ipcm® n. 72 - November/December 2021 by ipcm® International Paint&Coating Magazine

The smart journal for surface treatments

In this issue: SPECIAL ON ACE & OFF ROAD VEHICLES & INDUSTRIAL CLEANING TECHNOLOGIES

INTERNATIONAL PAINT&COATING MAGAZINE

ISSN 2280-6083

ipcm digital on www.myipcm.com 2021

12th Year - Bimonthly

N° 72 - NOVEMBER/DECEMBER

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

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CONTENTS NOVEMBER/DECEMBER 2021 © IM GROUP

SPECIAL ISSUE ON ACE & OFF ROAD VEHICLES

HIGHLIGHT OF THE MONTH

IEC+ Joins IM GROUP

FOCUS ON TECHNOLOGY Comer Industries: Innovative Industrial Choices with a View to Sustainability, Industry 4.0, and Coating Technologies Integrated in a High-Efficiency Plant

SPECIAL ISSUE ON ACE & OFF ROAD VEHICLES

52 05 06 08 10 22 24

FOCUS ON TECHNOLOGY How to Eliminate a Bottleneck in the Two-Coat Powder Finishing of Heavy Machine Parts: Cassetto’s Experience

EDITOR’S LETTER MARKET CLOSE UP

Protecting the World and Making it More Sustainable: The Coatings Industry is Ready to Start Again with New Drivers

IPCM IN REVIEW

SUSTAINABILITY

FOCUS ON TECHNOLOGY

HIGHLIGHT OF THE MONTH

BRAND NEW HOW IT’S COATED

ITA Airways: Does the Paint Chosen for the Livery Weigh too Much?

FOCUS ON TECHNOLOGY

In-house Powder Coating of High-Quality Enclosures for Technical Systems

INNOVATIONS: PRESENT&FUTURE Protect and Beautify Farm Machinery, a High-Tech Challenge

Sherwin-Williams listed Within the Best 100 ESG Companies of 2021

FOCUS ON TECHNOLOGY

SUCCESS STORIES

Nissan Optimizes Paint Room Operations

Adapta’s Granite Vivendi Collection: Super-Durable Powder Coatings for Architectural Aluminium Imitating Natural Stone. The Sustainable Alternative for the Architecture of the Future

BUSINESS CARDS SPECIAL ISSUE - ACE & OFF ROAD VEHICLES

BRAND NEW

When Automatic Shot Blasting is a Recipe for Quality: Ideal System’s Automatic Mechanical Surface Preparation Line for MaximumFinishing Quality of Earthmoving Machinery Components

Emiliana Serbatoi’s New Water-Based Top Coat Halved Drying Times and Increased Production Throughput

A “Cartesian” Coating System and a New Pre-Treatment Process to Increase Corrosion Resistance Fivefold. Alpego: When Chemistry Matters.

Dürr Builds Two Paint Shops for Sinotruk

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.

CONTENTS NOVEMBER/DECEMBER 2021

110

FOCUS ON TECHNOLOGY SIGE S.p.A.’s Upgraded Coating Booths for Improved Product Quality and Reduced Environmental Impact

84 90 96 100 102 116

The Key Role of Multi-Metal Pre-Treatment in Improving Powder Coating Adhesion and Quality

176

130

FOCUS ON TECHNOLOGY

ICT - HIGHLIGHT OF THE MONTH

178

Reduced unit costs thanks to higher cleaning performance and lower energy consumption

FOCUS ON TECHNOLOGY

Cranes with Perfect Surfaces

BRAND NEW INNOVATION: PRESENT&FUTURE Fully Automatic Coating System for Complex Gear Components

SUSTAINABILITY

AkzoNobel’s White Paper on the Importance of Powder Coating for EVs

FOCUS ON TECHNOLOGY

Profilglass Choose Recycling and an Advanced Water Treatment System to Reduce the Environmental Impact of its Aluminium Processes

INNOVATION: PRESENT&FUTURE An Innovative, High-Tech, Easy-to-Use Portable Tool: The QNix 9500 Thickness Gauge

ICT - TECHNOLOGY OVERVIEW Optimal cleanliness for the next production step

122

SUSTAINABILITY

144

SPECIALIZED TRAINING

124

SUSTAINABILITY

146

STANDARD & LEGISLATION

126

HIGHLIGHT OF THE MONTH

148

ZOOM ON EVENTS

128

ART WITHIN SURFACES

136 138

Chemical Companies Team Up to Accelerate Net-Zero Climate Technologies

Merck Establishes External Expert Advisory Panel for Sustainability

BASF`s Coatings Division presents Automotive Color Trends 2021-2022

Shortage of Skilled Personnel: The Training Needs of Companies

Is Corporate Sustainability a Mirage?

ICT - INDUSTRY NEWS

ART WITHIN SURFACES

167 172 182

THE MARKETING CORNER

186

ICT - ZOOM ON EVENTS

Graco’s Winning Team to Celebrate the Best Cyclists in the World

Sonic Bloom: Communicating Through Colourful Horns

2022 Social Media Trends: Everything There is to Know

ICT - INDUSTRIAL CLEANING TECHNOLOGIES

ICT - TECHNOLOGY OVERVIEW

Ecoclean: efficient and reliable cleaning with the optimum solution

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EDITOR’S LETTER

Richiedi la versione in italiano a info@ipcm.it

t has only been two years since 2019, but it feels like we have experienced a time jump that nullified one of them. Yet, we have lived through both 2020 and 2021, albeit for most of the time without certainties and above all without making plans and with only limited visibility of the future, including the immediate future. In the same period, the digital world has colonised large portions of our private and professional lives, becoming something pervasive, which we perceive as an important advance, but also as something inescapable. Such lack of planning, together with the fluctuation of raw material prices, the demand for just-in-time rather than just-in-case production, the crisis in maritime transport with the shortage of containers and skyrocketing container prices, and the spread of Industry 4.0, is reinforcing a trend that had already emerged before the pandemic: that of re-shoring, i.e. the return to local manufacturing, in which companies enhance the value of their country (or continent) of origin by bringing back to it economic activities that had been transferred outside its borders. The continuing pandemic and macroeconomic instability are changing the pattern of the global value chain. This is the opposite of delocalisation – going local instead of going global. “According to experts at A.T. Kearney, one of the world’s leading consultancy firms, the digital revolution is fostering re-shoring. Companies that want to reach the highest technological levels do not need cheap labour specialising in single operations (essential elements of assembly lines), but they rather look for qualified and competent personnel. In short, Industry 4.0 is transforming the production models, defining new essential figures for companies, and calling for different places and ways than the past. Advanced countries that have retained a large manufacturing base, such as America, Japan, Germany, and Italy, will be faced with great opportunities, if they are able to seize them. It is about bringing back the highest valueadded productions, focusing on quality and not quantity, while continuing to work for the whole world.1” This editor’s letter, which is too brief to go into such vast topics destined to affect the whole world’s economy, is only intended to provide some food for thought and a key to interpreting some of the reports and articles you will find in this year-end issue, traditionally one of the most important and rich in content. 2022 is fast approaching. It is impossible to make predictions, because there are still too many elements in play to determine what it will be like in terms of economy and if the positive parameters recorded since the beginning of the summer will be confirmed. However, I believe that one thing is for sure: we should not lose the optimism and resilience that have brought us this far.

From an article by Stefano Cingolati, a professional journalist specialising in foreign policy and economics, in Il Foglio, 17-18 April 2021.

Alessia Venturi Editor-in-chief Direttore Responsabile

international PAINT&COATING magazine - NOVEMBER/DECEMBER 2021 - N. 72

MARKET CLOSE UP

SPECIAL ISSUE ON ACE & OFF ROAD VEHICLES

Protecting the World and Making it More Sustainable: The Coatings Industry is Ready to Start Again with New Drivers Monica Fumagalli ipcm®

he interviews in this column, which has

although with very different needs and targets.

In fact, three themes recur in almost all of

been published in the first few pages

Secondly, from the United States to South

our interviews: sustainability, relationships

of our magazine for two years now,

Africa, from Mexico to Italy, there is a clear

with regulatory bodies, and digitalisation. For

have been aimed at offering to our readers

awareness of the importance of our sector

these associations, listening to their members

an authoritative insight into the international

within the production chain. Victor Leal, the

and the sectors they represent means acting

markets at the turn of the century and after

president of the Mexican Paint and Printing

as spokespersons for their needs in these

the pandemic crisis, in order to understand

Ink Manufacturers Association (ANAFAPYT),

three areas. Above all, sustainability is an

how companies in the sector and their

states: “Virtually every man-made product

issue that has come up frequently in recent

representatives, such as associations and

has a coating that not only allows it to retain

years and has been receiving increased

institutions, are reacting. This time, we want to

its value, but also gives it colour, protection,

attention on the occasion of events such

draw some conclusions from our investigation

and durability.” André Vieira de Castro, former

as the recent COP26. Raising awareness

activity. First of all, while the pandemic is

Chairman of the Board of CEPE, the European

and guiding companies towards reducing

still unfortunately having a major impact on

Council of the Paint, Printing Ink, and Artists’

emissions, of which our sector is among the

the industry and the manufacturing sector,

Colours Industry, who ended his mandate in

most responsible, seem to have become

a consistently positive approach has always

October this year, confirms that “paints are

priorities for all the organisations interviewed.

emerged from the answers to our questions.

inherently environmentally friendly products.

