantees that the product can be continuously filtrated, with the

synthetic resins. Far from being a disadvantage in any way, this is actually

consequent removal of any contamination, and stored in an integrated

one of the strengths of the 3M synthetic resin, as it does not affect its

hermetic tank during its resting phase. A continuous control system for

performance, nor does it affect the homogeneity and spread of the

the concentration of the 3M resin is also being prototyped to ensure

applied coating, but it rather results in product savings, short processing

maximum yield at all times.

times, and easy removal for the rework of already-treated devices.

their concentration on the edges of the treated board and, therefore,

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N. 69 - MAY/JUNE 2021 - international PAINT&COATING magazine

Machines for precision cleaning and surface treatment

Electronic grade coating Tropicalization of printed circuit board assemly with complete or selective immersion. The most modern solution for a thin synthetic resin coating!

• Automatic immersion-drying cycle in 1 minute • High precision and repetibility of the result • User-friendly process • No masking • Easy reworking of the PCB • Respect for the environment • Low consumption of energy and product

meg.it info@meg.it

Follow us on

ICT | CASE STUDY

GABRIELE LAZZARI ipcm

© ipcm © Benevenuta & C. SPA

Automotive components produced by A. Benevenuta & C. SPA.

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®

ICT | CASE STUDY

The Importance of Proper Cleaning for the Production of Automotive Components: Benevenuta’s Project A. Benevenuta & C. SpA has almost completed the installation of a new laser hardening machine for the production of steel parts, which is going to enrich its already wide range of automotive components. With the rotary-table metal cleaning machine supplied

by Union, it will be possible to clean three steel components at a time and eliminate swarf and emulsions, thus optimising the company’s production process.

I

n recent years, the technological and

by the Benevenuta family, who still owns and

warehouse due to our need for more storage

production systems for steel hot stamping

runs this business. Around forty years ago, the

space. Established at the beginning of the

and machining have undergone a total

company also set up a machining department.

millennium, our fourth plant is in Cordoba

evolution. The automotive sector has

Currently, Benevenuta employs around 150

(Argentina), where we produce gearbox forks

particularly benefited from this: through hot

people at four locations. Antonello Tufano

for the Stellantis group. Although our main

stamping with mechanical presses, parts can

is its manufacturing engineering manager:

target market is Italy, the South American one

be assembled with other components to

“We have two production plants in Italy:

is important for us as well.” Benevenuta is now

guarantee the rapid and optimal production of

one in Forno Canavese (Turin), specialising

completing the installation of a new line for the

essential elements for vehicle operation. One

in stamping processes and regarded as

production of automotive parts. The materials

of the main manufacturers of these products

our headquarters for sentimental reasons,

will be treated with a Union metal cleaning

is A. Benevenuta SpA, a company based in the

since it was the company’s first site, and one

machine to remove chips and emulsions from

Canavese area (Piedmont, Italy) with over a

in Valperga (Turin), where our mechanical

their surfaces; then, they will undergo a laser

century of history. It was founded in 1891 as

machining department is located. Three

hardening stage.

a cooperative devoted to steel stamping and

years ago, our old machining plant was

forging. In the 1930s, it was entirely taken over

decommissioned and converted into a remote

© ipcm

The entrance to the Valperga production plant, with a display of some of the workpieces produced by the firm.

international PAINT&COATING magazine - MAY/JUNE 2021 - N. 69

187

ICT | CASE STUDY

© ipcm

Components for the entire automotive sector Benevenuta has several different production lines to manufacture parts intended for automotive suppliers, especially in the fields of trucks and earth moving machinery. “Our core business are gearbox forks, that is, the forks that operate the gears and determine their engagement/disengagement. This product is in great demand, not only in Europe but also in North and South America, for trucks, cars, and earth moving machinery.

In the last fifteen years, we have also been developing a range of products relating to braking systems, from calliper body support brackets for high-performance cars to pad operating levers for trucks. We also have further product lines: calliper body brackets for cars, cylinder bodies for hydraulic control of mechanical arms, and components intended for assembly on the axles of light

Production station with the cleaning system by Union.

commercial vehicles to manage their wheels’ load bearing capacity (for instance, on earth moving machinery).”