The Green Deal, the set of initiatives promoted

This includes the voices of a market, that of

In addition to their aesthetic appeal, they act

by the European Commission to achieve

wall painting, which we do not usually cover in

as a protective barrier against weathering

climate neutrality by 2050, has become a

our articles specialising in industrial coatings,

and microbiological degradation of all types

major focus for the European ones. On the

but which has actually played an important

of substrates, thus increasing the service life

other hand, relationships with the institutions

role in dragging the coating market out of the

length, safety, and performance of products

that establish the dangers and, therefore,

doldrums it had found itself in. Most of the

and structures. Therefore, paints contribute to

the legal limits of the substances used in the

associations we contacted have in fact two

the overall objective of greater sustainability,

formulation of paints represent one of the

cores, managing relationships with members

thanks to the longer service life they

most complex tasks for the associations to

from both the wall and industrial fields,

guarantee.”

manage. In many cases, this is made more

N. 72 - NOVEMBER/DECEMBER 2021 - international PAINT&COATING magazine

MARKET CLOSE UP

SPECIAL ISSUE ON ACE & OFF ROAD VEHICLES

complicated by the regulatory misalignment

recently, finally returning to face-to-face

support the industry in finding solutions for

between different countries and continents.

events.

more environmentally friendly and digital processes and products.

Last, but certainly not least, the digitalisation issue has been booming with the fourth

It is not always easy to understand and

These few lines explain why we gave the stage

industrial revolution, also called Industry 4.0,

represent the needs of a sector, to interact

to associations in the midst of the pandemic.

which is involving the entire industrial sector

with companies of different sizes and

We were looking for a firm point of reference

without exception, from SMEs to multinational

therefore with different needs, and to collect

with impartial, positive opinions, able to

groups.

their requests, ideas, and even complaints. It

convince companies that, if things could not go

The tools used by the associations are

is a balancing act, in which many factors have

back to the way they were before, they would

different, but all based on a common element:

to be weighed up. This is why there is the

go back to being even better. This is also

clear communication, reinforced through

need to thoroughly know the sector and how

the reason why we will continue to interview

different channels, such as social media and

to approach it as clearly and transparently as

associations in future issues of ipcm® as well,

websites, and through meetings, fairs, or

possible. At the same time, it is necessary to

to provide a different view of the industry and

training courses organised by the associations

interact with authorities and reference bodies,

a lucid analysis of market needs in the various

themselves. Even during government-imposed

conveying the needs of companies, and then

countries.

lockdowns, these were promptly replaced by

educating these back on new regulations,

online meetings or, immediately at the onset

making it easy for them to understand the

of recovery, by hybrid meetings that occurred

new rules and helping them find compliant

partly in presence and partly remotely, while

solutions. In the same way, it is important

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IN REVIEW

September and October in Review The return of face-to-face meetings and the newfound importance of trade fairs.

eptember brought with it a moment that we had been waiting

editorial programs, which will follow the trade fairs even more closely.

for over a year: the return of in-person meetings and fairs.

In fact, 2022 promises to be a year full of important events for the

At last, we were able to personally distribute our magazines

sector, starting with PaintExpo, which will return for its eighth edition in

and meet our customers at various national and international fairs,

Karlsruhe, from 26 to 29 April.

such as the Salone del Mobile.Milano, Expo Ferroviaria (Milan), OMC (Ravenna) and Eurosurfas (Barcelona). There, we have met companies

The month of October reconfirmed the positive trend in terms of

and people who are enthusiastic about being able to interact again in

participation in trade fairs and events, together with great international

person and ready to face the new challenges that the market offers.

enthusiasm.

Another meeting we took part in (this time virtually, due to restrictions

Many trade fairs took place in these 31 days, and the ipcm® team

on travels to the United States still in force) is the Powder Coating

participated in-person to many of them. Among these, the three most

Summit, officially opened by Alessia Venturi, editor-in-chief of the

important events of the year for the industrial cleaning sector stand

ipcm® magazines, with a presentation dedicated to Smart Coatings. An

out: at EMO Milano, parts2clean in Stuttgart and DeburringExpo in

important occasion that we hope to be able to repeat soon, this time

Karlsruhe we distributed over 600 copies of the latest October issue of

in person.

ICT_Industrial Cleaning Technologies.

September also meant the publication of one

The pleasure of getting together, traveling

of the most important issues of the year: the

again and participating in international

special issue dedicated to architecture and

events is also reflected in the video-

design of ipcm . An edition full of inspiration,

interviews from the DeburringExpo fair that

of many “wow!” articles for insiders, and

we broadcasted live on our social media

of numerous innovations in the field of

channels. Several exhibiting companies

chemistry.

had the opportunity to briefly present

The new ipcm blog ®

their industrial company as well as their impressions about the post-pandemic

We inaugurated on 13 September the official

trade fair experience.

blog of ipcm®: Surface Treatment 101.

Regarding the events, on 7th October we

Currently available in English and Italian, the

were invited by the paint manufacturer PPG

articles that we will publish in this new space

to the inauguration of the new chemistry

aim to help those taking their first steps in

laboratory dedicated to STEM education

the world of surface treatment to have a

at the National Museum of Science and

better understanding of the processes and

Technology “Leonardo da Vinci” in Milan,

technologies that rule it.

created thanks to the support of the US

The first article that officially launched the

multinational company.

blog is dedicated to PVD processes, and explains what they are, the most common

On the 14th, on the other hand, we

industrial uses, application technologies and

participated in the inauguration of the

the advantages in terms of production and

Axalta Coating Systems Colour Experience

sustainability.

Room in Cavenago di Brianza (Italy), a

Work in progress for 2022

permanent space where the company’s experts will be able to present their

As always in the last four months of the

range of colours and powder coatings for

year, we are actively working on next year’s

architecture to architects and designers.

N. 72 - NOVEMBER/DECEMBER 2021 - international PAINT&COATING magazine

Ilaria Paolomelo and Barbara Pennati, ipcm®

 

A new issue October was also the month of the 39th issue of ipcm®_Protective Coatings, our magazine dedicated to corrosion prevention and control technologies. This number is focused on innovative technologies and processes to mitigate and contrast corrosion that are less conservatives and used. Think for example of high-thickness water-based paints, which also have the advantage of being nonflammable, or powder coatings, which are an effective and zeroemission solution for the protection of external structures and metal carpentry.

Training continues While we are defining the last details of the training program for the 2022 course for Technicians of Industrial Surface Finishing Processes organised by ipcm®_Academy, five modules of the second session of 2021 took place in October: powder coatings application, liquid coatings application, controls, failure analysis and maintenance. During the training day dedicated to controls, the trainees had the opportunity to try out numerous coating measuring and control tools and to (finally) get to know each other and the ipcm®_Academy team in person. Stay tuned to discover topics and complete programme.





BRAND-NEW

Rostirolla Develops the GNW Interlocking system Rostirolla has recently registered the design for the GNW interlocking system, which allows the quick and easy insertion of hooks of various shapes and sizes.

n order to facilitate and speed up the hanging operations of the items to be coated, Rostirolla has developed and registered the GNW interlocking system.

GNW has a diamond-shaped punched slot in which hooks of various shapes and sizes can be easily inserted. In fact, the system is specially designed to quickly and easily insert hooks and springs into the slot– an operation that takes only a few seconds. GNW is available in stock and ready to be assembled. In addition, it can be used in combination with Rostirolla’s P20 and P25 systems, designed for hanging both small components and pieces that require a more robust structure. The combination of the P20 and P25 columns and the GNW system makes the preparation of the pieces to be coated even faster and more flexible, and guarantees the management of a smaller number of coating accessories, making the paint stripping operations more streamlined, as well. “At Rostirolla we always strive to create solutions that can help our customers manage industrial coating processes quickly and easily,” says Simone Rostirolla who, together with his brother Pierluigi, is at the helm of the company. “GNW is one of the latest systems developed for this purpose. Its structure and the possibility of installing it on columns such as the P20 and P25 make it the perfect solution for every coating need”. “Like many of our products, GNW is available in stock. Furthermore, our customers can request a sampling kit to personally test the ease of use of this system”, adds Pierluigi Rostirolla. For further information: www.rostirolla.it

N. 72 - NOVEMBER/DECEMBER 2021 - international PAINT&COATING magazine

BRAND-NEW

AkzoNobel’s Interpon Cr: All the Shine, None of VOCs Interpon Cr creates a brilliant metallic-effect finish which is far more sustainable, durable, and more flexible than real chrome plating.

he powder coating that enables general trade coaters (GTCs),

Daniela Vlad, Managing Director of Powder Coatings at AkzoNobel,

OEMs and designers to deliver the style and appearance of

says the new powder coating provides the reliability and performance

chrome plating but with a powder coating has been launched by

professionals need: “The Interpon Cr Basecoat and Clearcoat system

AkzoNobel’s Interpon brand.

provides resistance to corrosion and staining, as well as the durability

Interpon Cr provides a sustainable alternative that is free from Volatile

to protect products from all life can throw at them. Designers can now

Organic Compounds (VOCs) and produces no hazardous waste. With a

achieve a bright metallic effect, even on the more challenging shapes

simplified finishing process, customers can quickly and easily produce a

and angles, and have the comfort of knowing the product they are using

brilliant metallic-effect finish that is less harmful to the environment.

is better for the environment and more sustainable in every sense.”

Perfect for metal furniture, the automotive aftermarket, components

She adds that Interpon has built a powder coating to meet the needs

and fittings, lighting, leisure equipment, retail displays and small

of the modern day: “Interpon is a global leader in powder coatings

household appliances, the powder coating is applied in a simple and fast

technology and has used its vast experience as well as its state-of-

two-step process, which does not require any additional preparation

the-art R&D facilities to create a sustainable, cost-effective and high

steps, such as grinding and polishing. As such users are able to reduce

performing powder coating to meet your business needs.”

costs compared to traditional chrome plating, which is often timeconsuming and expensive. This enables businesses not only to increase

For further information:

productivity but also accelerate delivery times.

https://industrial.interpon.com

N. 72 - NOVEMBER/DECEMBER 2021 - international PAINT&COATING magazine

BRAND-NEW

Efficient and reliable

solutions for surface coating since 1988.

Rösler Has Developed the New MultiShape Ceramic Media Rösler has expanded its range of mass finishing consumables with the new MultiShape ceramic media with a globally unique geometry.

electrostatic systems for liquid painting

ösler, a provider of surface finishing solutions, has expanded its range of mass finishing consumables with MultiShape, the new ceramic media with globally unique geometry that is able to

electrostatic systems and spraying booths for powder coating

adapt to different work pieces. Usually, ceramic media gets lodged in the work pieces, especially during the treatment of parts with complex shapes and extensive inner channels, preventing excellent finishing results. Rösler has then

pneumatic systems for high-, medium-, and low-pressure painting

developed MultiShape, a globally unique shape of ceramic media with rounded areas on all sides. Rösler MultiShape is ideal for the precise finishing of complex parts with difficult-to-reach surfaces, edges, notches and slits. Even after

IR and UV drying systems

extended usage, the new media maintains its shape and prevents the risk of lodging. In addition to this, it increases the speed of the media movement in the processing bowl by up to 10% compared to other similar products, while also producing a higher material removal rate

robot and reciprocators

on the entire work piece. The new product has an especially positive effect on the overall costefficiency, because it reduces the required processing times, allows using the media for a longer time period and eliminates unwanted costs for rework. An international patent application for the MultiShape ceramic media has been filed under WO 2020/052797 (PCT/EP2019/000264).

www.cmspray.it

eosmarketing.it

For further information: https://de.rosler.com/en-en/

CM SPRAY s.r.l.

BRAND-NEW

Evonik Launches Three Universally Applicable Matting Agents The three new matting agents based on precipitated silica will expand Evonik’s ACEMATT® product line.

he Coating Additives Business Line of

The main application field for the new matting

agents in the portfolio, plus our tried-and-

Evonik has recently announced that it is

agents are coatings for plastics – for example

true ACEMATT OK 520 has been joined by an

expanding its ACEMATT product range

on laptops or smartphones – and wood

unwaxed variant, ACEMATT HK 520, which

with three new universally applicable matting

coatings, for example on parquet flooring,

performs equally well,” added Morin.

agents which are based on precipitated silica:

tabletops or kitchen countertops. In the

One of the advantages of the untreated

the fine-particle products ACEMATT OK 390

applications on interior components for the

silicas in ACEMATT HK 390 and ACEMATT

and ACEMATT HK 390 and the versatile silica

automotive industry, such as dashboards

HK 520 over waxed silica is their better

ACEMATT HK 520.

and trim, the matting silica provides also a

orientation in water-based systems that

The three new matting agents developed by

glare-free matte surface. Moreover, despite

prevents uneven particle distribution in

Evonik are characterised by a combination

the small size of the particles, customers will

some plastic coatings, resulting in a smooth

of ultra-deep matting, high transparency and

be allowed to reach the same deep degree of

and deep matte surface. On the other hand,

extremely fine surface haptics. They can all be

matting with the same amount of powder as

the post-treatment of precipitated silica in

used universally in water- and solvent-based

with products with larger particles.

ACEMATT OK 390 ensures that the product

systems, as well as in pigmented and clear

“As a result, they produce a very fine surface

does not settle during storage, so it is more

formulations.

feel. This means the same efficiency without

stable in the coating. The three new silicas

“Due to their outstanding transparency

sacrificing transparency,” commented

show little influence on the viscosity of the

properties, they provide a deep matte surface

Thomas Klotzbach, head of ACEMATT

formulation and have excellent dispersion

without a milky white haze, especially in clear

application technology.

behaviour.

coatings,” stated Maximilian Morin, the head

“Now the whole ACEMATT family consisting

of the Industrial & Transportation Coatings

of surface-treated and untreated silica is

For further information:

market segment at Evonik.

complete. We have fine particle matting

www.coating-additives.com/en

N. 72 - NOVEMBER/DECEMBER 2021 - international PAINT&COATING magazine

BRAND-NEW © H2O GmbH

H2O Released a Guidebook on Wastewater-Free Production The guidebook on wastewater-free production is freely available on H2O GmbH website.

he German manufacturer of wastewater

We want neutral, valuable information that gives

recycling systems H2O GmbH has recently

us a good overview. This is not only the case in the

published a new guidebook on the subject

consumer sector, but also in industry. That’s why

“Wastewater-free production”. The guidebook is freely

we created this guidebook. Over the years and the

available on the company’s website, both in German

multitude of different projects, H2O GmbH has

and English language.

gathered a lot of useful experience that not only

Sharing their industry knowledge on the field of the

concerns pure vacuum distillation, but also other

professional treatment of industrial wastewater,

technologies, processes and regulations,” stated

H2O has provided interested users with informative,

Catherine Akintschin, the public relations officer of

practical and comprehensible articles on various

H2O GmbH.

industrial processes, as well as functional

The English version of the guidebook contains five

descriptions, regulations and comparisons of

articles so far, new contributions will be published

different technologies and processes.

regularly.

“The need for information in this digital world is enormous. Before we buy something, we want to

For further information:

know exactly about the technologies on the market.

www.h2o-de.com/en

BRAND-NEW

Dörken Expands the Analytical Services With a New Microbiological Laboratory At the end of October, Dörken inaugurated a new microbiological laboratory to ensure the quality of products, materials and production environments through accurate hygiene management process and samples analysis.

or manufacturers of paints and varnishes, the issue of hygiene

then possible to develop special cleaning and disinfecting measures.

management in production is a very important one. All stages

Ramona Lux, Biological-Technical Assistant, praises the new lab: “Overall,

need to be carefully investigated, from the development of a

the lab gives us the opportunity to analyse our products, materials

product to the procurement of raw materials and on to the production

and the production environment quickly and regularly on site, and to

and application stages. This relevance has increased further with

process the findings promptly.”

the growing number of water-based paints and varnishes, since

In addition to analysis in the laboratory, further hygiene measures

water causes the proliferation of germs. For this purpose, a new

are also carried out. “Ramona Lux regularly conducts hygiene training

microbiological laboratory has now been established as part of

with the employees,” explains Torsten Zimny, Hygiene Manager at

Analytical Services of Dörken in order to conduct detailed analysis into

Dörken. “Ultimately, people also obviously transfer germs. In addition,

these aspects.

we have already installed a new process water system for our paste

In the new lab, the products, the materials, the water and the monitoring

production hall.” These measures serve to promote the CIP - continuous

samples are accurately checked to search for any microbiological

improvement process - and significantly enhance corporate hygiene.

content. Possible and potentially critical contamination sources are sampled and investigated thoroughly. With the aid of these findings, it is

N. 72 - NOVEMBER/DECEMBER 2021 - international PAINT&COATING magazine

For further information: www.doerken.com

BRAND-NEW

Wagner Upgraded the SprayPackE Control Unit Wagner made its SprayPackE control unit more flexible and efficient.

agner has recently announced the upgrade

simultaneously for all guns, by groups (up to 8

of SprayPackE, an entry-level control unit

groups) and also individually. The automatic gap

particularly suitable for painters who are

and height control, as well as depth control via

switching from manual application to automatic

recipe parameters also ensure that the spraying

coating that allows to easily and efficiently control

takes place only when the workpiece is actually in

automatic guns and motion systems in a connected

front of the guns, and the distance between the

powder booth. The new function upgrade now

guns can be further optimised. The raw data of the

ensures even more flexibility and opportunities to

coating, for example application, movement and

increase productivity. Previously SprayPackE could

recipe parameters, can either be shared with the

control a maximum of 20 automatic guns, while the

customers’ central control system for documentation

new expansion module now allows to connect up

via an MES interface (OPC-UA) or processed with the

to 32 guns. Moreover, the intuitive touch-screen

information and management platform COATIFY.light

ensures menu-guided colour changes and other

provided by Wagner.

operations that save both time and money, avoiding also operating errors.

For further information:

The required powder quantity can be set

www.wagner-group.com

COMPLETE SOLUTIONS for

HANGING and

MASKING

www.rostirolla.it

HIGHLIGHT OF THE MONTH

IEC+ Joins IM GROUP Silvio Cimenti IM Group – San Gillio (Torino) – Italy

scimenti@inkmaker.com

IEC+ announced that it has joined IM GROUP with the aim of strengthening their presence in the market globally.

M GROUP has announced that IEC+ srl, the specialist in mechanical

was to lay the foundations of IM GROUP by structuring our brands to

engineering renowned for the design and manufacture of

focus on their individual specialties, yet for them to come together to

dispersing, grinding and mixing equipment, as well as complete

offer total process-engineering solutions, under a single group, when

engineering studies and turnkey solutions, has joined the group.

required. The second phase was to evolve this to an advanced stage,”

IEC+ has been collaborating with IM GROUP for several years offering

said Christophe Rizzo, CEO of EMEA/Americas, IM GROUP. “Today, we

dispersing, grinding and mixing equipment. Now the entry of IEC+

are adding a significant boost to our portfolio with the addition of a

represents a unique opportunity for the evolution of both companies.

company that will act as a central catalyst to unite and spearhead each

The decision to announce the joining of IEC+, six months after the

of our other brands into: Advanced engineering solutions”, continued

launch of IM GROUP, is based on a dual strategy. “The initial phase

Rizzo.

IEC+’s entry into IM Group was announced during an event held at the IEC+ headquarters in Traversetolo (Parma) with (from left): Silvio Cimenti, Christophe Rizzo, Roberto Guerra, Valentina Cigna, Gianluca Incerti, Fabrizio Musi and Antonio Riggio.

N. 72 - NOVEMBER/DECEMBER 2021 - international PAINT&COATING magazine

HIGHLIGHT OF THE MONTH

The announcement was filmed at the IEC+

capital initiatives such as advanced IoT training, to

headquarters in Traversetolo (Parma, Italy), at

improve industry 4.0 experience and skills”, explained

Inkmaker in Shanghai (China) and at the IEC Plant

Cigna.