© ipcm

From raw materials to end products Generally, Benevenuta’s production flow starts with raw materials, i.e. carbon steel bars (although with various possible peculiarities depending on production), and ends with finished products. “In the past, we sawed our bars in-house and then heated them prior to stamping, but we have recently started outsourcing this process while switching to cutting, with considerable benefits in terms of material management and part quality. We work on five production lines with mechanical presses with a load of up to 2,500 tonnes, two of which are robotic and three are manual, handling small to medium-sized components (max.

250-300 mm) and enabling us to obtain end products in two or three steps. The round or square metal pieces are heated to 1,200 °C in induction ovens and then forged in Other components produced by Benevenuta.

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ICT | CASE STUDY

two or three successive deformation steps. The following station on

© ipcm

the line is a trimming press for removing any burrs. After stamping, all unfinished parts must undergo a surface cleaning treatment by shot blasting to remove any oxides and deposits formed during forging. This operation is performed in-house on brake levers and by contractors if the parts are to be heat-treated, such as in the case of forks. Finally, for some products, especially if intended for safety applications, a magnetoscopic inspection is also carried out to verify the absence of any folds in the material. The blanks obtained in this way are then sent to the subsequent cold coining and/or machining stations.”

Union’s metal cleaning system For a few years now, Benevenuta has also been developing a laser hardening technology to be employed in some applications as an alternative to the conventional induction hardening process.

Production is scheduled to start next year.

Antonello Tufano stresses that this process requires a cleaning operation to remove swarf and emulsions: this is why the company turned to Union (Bologna, Italy), a manufacturer of industrial metal cleaning equipment. “Our collaboration with Union started four years ago, after an initial screening that we carried out while defining our new plant’s characteristics and needs. Although the financial investment required was significant, Union was the supplier that provided us with the best technical solution: the right compromise between quality and price. Indeed, its machine guarantees high productivity levels while meeting all our quality requirements. We have extensively tested this solution and obtained excellent results right from the start.”

These parts need thorough cleaning because, during the subsequent laser hardening process, an optical pyrometer adjusts the laser power according to the temperature detected on the surface subjected to its beam; any emulsion, dust, and limescale residues could affect the

with

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Loading station.

ICT | CASE STUDY

pyrometer reading and lead to an inadequate quality degree of the

to be hardened in a stable range that does not vary as a function of

hardened layer.

the possible storage conditions of the material. Again, the cleaning

This is why Union’s machine was conceived with dedicated,

system plays a key role in this, because, by means of a special hot

separate degreasing, rinsing, passivation, and drying stations and

drying and air-conditioned cooling system, it guarantees optimum part

for the use of degreasing and passivating products mixed with

temperature prior to laser hardening.

demineralised water.

Union’s rotary-table metal cleaning machine includes therefore eight

Furthermore, the transformation and hardening of the treated

fully automated stations: loading/unloading, cleaning (with a series of

surface layer occur as a result of the sudden temperature change

fixed, straight-jet bars and nozzles, ideal for treating workpieces with

to which the material is subjected under the laser’s action: for

particularly complex shapes), draining, rinsing, draining, blow-off (with

this reason, in order to achieve a high level of process stability,

an air flow that eliminates any water residues), and cooling (through

it is necessary to condition the starting temperature of the parts

micro-filtered and conditioned air).

© ipcm

© ipcm

Union’s metal cleaning machine.

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Detail of the cooling system.

© ipcm

Control touchscreen of the cleaning system.

Conclusions In spite of its long history and solid roots in its region, Benevenuta is an ever-evolving company, always seeking to innovate its production processes to achieve better and better products. That is why it set up a modernisation operation that would allow it to expand and project itself into the future, as Tufano explains: “The Valperga plant was acquired precisely to enable us to better serve our customers and our target market. As we began developing new projects and reorganise our production flows, in 2016 we decided to buy this building and renovate it. It was a major investment, in terms of both finances and organisation. We also decided to implement Industry 4.0-oriented IT solutions, up to developing with a partner company a specialized and innovative MES software package because nothing on the market suited our needs. For example, there are now tablets on board the machine that guarantee more careful and precise production management in terms of both manufacturing parameters and quality aspects, reminding the operator of the checks that need to be carried out and recording them.” All production and quality data are available in real time to the various department and function managers, so that they can continuously analyse and optimise the company’s production, logistics, and quality performance.

Union’s metal cleaning machine, integrated in the new production plant and in the new factory organisation, will therefore enable

The original: Sonopush HDT rod transducer.