Engineering headquarters in Kuala Lumpur (Malaysia)

“IEC+ is an extraordinary company with a technical

and recently presented on YouTube, in occasion of

know-how gained from over 20 years’ experience

the conclusion of the third quarter of the year 2021

of its team. It can offer, ‘advanced engineering’,

of the Group.

by this we mean that the design, projection, and

In anticipation of the news spreading throughout

management services are extended to all the

the market, Roberto Guerra, CEO of IM GROUP Asia

production processes, site management and

Pacific, said: “we are ready—with our industry-4.0-

software interface. This starts from preliminary

equipped factories—to offer our clients this next

engineering studies through to the complete project

phase. Other than just expanding our premises we

implementation and delivery—as such this will use

have been busy, paving the way, by strengthening our

the specialisations from all our brands,” explained

bond with Malaysian-based IEC Plant Engineering,

Gianluca Incerti, Global Commercial Director, IM

a specialist in this industry since 1992. They have

GROUP, “each brand will continue to be differentiated

an extensive sales and service network throughout

through their expertise, and compete in their

Southeast Asia; especially in Malaysia, India and

individual market sectors, and when required, they

Vietnam. Additionally, their CEO, PM Ravi, an existing

will come together on large projects for IM GROUP.”

shareholder of IEC+, has been fine-tuning an excellent

Lau Kar Seng, General Manager of Inkmaker Shanghai

inter-brand relationship with us—which is a bonus”.

and member of the board, explained that even in

“The two companies will also share a lot of human

China, since the launch of IM GROUP in April, the

resources,” explained Valentina Cigna, Global Director

company has been finalising preparations on two

of HR and President of IM GROUP. Plans are also

fronts: firstly, by expanding its offices to align with

underway to create new jobs for the Parma office.

IEC+’s specifications to manufacture and customize

“We plan to increase IEC+’s workforce, by around

large heavy equipment for dispersing, grinding and

15-20% within the next 5 years, and invest in human

mixing and; second, to form a joint venture company,

An IEC+ Installation for a prominent client in Europe.

The ‘Plusmill’ basket mill developed by IEC+.

The IEC+’s mobile-tank double shaft dissolver.

with Zhuhai Longtec Corp. Ltd., called “Inkmaker Intelligent Systems” in

Fabrizio Musi, founding member of IEC+, who will continue to work as

order to offer the service, experience and machinery of IEC+. “Longtec,

operations manager, said: “this is a significant moment in a strategic

is a large cooperation, listed on the Shenzhen New Third Board, and

global plan, I am confident that, through IM GROUP’s leadership

will significantly boost our market reach throughout China,” explained

and by joining the IM GROUP family of brands, IEC+ has secured the

Mr. Lau, “the addition of IEC+ is a bonus that many competitors will be

continuity of its business and is set to make the group stronger and

unable to match in China, especially with IEC Plant Engineering (in Asia)

increase its market position,” he concluded, “Antonio Riggio, is a proven

as our partners.” IEC+ shareholder and Inkmaker’s long-term partner

General Manager with a very good track record and I warmly welcome

PM Ravi, CEO of IEC Plant Engineering, said: “I am particularly happy

him in his new role at IEC+.” Antonio Riggio, General Manager of IEC+,

with this outcome. It is an ideal collaboration for all; IM GROUP, IEC+

concluded by outlining the strategy for IEC+ in the short term which

and IEC Plant Engineering, too”. With over 30 years of experience in

will be based on 3 pillars: strengthening system engineering capacity,

the Southeast Asian region, IEC Plant Engineering boasts an extensive

increasing production capacity and improving service.

network of subsidiaries, factories and after-sales service facilities as well

IEC+ has set itself the goal of doubling the size of its facilities by the

as a workforce of skilled engineers.

end of the year.

N. 72 - NOVEMBER/DECEMBER 2021 - international PAINT&COATING magazine

AUTOMATE YOUR PAINTING PROCESS Compact solutions for industrial plants

Lesta Srl +39 0331 430817 info@Lesta.it

www.Lesta.it Lesta srl

Lesta srl

Lesta

HOW IT’S COATED

ITA Airways: Does the Paint Chosen for the Livery Weigh too Much? According to the estimates of Italian newspaper Domani, the metallic blue paint chosen for the new Italian flag carrier, ITA Airways, weighs more than a white livery, resulting in a greater waste of fuel.

he Italian newspaper Domani revealed that the metallic blue

aircraft, where small leaks of hydraulic oil often occur, it is easy for

livery chosen for the planes of the newborn ITA Airways weighs

the paint to get damaged.

up to 300 kg more per aircraft due to the use of mica to obtain

However, some industry experts argue that the controversy is not

the metallic effect. This would result in a greater waste of fuel, a

justified. In particular, analyst Gregory Alegi, journalist and lecturer

greater impact on the environment and a competitive handicap, as

active in the aerospace field for over 35 years, declared to newspaper

fuel consumption has become the first item to be cut down to reduce

La Stampa: “If ITA had chosen the white livery of the old Alitalia,

costs and increase profit margins.

someone would have stigmatized the lack of imagination. I see a bit

According to the newspaper, the top management of ITA admitted

of bad faith in these excessive criticisms that tend to be made of ITA.

the inconvenience. However, according to the technicians of the new

Counter-proof: when the white plane with the words ‘Born in 2021’

airline risen from the ashes of Alitalia, the additional weight of the

was presented, I did not hear praises for the ecological value of that

mica blue paint would be of maximum 120 kg.

choice”.

In addition to the weight problem, the choice of this livery could

The analyst adds that “in the recent past, Alitalia had excessive

also entail higher maintenance costs. Particularly in the belly of the

scruples on fuel saving, so much so that pilots criticized the company

N. 72 - NOVEMBER/DECEMBER 2021 - international PAINT&COATING magazine

Barbara Pennati, ipcm®

for the practical management difficulties that this

KLM has a blue livery and is not the only airline

policy entailed. So, let’s not point our finger at ITA

that opted for a colour other than white. As for why

as major polluter only because the chosen paint

white predominates, in my opinion the real reason

weighs a little bit more”.

is that if you take or return leased aircrafts, having

On the fact – cited by many critics – that most

white as the base colour of almost all operators

airlines opt for a lighter, easier-to-maintain white

is the simplest solution to change the livery of an

livery, Alegi notes: “Colour other than white is an

aircraft with the minimum aesthetic intervention

unusual but not extravagant choice. For example,

on the nacelle”.

Hooks & CE Hooks

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

ITA Airways ITA Airways, operating since November 2020, is a company state-owned by the Italian Ministry of Economy and Finance for the exercise of activities in the air transport sector. The company’s goal is to guarantee Italy quality connectivity both with international destinations, so as to encourage tourism and foreign trade, and within the country, also taking advantage of integrated mobility. ITA Airways was established to provide Italy with a flag carrier following the end of the extraordinary administration of Alitalia, whose brand was acquired by ITA on 14th October 2021 for 90 million euros. The first flight, which took place via an Airbus A320, departed on October 15th from Milan Linate and landed at Bari airport. The first two aircraft belonging to the new company, EI-EJN (Airbus A330) and EI-EIB (Airbus A320), have the wording “Operated by ITA” on the fuselage. The metallic blue chosen as colour was conceived as a symbol of unity, cohesion and pride for the country, being also representative of the Italian national sports

HOOKS & CE HOOKS

teams. On the helm, the aircraft of the fleet also display the tricolour flag, the gold, white and red logo of ITA Airways and some stylized icons inspired by the national artistic heritage. ITA currently operates a fleet of 52 aircraft, however the company has already announced that by the end of 2025 the fleet is expected to grow by another 27 units. ITA Airways will initially operate with a network of 44 destinations and 59 routes, for a total of 191 flights (24 domestic and 56 international). In 2022, destinations are expected to increase by 14 units and routes by 15, to reach a total of 74 destinations and 89 routes by 2025. The company has also expressed its intention to equip itself with a more modern, technological fleet that allows it to reduce the environmental impact of operations.

COMPLETE SOLUTIONS FOR HANGING AND MASKING

www.rostirolla.it

FOCUS ON TECHNOLOGY

In-house Powder Coating of High-Quality Enclosures for Technical Systems Edited by Nordson Corporation ics.eu@nordson.com

The de Crignis Blechverarbeitung GmbH German company is specializing in manufacturing steel, stainless steel, aluminium and non-ferrous metals machine enclosures. It chose the Nordson’s dense-phase technology in order to increase quality and flexibility of its coating process and save costs.

he company de Crignis has powder coated externally the

tradition, de Crignis Blechverarbeitung GmbH has grown into a well-

finishes of its high-quality enclosures for technical systems

known system supplier of equipment enclosures.

for years.

Their advanced machinery assists the motivated employees in all steps

The intention for having its own system was to make production more

of metal processing - only the finishing has always been entrusted to

flexible and save time and costs. In 150 years of company and family

external specialists.

The Spectrum HD powder feed centre with PowderPilot HD control system.

N. 72 - NOVEMBER/DECEMBER 2021 - international PAINT&COATING magazine

FOCUS ON TECHNOLOGY

The challenge: outsourcing requires high logistics effort

The solution: in-house powder coating

In Germany, almost

a suitable solution, CS

anyone who parks at

Oberflächentechnik,

a parking meter, then

Nordson‘s representative

deposits coins or money

for the southern part of

into the automatic

Germany, was soon found.

acceptance point is

They offer their customers

probably interacting with

consulting, planning and

a machine enclosure

construction of a powder

made by de Crignis. “With

coating system all from

the move to our current

one source.

location in Augsburg,

“CS Oberflächentechnik

Germany, we made the

was a really lucky choice

step from sheet metal

for us because of their

processor to system

experience with all

provider for sophisticated

available powder coating

enclosures around 20

technologies as well as

years ago,” recalls Herwig

with systems of any size”,

Kleiner, Managing Director

says Mr. Kleiner. “And the

at de Crignis. “Since

close and well-rehearsed

During the search for

cooperation between

then, we have had the most modern punching, bending and laser technology at our disposal and since 2007, we have

De Crignis Blechverarbeitung GmbH’s range of products and services focuses on enclosure construction including system solutions.

them and Nordson made it possible that the installation was completed only four months after the

also had an extremely efficient welding shop.”

order was placed and we were able to start testing the operation with

For most device enclosures, the finishing is an essential part of their

our system”.

functionality: parking ticket machines are exposed to the weather for

De Crignis installed Nordson’s ColorMax® 3 booth with a Spectrum® HD

many years, special demands are made on the powder coating of

powder feed centre and advanced controls. The booth is designed to

medical devices, and reverse vending machines must withstand high

provide reliable powder containment while also ensuring soft airflow

mechanical specifications. To ensure that the external enclosure still

in the spray area. The booth floor is made of the patented composite

protects the technology installed in them for a long period of time, both

material “Apogee” and the AirWash automatic floor cleaning system

the coating materials and the coating processes are engineered for the

keeps the powder overspray in the booth to an absolute minimum. The

intended end use. “Until mid-2018, we had the coating done externally,”

ColorMax³ fast colour change powder coating booth is designed for

explains Kleiner. “These steps were outsourced to specialists, but the

fast, thorough powder contamination, and easy colour changes within

logistical effort was still enormous. Preparation for transportation,

minutes and is equipped with eight Encore® HD automatic powder

packaging, and receipt of the finished coated parts cost us almost a

coating guns. These are controlled by reciprocators for maximum

five-figure sum every month! In order to minimize these costs and

efficiency and automatic coating.

the dependence on external partners, while at the same time making

The Spectrum HD Powder Feed Center, in combination with the HDLV

our own production even more flexible, the de Crignis management

(“High Density, Low Velocity”) pumps of the Encore HD spray system,

decided to install their own powder coating system in-house”.

ensures highly efficient supply of powder.

international PAINT&COATING magazine - NOVEMBER/DECEMBER 2021 - N. 72

The ColorMax® 3 booth with eight Encore HD automatic powder guns.

The complete powder management and application solution is

as those produced by the Augsburg company for Tier 1 suppliers to

designed for convenient powder handling with low operator and

the aerospace and medical technology industries, are also consistently

maintenance effort, so the powder feed centre plays a significant role

applied. “We regularly use the function of storing recipes in the powder

in the efficiency of the entire system.

coating system and retrieving them at any time,” explains Mr. Kleiner.

“After one year of in-house powder coating in single-shift operation,

“Instead of having to spend time adjusting the system to the new order

we are still in a phase of recording data, but we can already safely

after a changeover, we simply call up the required parameters from

note three interesting observations as interim results: In terms of

the system controller and off we go,” he says and he is very pleased

quality, throughput time and costs, our expectations have even been

with the minimal set-up times.

far exceeded,” says Kleiner, summarizing his experience. “The dense-

They also benefit from the user-friendly operation of the entire system

phase technology is absolutely convincing for us in terms of application

via the colour touch screen of the PowderPilot® HD control system.

efficiency and coverage, and even when coating corners and recesses,

All parameters of both the powder application and the booth control

we achieve a superior coating quality.”

are displayed and controlled centrally using easy-to-read icons. For

Single coatings are usually applied to layer thicknesses between 60

different products and powder materials, numerous, highly adaptable

and 80 microns and achieves uniform high coating quality and film

programs can be stored so that processes leading to optimum

thickness without reworking. Particularly demanding enclosures,

coating results can be reproduced as desired. The system operator

such as parking meter machines, are double coated to withstand the

is supported in his work by step-by-step instructions, thus reducing

effects of weathering for a long period of time. Special coatings, such

intensive training phases to a minimum.

N. 72 - NOVEMBER/DECEMBER 2021 - international PAINT&COATING magazine

FOCUS ON TECHNOLOGY

The soft spray of the Encore HD powder coating system ensures maximum process control.

The result: unmatched coating quality and savings As expected, the company has also recorded a major time savings in terms of throughput times, “For the quantity of sheet metal and other parts that we now process in the course of a shift, we had to allow for around five days in the times of outsourced job coating - and we also had a great deal of logistical effort, which is now also eliminated,” says Kleiner. Since time is money, the managing director calculates that without any logistics adds up to monthly savings of around 10,000 euros. “As I said, we are currently still collecting data that we will systematically evaluate in the near future in order to incorporate the knowledge gained into the further optimization of our processes,” says Mr. Kleiner. It is quite possible that de Crignis will then make its knowledge available to external customers. “We cover our own requirements with our highly efficient system in singleshift operation. A second shift would create large capacities that we could offer to sheet metal processors in the region. The powder coating system would then add job coating to our portfolio”.

SUSTAINABILITY

Sherwin-Williams Listed Within the Best 100 ESG Companies of 2021 IBD’s third annual list of best ESG companies doubles the number of businesses involved and places Sherwin-Williams third in the Industrials category.

nvestor’s Business Daily (IBD), the American website and magazine

into consideration environmental, social and corporate aspects.

specialising in equity markets, international business, economics

Because of Millennials, who do not accept dispensations on sustainable

and finance, publishes annually a list of the best ESG companies

policies anymore, and the increasing interest shown by investors in ESG

in the world. “ESG” is the acronym for “Environmental, Social,

issues, the list of companies with high sustainable performance has

Governance”. In the economic and financial sector, it indicates the

doubled in the space of a year.

companies dedicated to responsible investments that will allow to

The third annual list published by IBD increases the number of

pursue the typical objectives of financial management while also taking

companies from 50 to 100, dividing them into 9 categories:

N. 72 - NOVEMBER/DECEMBER 2021 - international PAINT&COATING magazine

• Consumer Goods • Financials

Custom-built painting installations Macchine e impianti realizzati su misura

• Health Care • Industrials • Mining & Minerals • Retail • Services (Commercial, Retail)

Shot blasting booths Cabine di sabbiatura

• Technology • Transportation Microsoft was named the best ESG company, while SherwinWilliams, the US company specialising in the production, distribution and sale of paint products, ranked third in the Industrials category, after Linde and Xylem. “ESG turned a corner this year, with a wide range of companies

Washing tunnels Tunnel di lavaggio

adapting their practices in positive ways,” said Susan Warfel, managing editor of IBD. “This has been key to market health, as investors care more deeply than ever about social, environmental and governance issues. Many simply will not invest in companies that don’t align with their belief systems.” Liquid painting installations

Impianti di verniciatura a liquido

Powder painting booths

Cabine di verniciatura a polvere

Curing ovens

Forni di cottura

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 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

For further information: www.businesswire.com

FOCUS ON TECHNOLOGY

Nissan Optimizes Paint Room Operations Edited by Graco Distribution BV Maasmechelen – Belgium

miranda.houbrechts@graco.com

Graco’s ProMix PD2K helps Nissan St. Petersburg improve paint quality, increase efficiency, and reduce downtime.

n the northern outskirts of St. Petersburg, Russia, in the

changing the clear-coat painting line from one-component to two-

municipal settlement of Pargolovo, Nissan operates one of

component. Also called plural component paint, 2K involves a resin

its highest quality factories globally. Established in 2009 on

and a catalyst that are mixed together in a certain ratio to start a

an area of 60,000 square meters, 1,500 people work at the plant to produce the Nissan Qashqai, Nissan X-Trail and Nissan Murano. The

reaction.

plant’s production capacity is 100,000 cars per year.

The benefits of 2K

Not surprisingly, top-quality paintwork is a priority.

Compared to single component paint, plural component paint

To raise the bar still further, Nissan decided to increase the durability

displays improved durability. It has a higher mechanical strength

of the paint applied to its cars in St. Petersburg. This involved

which allows it to withstand abusive conditions better than other

N. 72 - NOVEMBER/DECEMBER 2021 - international PAINT&COATING magazine

FOCUS ON TECHNOLOGY

paints. It also has better chemical resistance, so can better withstand

In St. Petersburg, another challenge was that two different types of

exposure to a wide range of abrasive chemicals. 2K paint is therefore

clear coat had to be used on one line. At first sight this might not seem

being increasingly applied by automotive manufacturers.

problematic, but remember that the cars are constantly moving along

Plural component paint demonstrates increased flexibility. This means

the conveyor line; the right paint must be ready instantaneously when

that painted polymeric substrates such as a car bumper are less likely

needed. A further potential bottleneck in the process is that although

to crack on impact. Another benefit is that less energy is required to

most of the painting is done by robots, the door openings and trunk of

cure the paint. Ovens can therefore be run at lower temperatures,

each car are painted manually.

which reduces cost. Faster cure times are possible with plural

Furthermore, management at St. Petersburg was keen to reduce the

component paints, and curing is much easier to control.

effect of the production process on the environment. VOC emissions as

Increasingly important these days, especially with companies keen

well as paint waste had to be reduced to the absolute minimum.

to enhance their green credentials, are the environmental benefits of plural component paint due to lower VOC’s because there’s no

Call in the paint-shop experts

necessity to evaporate solvent. Finally, plural component paints can

To get some help navigating through these often conflicting

have a higher solid content, which leads to better surface coverage.

requirements, Nissan sought the advice of paint-shop specialists from

The challenges of 2K

Graco. After visiting the factory and talking with management and engineers, Graco’s specialists went away to work out what was the

However, 2K isn’t free from its challenges. The 2K mixing process

best equipment and configuration to use for the task at hand. They

requires constant monitoring. Moreover, to ensure the specified

recommended the Graco ProMix PD2K, the company’s most advanced

characteristics, the mixture must always be fresh.

2K mixing and spraying technology to date.

A phase of the underbody automatic processing in the Nissan’s paint shop in St. Petersburg.

The Graco’s proportioner ProMix PD2K is provided with electrically powered and controlled positive displacement dosing pumps.