360° effect. Robust, durable and suitable for the toughest applications.

Benevenuta to optimise production and achieve the increasingly high quality performance required by the automotive world.

WEBER-ULTRASONICS.COM

JOACHIM RITTER

ICT | TECHNOLOGY OVERVIEW

Ecoclean GmbH - Monschau, Germany joachim.ritter@ecoclean-group.net

Cleaning weld seams on outer and inner surfaces in a targeted, sustainable and efficient manner To avoid quality issues during the subsequent cathodic dip painting process, a renowned automobile manufacturer relies on Ecoclean’s EcoCbooster technology for cleaning weld seams on integral subframes for electric vehicles. In contrast to the previously used method of solid media blasting, which requires an additional aqueous cleaning step, this virtually wear-free, fully automated process removes welding residues from the exterior and interior of parts in a targeted, resource-saving and cost-saving manner without the need for abrasives.

E

lectric and hybrid vehicles are changing the way vehicles are built

blasting with a solid medium, for example corundum. To remove dust

in ways that go far beyond the drive technology. For example,

and abrasive residues from the parts prior to cathodic dip painting,

due to the weight of the battery, integral subframes now need a

another cleaning step in a separate machine is required.

higher load-bearing capacity. The redesign of these axle components reassess their production processes. One of these processes is the

Focus on cost efficiency, sustainability and occupational health and safety

cleaning step to remove impurities such as silicate islands, scale

These conventional blasting processes with an additional aqueous

and smoke residues formed during welding; these can cause major

cleaning step are wear-intensive and costly. Therefore, when

quality issues in the subsequent cathodic dip painting process and

designing a new production line for integral subframes, the project

lead to corrosion damage. The cleaning technology generally used is

planner of a renowned German OEM sought information at

is also prompting many vehicle manufacturers to reconsider and

© Ecoclean GmbH

The loading robot places the integral subframes to be processed on the transfer stations of the jet modules.

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ICT | TECHNOLOGY OVERVIEW

parts2clean about ways to optimize this cleaning process. On the one

step and the corresponding machine. This not only noticeably

hand, the aim was to clean weld seams with same or better results,

decreases investments related to the cleaning process, but also

but cheaper, with less maintenance, and saving on resources. On the

ensures more competitive unit costs because operating costs

other hand, the dust pollution occurring in the vicinity of the solid-

are significantly reduced. Another factor contributing to the high

state blasting machines due to fragmented abrasive needed to be

economic and resource efficiency of the process is the effective

eliminated in order to improve working conditions.

treatment of the process water, which is mixed with a corrosion protection medium so that it can be recirculated for a long time.

Removing welding residues – parts cleaning included The planner found what he was looking for with Ecoclean’s

Selectively cleaning external and internal geometries

EcoCbooster technology. The patented process employs medium-

The effective range of the water jet can be precisely adapted to

pressure water jetting in the range between 300 and 700 bar without

the application by using different nozzle geometries, for example

addition of abrasives. Through the use of ultrasound, the pre-stressed

fan and solid-jet nozzles as well as lances. Among other things, this

column of water turns into an ultra-high frequency pulsating water

enables not only the outer but also the inner contours of the integral

jet after exiting the nozzle. This imparts a much higher kinetic energy

subframes to be selectively cleaned, in contrast to conventional jet-

to the jet, such that it reliably and reproducibly eliminates silicate and

cleaning processes with abrasives.

weld spatter as well as scale and smoke residues from the surfaces in second are possible, with a robot moving either the workpiece or the

Process engineering and validation in Technology Centre

nozzle tool.

The process parameters, such as nozzle geometry, pressure and

The part is also cleaned at the same time the welding residues are

feed rate, were precisely adjusted using a special test set-up at the

removed, thus dispensing with the need for an additional cleaning

manufacturer’s Technology Centre in Monschau. To validate the new

a clearly defined operating window. Feed rates of up to 800 mm per

© Ecoclean GmbH

The fully automated machine concept enables an integral subframe to be jetted, cleaned and dried within 50 seconds.

international PAINT&COATING magazine - MAY/JUNE 2021 - N. 69

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ICT | TECHNOLOGY OVERVIEW

water jetting process, integral subframes were coated in the cathodic dip painting line cleaning and then subjected to a lengthy salt spray test.