Opening photo: the top-quality paintwork is one of the priorities of the Nissan automotive manufacturer. In the Nissan’s plant in St. Petersburg (Russia) the Nissan Qashqai, Nissan X-Trail and Nissan Murano models are manufactured.

international PAINT&COATING magazine - NOVEMBER/DECEMBER 2021 - N. 72

Graco’s 2K proportioner ProMix PD2K is based on unique technology of electrically powered and controlled positive displacement dosing pumps. The use of 100% positive displacement technology allows accurate mix ratios (within 1%) and consistent performance. It’s particularly ideal for short pot life materials, as the ProMix PD2K mixes the material close to the gun so the flush zone is significantly smaller. This allows for faster colour changes, less material usage, © Nissan Motor Co., Ltd

and reduced disposal costs. In fact up to 80% reduction in flushing waste is possible compared to the most efficient traditional proportioning systems. It also stalls under pressure for consistent, on-ratio results, and is field serviceable in less than 20 minutes, which means there’s no need for costly factory rebuilds like gear pumps.

Complete control with minimal waste One of the key reasons why Graco recommended PD2K is its inherent modularity. This allows it to be configured – or even customized – directly to meet the specific requirements of the application. In this case, the unit was equipped with four dosing pumps controlled by one control © Nissan Motor Co., Ltd

module. This approach made it possible to use two types of clear coat separately and independently from each other. As to implementation, the control panel of the unit and special flushing boxes are installed in the spray booth, where the spray gun is placed when it is not used by the operator or when it needs flushing.

From top to bottom: – Topcoat application. – The bodies exiting the paint shop. © Nissan Motor Co., Ltd

N. 72 - NOVEMBER/DECEMBER 2021 - international PAINT&COATING magazine

– The bumpers are coated in a different line.

FOCUS ON TECHNOLOGY

Once the operator at the control panel asks for the material they

errors and sends reminders of planned maintenance.

want, it is ready to spray in less than 15 seconds. This has the

Despite the fact that the proposed configuration is intended for

significant advantage that the material does not have to be kept ready

manual operation, Nissan engineers immediately indicated the need

in a mixed state. As soon as the operator sees that he needs more

to connect the PD2K to the factory PLC to collect and analyse all

material, he simply presses a button on the remote control panel and

the data. This was implemented via a pre-selected communication

in a matter of seconds he can start painting.

protocol. As a result, plant management can receive complete

This has an important knock-on effect. As the material is mixed in

information about the mixing and painting process from a remote

the immediate vicinity of the spray gun, this reduces the quantity of

location.

solvent required to flush the system, thereby reducing environmental

They can see in real time all the parameters used by the system, keep

emissions. And since the system automatically maintains the preset

records, and timely track and prevent possible errors.

paint pressure, it is possible to reduce paint waste during the painting

That’s not all. To ensure consistently high mixing quality and trouble-

process.

free operation, the Graco PD2K system regularly self-diagnoses

Data logging reduces maintenance

for problems, and immediately notifies personnel if any action is necessary. Finally, customizable maintenance notifications improve

The benefits of the PD2K extend long after the paint has dried. During

the efficiency of regular service and avoid unexpected downtime.

its operation, the Graco system collects and stores a wealth of data on

All in all, Nissan management is delighted with the significant benefits

the material used.

of higher paint quality, improved operational efficiency, reduced

It links paint usage to specific operators, and monitors all events

maintenance, and less waste thanks to the implementation of the

that occur during the mixing process. It logs and reports operational

Graco PD2K at the St. Petersburg factory.

HIGHLIGHT OF THE MONTH

Adapta’s Granite Vivendi Collection: Super-Durable Powder Coatings for Architectural Aluminium Imitating Natural Stone. The Sustainable Alternative for the Architecture of the Future Alessia Venturi ipcm®

ranite is one of the most abundant

certainly the best known among those

on the September1 issue of ipcm®, a second

types of rock on the earth’s surface.

offered by the powder coating industry to

series developed by Adapta Color in 2020 and

A natural stone, its name describes

produce aluminium profiles – also widely

launched in January 2021 stands out in the

its particular structure made of medium to

preferred by the modern construction sector

range of aluminium finishes imitating natural

large grains. Mostly consisting of feldspar,

to less sustainable and more laboriously

stone: it is the Granite Vivendi Collection,

quartz, and mica, its colour is highly variable:

and frequently maintained wooden profiles

made up of 36 finishes that evoke the effects

white, yellow, pink, red, brown, and green.

– recalling the warm effect of the natural

of granite stone in all its shades of colour and

Because of its beauty, scratch resistance, and

texture of real wood. However, over the last

grain size.

intrinsic hardness, granite has always found

ten years, companies have created many new

wide application in architecture and design:

finishes with nature-inspired effects. One of

from washbasin tops and kitchen countertops

the most active and capable of developing

to windowsills, door and gate thresholds,

truly evocative colour ranges is Adapta Color

The world’s most famous peaks to evoke the finishes of the Granite Collection

fireplaces, and even street furniture and

(Peñiscola, Castellón, Spain). After the Patina®

From beiges, creams, and greiges with a fine

monuments.

Ceramic Collection, which was presented

grain and rough feel to solid greys and warm

For some time now, however, all these sectors

browns with a dense texture, from metallic

have been gradually moving

shades where the granite

towards the adoption of

effect is barely noticeable as

more sustainable materials,

it blends with the metallic

which are lightweight, anti-

particles and the effect

seismic, and recyclable

is velvety to the touch to

and whose life cycle has

colours with a smooth finish,

a lower environmental

all the shades included in

impact. These materials, of

the Granite Collection are

which aluminium is the best

inspired by the world’s most

known, can be ennobled with

famous mountain peaks. This

finishes that imitate natural

creates a journey that crosses

materials, so as to combine

the American continent

an already well-known and appreciated aesthetic effect alternative materials. Wood-effect finishes are

A. Venturi, Patina® Ceramic Collection: Adapta’s Dreamlike Journey Along the Colours of the Silk Road”, ipcm®_International Paint&Coating Magazine no. 71, Vol. XII, September-October 2021.

with the modernity offered by © Adapta

N. 72 - NOVEMBER/DECEMBER 2021 - international PAINT&COATING magazine

HIGHLIGHT OF THE MONTH Your Leaders in Zero Liquid Discharge

Industrial Wastewater Treatment

Simple Principle from Argentina, Chile, Mexico, and Peru to Georgia,

to natural granite stone. The powders in this range

Canada, and Alaska; the Asian continent between

are available in various gloss levels, finishes, and

China and Nepal, Pakistan and India; Africa, with

colours, with the possibility to create custom-

the peaks of Kenya, Tanzania, and Congo; and the

colour formulations. They have been formulated

European continent between Russia and Turkey.

with the Vivendi SDS technology, which guarantees

The world’s 8000-meter peaks well represent the

excellent outdoor durability together with high gloss

shades of beige, cream, warm white, and greige

retention and colour stability. Every paint, from all

through to brown and taupe. The Latin American

Adapta collections, formulated with the Vivendi SDS

peaks inspire the whole range of reddish browns and

technology meets or exceeds the requirements

burnt earths through to light and metallic greys. Cool

of international specifications for architectural

blues, blacks, greys, and browns recall the colours

aluminium, such as Qualicoat Class 2, GSB Master,

of the North American peaks, while darker shades

and AAMA 2604. In terms of corrosion resistance,

of brown, grey, and black are typical of African and

these coatings exceed 1000 hours in salt spray and

European mountains. A source of inspiration for

humidistat chambers, as well as 30 cycles without

architects and designers, the Granite Collection

blistering in Kesternich tests with SO2.

complements the Patina® Ceramic Collection and

The use of the Adapta Rustproof primer is

completes Adapta Color’s range of colours and

recommended to further increase the corrosion

finishes to imitate natural stone.

resistance of both aluminium and hot dip galvanised

Technical characteristics of the Granite Vivendi Collection powders

steel. The use of Adapta’s CR-0000 cleaning, removal, and maintenance solution is also highly recommended as part of an effective façade

Much like the Patina® Ceramic Collection, the Granite

maintenance programme, in line with the cleaning

Vivendi Collection consists of powder coatings

protocol or procedures outlined by Qualicoat

based on TGIC-free saturated polyester resins and

and the American Architectural Manufacturers

it has been developed as a sustainable alternative

Association.

Effective Result

Leading companies rely on vacuum distillation systems for the sustainable treatment of industrial wastewater. Do you want to benefit from a zero liquid discharge production with VACUDEST aswell?

www.h2o-de.com

ON THE ROAD TO ipcm

n. 72

N. 72 - NOVEMBER/DECEMBER 2021 - international PAINT&COATING magazine

FILTRAZIONE PER IMPIANTI DI VERNICIATURA FILTERING FOR FINISHING LINES

rotoli, pannelli e celle in fibra di vetro

rolls, panels and cells of glass fiber

celle filtranti per alte temperature

filtering cells for high temperatures

rotoli e pannelli in fibra sintetica accumulatore vernice “Columbus” filtri “Andreae” cartucce filtranti filtri assoluti applicazioni speciali

rolls and panels of synthetic fiber paint accumulator “Columbus” “Andreae” filters filtering cartridges absolute filters special application

FILTRO ALVEOLARE MAX PAINT distributori esclusivi per l’Italia

massima efficienza massimo accumulo di vernice massima durata

minori costi di smaltimento minori costi di manutenzione

L’esclusivo design alveolare permette di trattenere quantità di overspray notevolmente superiori rispetto ai filtri oggi in commercio

www.defil.it

SPECIAL ISSUE ON ACE & OFF ROAD VEHICLES

40 44

BRAND NEW FOCUS ON TECHNOLOGY

Comer Industries: Innovative Industrial Choices with a View to Sustainability, Industry 4.0, and Coating Technologies Integrated in a High-Efficiency Plant

FOCUS ON TECHNOLOGY

INNOVATIONS: PRESENT&FUTURE

SUCCESS STORIES

FOCUS ON TECHNOLOGY

90 96 100

How to Eliminate a Bottleneck in the Two-Coat Powder Finishing of Heavy Machine Parts: Cassetto’s Experience

When Automatic Shot Blasting is a Recipe for Quality: Ideal System’s Automatic Mechanical Surface Preparation Line for Maximum Finishing Quality of Earthmoving Machinery Components

Emiliana Serbatoi’s New Water-Based Top Coat Halved Drying Times and Increased Production Throughput

A “Cartesian” Coating System and a New Pre-Treatment Process to Increase Corrosion Resistance Fivefold. Alpego: When Chemistry Matters.

Protect and Beautify Farm Machinery, a High-Tech Challenge

Dürr Builds Two Paint Shops for Sinotruk

Cranes with Perfect Surfaces

BRAND NEW INNOVATIONS: PRESENT&FUTURE Fully Automatic Coating System for Complex Gear Components

SUSTAINABILITY

AkzoNobel’s White Paper on the Importance of Powder Coating for EVs

international PAINT&COATING magazine - NOVEMBER/DECEMBER 2021 - N. 72

BRAND-NEW

SPECIAL ISSUE ON ACE & OFF ROAD VEHICLES

Discovering Long-Term Rust Prevention for Automotive and Heavy Equipment Parts The VpCI®-369 and EcoLine® 3690 rust preventative products were developed by Cortec in order to supply automotive and heavy-equipment parts manufacturers with an innovative alternative to many common long-term rust preventatives on the market.

n the far-flung world of automotive and heavy-equipment parts suppliers, both short-term and long-term rust prevention is critical to prevent serious loss from rust claims.

Equally critical is finding a rust preventative that will be effective and easy enough to use. Cortec’s VpCI®-369 is one excellent option with widespread popularity. It has been found to be a convenient, superior alternative to many common long-term rust preventatives on the market. VpCI®-369 is an oil-based temporary coating that provides extreme corrosion protection in aggressive environments and is one of Cortec’s most-popular wet film corrosion inhibitors. It is an excellent option for protecting auto service parts and heavy equipment components before assembly. Since VpCI®369 is thixotropic, it can be mixed so that the product changes consistency to enhance sprayability for application with an airless sprayer. Once applied, it thickens so that it does not run off the metal. VpCI®-369 can be tinted to blue, green, or other © Cortec

custom colours if desired to help workers detect sufficient product coverage. Those working with military agencies can use VpCI®-369M as a MIL-spec version that conforms to MIL-PRF16173E (Grade 2). VpCI®-369 is a great option for protecting bare, unpainted metal equipment parts that suppliers need to ship to the assembly plant. As a long-term rust preventative, it is also excellent for service parts or spares that will be laid aside for five or 10 years before they might be needed again (e.g., marine engine crankshafts). Because VpCI®-369 does not dry, it can be used as a dual lubricant and rust preventative for moving parts. It is much easier to remove than other coatings that dry to a waxlike texture. Hence, there are countless industrial components that can benefit from a light coating of VpCI®-369 for either short- or long-term rust prevention: • Crankshafts • Camshafts • Engine heads • Engine assemblies • Wheel assemblies

N. 72 - NOVEMBER/DECEMBER 2021 - international PAINT&COATING magazine

• Axles, and more.

BRAND-NEW

SPECIAL ISSUE ON ACE & OFF ROAD VEHICLES

Those interested in branching off into greater environmental responsibility while still achieving excellent corrosion protection may be interested in trying Cortec’s biobased version of VpCI®-369 rust preventative: EcoLine® 3690. EcoLine® 3690 has been approved for 10-year long-term storage protection of service parts for a major automaker. Based on canola oil, EcoLine® 3690 contains 72% USDA certified biobased content. It is ready to use and designed for protection in severe marine and high humidity conditions. Very similar to VpCI®-369, EcoLine® 3690 leaves behind an oily protective film that does not dry. Whether a supplier or assembly plant chooses VpCI®-369 or Cortec’s biobased version, EcoLine® 3690, users can rest assured knowing they are getting an outstanding long-term rust preventative alternative to other options on the market, with a history of prominent industry users. For further information: www.cortecvci.com

SMART COMPLETE SOLUTION FOR POWDER COATING E-Line

Powder coating system • Economical entry into automatic coating • Optimized powder recovery with Energy Efficiency Package (EEP) • Fast color changes possible wagner-group.com

• • • •

Intuitive operation via 7“ or 12“ touch display Fully integrated system control Excellent, reproducible coating quality Low space requirement

BRAND-NEW

SPECIAL ISSUE ON ACE & OFF ROAD VEHICLES

Axalta Launches New Imron Industrial High-Performance Urethane DTM Primer Axalta has expanded its Imron Industrial portfolio with a new high-performance urethane direct-to-metal primer.

xalta announced the expansion of its US Imron Industrial

for applicators. “Our new primer technology increases spraying

Porfolio, with a sustainable, fast-cure, corrosion-resistant primer

productivity and improved application efficiency with its ability to use

for the agriculture, construction, and earthmoving equipment

one common activator for primer and topcoat applications,” said Dave

markets. The new product is a high-performance urethane (HPU)

Heflin, Vice President of General Industrial Americas at Axalta.

direct-to-metal (DTM) primer, which increases spraying efficiency while

“Combined with the long-term corrosion protection comparable to an

providing superior corrosion protection to its substrates.

epoxy, Imron Industrial HPU DTM primer showcases the added value

This technology offers corrosion protection typically observed with

and diversification of our Imron Industrial portfolio.”

epoxy primers as well as providing wet-on-wet topcoat application in as little as five minutes without sacrificing topcoat gloss. In addition, the versatility of the urethane primer uses one common activator for

For further information:

primer and a urethane topcoat, which simplifies the coating process

https://www.axalta.com/liquidindustrial_us/en_US.html

N. 72 - NOVEMBER/DECEMBER 2021 - international PAINT&COATING magazine

mer

strie

Indu

Comer Industries is a global player in the sector of transmissions for agricultural and earthmoving machinery.

FOCUS ON TECHNOLOGY

SPECIAL ISSUE ON ACE & OFF ROAD VEHICLES

Comer Industries: Innovative Industrial Choices with a View to Sustainability, Industry 4.0, and Coating Technologies Integrated in a High-Efficiency Plant Alessia Venturi ipcm®

In the era of interconnectedness, global competition, and just-in-time production, the industry can only remain competitive if it continuously innovates. The successful combination and integration of process engineering, product know-how, innovation, sustainability, quality, and efficiency were the winning factors that enabled the pool of Italian companies CMV, Verind, CMA, and Inver to meet the important requirements of sustainable industrialisation placed by Comer Industries, a global player in the sector of power transmissions for agricultural and earthmoving machinery, with the aim of enhancing the company’s technological competitiveness.

lant digitalisation is now standard for the surface technology

is a set of tools, machines, and equipment managed in an integrated

industry. The Industry 4.0 concepts are perfectly implemented

way and interconnected through a supervisory and control structure

in coating lines, allowing constant monitoring of operating

and through on-site sensors. What matters, therefore, is no longer just

parameters, complete traceability of products, and an ever-watchful

the digitalisation of the machines that make up the coating plant, but

eye on necessary maintenance. The latest lines installed, however, saw

rather their integration into a superior system that guarantees efficiency,

a positive move away from pure digitalisation, which is becoming just

operational and environmental sustainability, cost control, and material

one component of increasingly “smart” systems. A smart coating plant

flow efficiency.

N. 72 - NOVEMBER/DECEMBER 2021 - international PAINT&COATING magazine

FOCUS ON TECHNOLOGY

This fully reflects the characteristics of

including axles, wheeldrives, and planetary

the line implemented by Italian company

gearboxes for excavators and construction

Comer Industries in 2021 as part of a plan

and earthmoving machinery – each with its

to expand and completely reorganise

own painting line. This new, automotive-

its Reggiolo (Reggio Emilia, Italy) plant.

inspired production and logistics structure

Initially only devoted to the production of

has rationalised all spaces, doubling

components for the agricultural sector

the Reggiolo site from 20,000 to 40,000

and already the subject of an ipcm® report

m2. In addition, the new coating system

in 2015 , Comer Industries’ Reggiolo

enables us to coat components with a

production unit now also houses the firm’s

larger size and mass than before. We have

second painting line and the assembly department of components intended for

The Reggiolo plant of Comer Industries.

therefore taken the opportunity provided by our market’s needs to innovate on several fronts: structure, technology, and

the industrial sector. “Our company’s positive performance over the last few years has

automation.”

brought with it the opportunity to expand the Reggiolo production site,

Comer Industries also places great importance on sustainability.

not only by installing a new coating line and some new assembly lines,

This is also evident in the layout of the factory, where a series of

but also by upgrading the existing ones and relocating all logistics to an

measures aimed at improving the internal working environment, such

external hub adjacent to the production facility, where assembly kits are

as microclimate control, correct lighting, and the presence of green

prepared and subsequently sent to the assembly lines,” says Silvestro

plants, dominated the technological and product choices underlying

Carlucci, the Manufacturing Engineering Director of Comer Industries.

the design of the new coating line. The same suppliers who had

“In this way, we have brought together in a single production unit our

been involved in the development of the first painting line installed

agricultural products’ flow, gearboxes, and our industrial products’ flow,

in Reggiolo co-engineered this new project. These were CMV, which

M. Fumagalli, “Mechatronics for a flexible and sustainable factory: challenges for an increase in energy efficiency and a reduction in lead times” on ipcm® no. 35, Vol. VI, September/October 2015, pages 78-86.

took the prime-contractor role and designed and installed the plant, complete with a Power&Free conveyor, a pre-treatment system, drying and baking ovens, coating booths, a complete electric and softwares

Frontal view of the new liquid painting installation designed and installed by CMV of Pesaro.

international PAINT&COATING magazine - NOVEMBER/DECEMBER 2021 - N. 72

SPECIAL ISSUE ON ACE & OFF ROAD VEHICLES

systems; Verind, belonging to international group Dürr, which designed the paint management and application systems; CMA Robotics, which focussed on paint application automation with its articulated robots; and Inver, belonging to multinational company Sherwin-Williams, which supplied the water-based paint products, i.e. primers and top coats, and designed a coating system similar to the one used on the alreadyexisting line. “We asked our suppliers for an approach inspired by the concepts of Industry 4.0, but with an even deeper integration than before: indeed, our new coating plant is fully interfaced with the factory logistics systems through specially developed software. We also put a lot of emphasis © ipcm

on robotics, automation, process traceability, and Human-Machine Interaction, with an approach inspired by the technologies we use on our assembly lines, where the machines suggest a series of checks that the line operator must complete to ensure that the component can move forward,” indicates Carlucci. “Finally, as regards environmental friendliness and energy efficiency, we have equipped all our plants with software for monitoring energy consumption in order to eliminate waste and, at the same time, make the most of the renewable energy self-produced by the photovoltaic systems installed at Comer Industrie’s sites.”