The results were impressive: The weld seams were cleaner after treatment with the pulsating water jet than after blasting with abrasive media, and any discolouration from the welding process still visible on the surface had no effect on the quality of the paint finish. The high corrosion protection requirements had been met. The new cleaning solution also proved to be a good choice in terms of cost/benefit.

Fully automatic jetting, cleaning and drying in 50-second cycles In order to implement the developed process in a fully automated machine concept, an integral subframe had to be jetted, cleaned and dried within 50 seconds. To meet this requirement, the cleaning machine has three independently © Ecoclean GmbH

In the process module, the manipulator moves the subframe in a defined sequence under the jetting tool to specifically remove welding residues while cleaning the part at the same time.

This eliminates the need for an additional cleaning step in a separate machine.

functioning jetting modules with integrated manipulator, a hot air dryer, one robot each for loading and unloading, and a bath treatment unit for the process water.

Pallet cages loaded with several integral subframes to be processed are transported to the machine.

The machine’s loading robot picks up the parts and places them on the transfer stations of the jet modules. The manipulator of the respective module picks up the part and moves it to the jet tool in a defined sequence, treating the welding contours in a specific manner. After cleaning, the manipulator places the integral subframe a clean surface. From here, the loading robot takes it to the drying step. On exiting the dryer, the subframe is picked up by the unloading robot and hooked into the rack for painting.

To eliminate the transport path between the welding and cleaning process, the EcoCbooster can also be connected directly to the welding cell.

The vehicle manufacturer has been using the new cleaning system in series production since mid-2020. Due to the optimizations achieved, the company is now considering integrating the new

© Ecoclean GmbH

The machine comes with an integrated bath treatment module. This allows process water to be recirculated for a long time and thus contributes to lower operating costs.

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cleaning solution into further production lines for integral subframes.

ICT | ZOOM ON EVENTS

DeburringEXPO: increasing importance for burr-free, highly precise, clean surfaces The business climate and the order situation are improving for industrial enterprises. Now it is time for companies to generate fresh impetus with new and further developed solutions. DeburringEXPO offers an ideal platform to this end in the fields of deburring technology and precision surface finishing, and will be held at the Karlsruhe Exhibition Centre from the 12th through the 14th of October, 2021.

D

emand is rising in many industry

for their booth locations at the 4th

sectors such as machinery

leading trade fair in Karlsruhe from

manufacturing, medical

the 12th through the 14th of October,

and pharmaceuticals technology,

2021. The same goes for Rösler

toolmaking, metrology, precision

Oberflächentechnik GmbH, whose

engineering, sensor and drive

marketing manager Daniel Hund also

technology, as well as in the automotive

considers trade fairs indispensable:

industry. Amongst other factors, this

“Participation at DeburringEXPO is

trend is also being driven by export. As

a must for us as manufacturers of

a result, investments that were put on

solutions for mass finishing and shot

hold last year are back on the agenda

blasting technology, as well as post-

once again. Issues such as deburring,

processing of additively manufactured

edge rounding and the production of

parts. We meet up with our customers

precision surface finishes also play an

at the trade fair in a targeted

important role in this regard. Stricter

fashion and we’re looking forward to

as well as changing requirements must

exchanging ideas again personally

also be met in some cases during

after months of exclusively virtual

the production and reconditioning of

contact. Beyond this, participation at

products in these work steps.

the trade fair provides us with an ideal

As the only technology platform

opportunity for gaining a concentrated

for deburring, rounding and the

overview of what’s happening in the

production of precision surface

market, current and future focal points

finishes, DeburringEXPO provides

in various industry sectors and their

a complete overview of the current

latest developments. ”Furthermore,

state of the art, developments and

the exhibitor list includes numerous

trends, processes and methods, as

other solution providers from various sectors for deburring, rounding and

well as quality assurance and services.

“DeburringEXPO is an important trade

© fairXeperts

fair for 4MI GmbH, where we can

the production of precision surface finishes. “We’ve been experiencing a

present our solutions expertise in the field of flow grinding. And

significant increase in demand for booth floor space since the end

thus there’s no doubt that we’ll exhibit again – and we’re already

of February. Consequently, we’re quite confident that we’ll be able

looking forward to it now because we’ve found that although video

to hold DeburringEXPO in October 2021 on a scale comparable to

conferencing is useful for discussing and clarifying numerous issues,

the event in 2019 – of course in compliance with relevant protective

it can’t replace face-to-face meetings at a trade fair, to which visitors

measures and with a hygiene concept that offers exhibitors and

also bring parts and drawings,” adds Dr.-Ing. Detlef Bottke, CTO at 4MI

visitors greatest possible safety,” reports Hartmut Herdin, managing

GmbH. 4MI is one of the companies that have placed firm bookings

director of private trade fair promoters fairXperts GmbH & Co. KG.

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ICT | ZOOM ON EVENTS

© fairXeperts

Competitively decisive trending topics for the supplementary programme, too

are concerned, additive manufacturing

Knowledge as added value

is being used to an ever greater extent

The integrated 3-day expert forum at

in series production. However, surface

DeburringEXPO is also in demand as a

The exhibitors’ presentations at the

finishing remains a challenge in this respect.

source of knowledge. Solutions for actual

upcoming event will also be augmented

Automated solutions which ensure reliably

applications, as well as current developments,

by a supplementary programme adapted

reproducible results will be presented at

trends and future strategies will be at the

to the current, complex requirements

DeburringEXPO in a concentrated format

centre of attention at the simultaneously

of the user industries. The theme park

at the theme park for AM Parts Finishing.

interpreted presentations (German <>

covering Automated Deburring with

More and more attention is being focused

English).

Industrial Robots, organised together with

on component cleaning in production and

collaboration partner Robofunktion GmbH,

reconditioning. Ever stricter requirements

For further information:

fully demonstrates the possibilities of robot-

must be met in terms of both particulate and

www.deburring-expo.de

automated surface treatment – from the

film-like contamination in order to assure

feeding of components to position detection,

the quality of downstream processes such as

handling, burr detection by means of camera

coating, welding, bonding and assembly. And

or sensor technology and the deburring

thus cleaning processes which are laid out to

process with integrated tool change,

fulfil actual requirements are indispensable

right on up to quality assurance and final

after deburring or precision surface finishing.

component storage in workpiece carriers.

The Cleaning After Deburring theme park is

In particular where metallic components

dedicated to this issue.

international PAINT&COATING magazine - MAY/JUNE 2021 - N. 69

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ICT | TRADE FAIRS & CONFERENCES

MP

MEDIA PARTNERSHIP - ipcm® is present with own booth or press corner

JUNE 2021 biame

automatica sprint

emc

automotive manufacturing industry

Beijing, China

www.ciame-show.com

June 9-11, 2021

Munich, Germany

smart automation and robotics

June 22-24, 2021

www.automatica-munich.com/en/

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metalworking technologies

June 27-30, 2021

www.emc.gdmb.de/welcome/

JULY 2021 hvacr vietnam

am forum

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Ho Chi Minh City, Vietnam July 7-10, 2021

Berlin, Germany July 21-22, 2021

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AUGUST 2021 vietnam manufacturing expo

Hanoi, Vietnam August 11-13, 2021 Istanbul, Turkey

maktek eurasia

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August 31 - September 4, 2021

manufacturing industry www.vme-expo.com

machine tools for the metal industry www.maktekfuari.com

ICT | TRADE FAIRS & CONFERENCES

SPECIALIZED EVENT FOR SURFACE TREATMENTS INDUSTRY

SEPTEMBER 2021 fastener taiwan

Kaohsiung, Taiwan September 1-3, 2021

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September 6-9, 2021

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September 7-8, 2021

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equipbaie/metalexpo

Lyon, France

Warsaw, Poland

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fastener industry www.fastenertaiwan.com.tw production equipment and technologies, industrial subcontracting www.industrie-expo.com chemistry and automotive www.chemiaimotoryzacja.pl/en

machines and tools www.machineering.eu

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automation, robotics and industry 4.0

September 8-10, 2021

http://automationworldkorea.com

New Cairo, Egypt

steel, steel fabrication, metal forming, fabricating and finishing

September 9-11 , 2021

Birmingham, UK September, 14-16, 2021

www.metalsteelegy.com subcontracting, surface treatment and finishing www.subconshow.co.uk

Paris, France

metalworking industry

September 21-24, 2021

www.equipbaie.com

international PAINT&COATING magazine - MAY/JUNE 2021 - N. 69

199

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EVOLUTION TO E-MOBILITY C O AT I N G

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CLEANING

Our 70 years experience in Surface Treatment is ready for the E-Mobility market.

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