An innovative, increasingly green coating system Verind’s Industry Sector Sales Manager, Alessandro Soba, comments: “Every day, the industry is confronted with issues concerning shapes, surfaces, materials, and design on the one hand and productivity, cost © ipcm

optimisation, the environment, innovative technologies, and safety on the other hand. This mix contributes to a technological vision that integrates into production processes where excellent surface finishes are required as well as coatings with high protective and anti-corrosion performance.” The main objectives pursued by the Comer Industries team in the design of the new industrial coating plant were as follows: • Designing a coating system managed according to the concepts of digitalisation, with control logics and integrated automation towards robot stations; • Guaranteeing the best surface finishes, with the management of the various 2K coatings and of the whole process entrusted to specific automation systems – Application & Robots; • Monitoring all productivity/consumption information and any deviations from the set standard in order to take corrective action; • Ensuring savings on paints and cleaning products for colour changing

From top to bottom:

operations; • Developing a remote service with predictive maintenance and remote assistance actions;

- The control unit of the CMV painting installation.

• Meeting the highest quality standards required by customer

- An axel to be painted hanged to the power&free conveyor.

specifications in terms of product application and resistance to

- One of the two paint mixing rooms equipped with Dürr pumping and electronic dosing system.

N. 72 - NOVEMBER/DECEMBER 2021 - international PAINT&COATING magazine

corrosion.

FOCUS ON TECHNOLOGY

The new industrial plant The installation of the new coating plant at the Comer Industries’ premises started in February 2021 and it was completed in October with the product approval phase. The system was conceived to coat parts from Comer’s industrial range. The CMV-designed plant, which is the counterpart of the one supplied in 2015, occupies an area of 1200 m2 and it is equipped with a two-rail conveyor and loading and unloading overhead cranes to help line operators. It can coat up to 200 different parts with a fully water-based system. “Given our specialisation and experience in water-soluble coatings, the new plant in Reggiolo was built with our constant support in defining the layout,” notes Giuliano Grandi, Area Manager at Inver and the Comer Industries customer manager. “The line uses a high-performance, two-component, water-based system that includes

The pre-treatment tunnel.

SPECIAL ISSUE ON ACE & OFF ROAD VEHICLES

the Idroxinver Extra epoxy primer in 4 colours and the Inverpur

technicians carried out a set of salt spray tests that approved the

polyurethane top coat in 25 colours. These did not require any

pre-treatment cycle for a resistance degree meeting the products’

customisation, as they are suitable and widely used in numerous high-

specifications. “The pre-treatment tunnel is controlled by a PLC

level plants such as Comer’s.”

that monitors concentrations and operating parameters, manages

The pre-treatment tunnel was designed and manufatured by CMV

automatic backwashing operations, and signals any deviations from

to perform a 4-stage cycle with Chemetall chemicals, including

pre-set standards via SMS,” explains Saimon Frati, the owner of CMV

phospho-degreasing, first rinse with mains water, second rinse with

(Pesaro, Italy). “The two coating booths are pressurised and supplied

demineralised water, and application of the Oxsilan nanotechnology

with conditioned air that is treated with a triple dry filtration system

conversion product to increase paint adhesion and corrosion

(non-woven fabric, paint stop, and a synthetic filter for overspray)

resistance. Prior to the start-up of the new plant, Comer Industries’

serving both the suction and feeding pipes.”

From top left clockwise: - Dürr EcoDose 2k control panels with PLC. - The EcoDose 2k dosing and mixing unit. - The pressurised coating booths and paint kitchen booths line up.

N. 72 - NOVEMBER/DECEMBER 2021 - international PAINT&COATING magazine

FOCUS ON TECHNOLOGY

Each booth is equipped with a CMA GR 650 ST 6-axis painting robot, working in self-learning and point-to-point programming mode depending on requirements. A third blow-off robot was installed between the pre-treatment and drying stations. “The coating process required of this plant is complex and articulated, given the significant number of variables involved,” states Giovanni Benevelli, Area Sales Manager at Verind. “Joint and coordinated work with the other suppliers has ensured the development of innovative and industrially sustainable solutions, meeting the fundamental requirements of the market: environmental friendliness and safety in the working environment, limitation of transformation costs, high product quality, and digitalisation. For Comer Industries, we have developed a flexible and modular system that combines electrostatic application (through servo-assisted airless guns with an atomising air pressure of 1 bar and a threshold of 10 to 50 kilovolts) with an automatic electronic 2K paint dosing and mixing system (with fibre

FIT FOR WORKERS WHERE DOES IT WORK? WHERE YOU DO.

optic flow meter technology), the remote-control version of the EcoDose2k device. “The main technical performance values are as follows: • 1:1 to 30:1 stoichiometric catalysis ratio • possibility to store over 1024 treatment programs • dosing tolerance of less than 1% • Direct Injection Technology (D.I.T.) for dosage with two channels (A and B) and separate cleaning circuits: • modular and expandable automatic colour change system for paints and catalysts • advanced management of the pot-life and pot-time parameters (i.e. status control of the pre-mixed paint in the pipes before reaching the automatic gun) • closed-loop flow control • local and remote function control.”

Industry 4.0 The most significant objective achieved by Comer Industries with the installation of this coating line is the level of integration reached: thanks to a major co-engineering effort, industrial systems from three different suppliers can work, dialogue, and interface perfectly to guarantee high production reliability. “On this line, we went even further in terms of plant integration,” states Silvestro Carlucci from Comer Industries. “We developed an MES that automatically sends orders to the plant, which in turn loads the programs to be performed. In this way, we can take the Human-Machine collaboration to an even higher level. We offer smart videos on each workstation that suggest SOPs (Standard Operational Procedures) to the operators to carry out any non-automated steps while maintaining high quality and productivity standards. Digital selfcontrol sheets will also be integrated for full process traceability.” “The plant is interconnected with the factory’s logistics systems, in

FIT FOR WORKERS WHERE DOES IT WORK? WHERE YOU DO.

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SPECIAL ISSUE ON ACE & OFF ROAD VEHICLES

Each booth is equipped with a CMA GR 650 ST 6-axis painting robot.

The control desk of the CMA articulated robot.

Finished axels arriving at the unloading area.

From the left Alessandro Soba and Giovanni Benevelli of Verind, Silvestro Carlucci and Federico Ferrario of Comer Industries and Saimon Frati of CMV.

particular with the SAP MII (Manufacturing Intelligence & Integration)

“The major automation effort we asked CMA and Verind to make in

tool, which connects to the system and sends all the order details to

relation to the robots’ self-programming phase involved the possibility of

the CMV PLC during loading,” says Federico Ferrario, a Manufacturing

switching electrostatics on and off or modulating their power at certain

Engineering Specialist at Comer Industries. “The PLC managing the

stages of the coating process to reduce overspray even further,” adds

CMV-designed plant, which is the line master, provides the CMA and

Ferrario. “With the robots of our first line, electrostatic application is

Verind slave PLCs with the right painting recipe depending on the

always on or always off, but that would have been a limitation due to

component in the booth. On the other hand, the SAP MII tool collects

the particular geometry of the components treated on this second line.

information on each order’s status, including paint consumption

CMA’s solution now enables us to make an even smaller impact on the

statistics per application station from Verind’s equipment and spraying

environment by avoiding paint waste and improving our results’ quality

cycle times from CMA’s robots. All these parameters are essential for

level, especially in terms of paint application consistency.”

process optimisation, traceability, quality, and waste reduction.”

N. 72 - NOVEMBER/DECEMBER 2021 - international PAINT&COATING magazine

www.infragas.com

INFRARED RADIANT GAS SYSTEMS FOR THERMAL TREATMENTS

FOCUS ON TECHNOLOGY

How to Eliminate a Bottleneck in the Two-Coat Powder Finishing of Heavy Machine Parts: Cassetto’s Experience Alessia Venturi ipcm®

When the finishing requirement for its agricultural and construction machinery components changed from a one-coat to a two-coat powder system, Cassetto Srl, an Italian supplier of components to major companies in the ACE sector, acted on two fronts to avoid creating a bottleneck. It upgraded its powder application equipment and it integrated Infragas Srl’s catalytic IR technology to gel the first layer before applying the second coat.

“W

hen times are bad is when the real entrepreneurs emerge.”

This quote from American entrepreneur, writer, and businessman Robert Kiyosaki perfectly reflects the history of Cassetto Srl over the last decade. Based in Lugnacco (Turin, Italy), this company traces its roots back to 1966, when it was founded as a workshop producing frames for galvanic plants. At the beginning of the 1980s, the desire to expand progressively led Cassetto Srl to enlarge its factory and implement new processes such as laser cutting, bending, and punching with numerically controlled machines. Such transition from an artisan to an industrial business laid the foundations for the firm’s future.

The panels manufactured by Infragas Srl.

N. 72 - NOVEMBER/DECEMBER 2021 - international PAINT&COATING magazine

FOCUS ON TECHNOLOGY

The actual turning point came twenty-

of the workforce at the Lugnacco plant

five years ago, when it crossed paths

to over seventy employees. “One of

with Caterpillar, the world’s leading

the things we focus on, and of which

manufacturer of construction and mining

I am very proud, is the significant

equipment, with whom a partnership

generational growth within our staff.

was established that grew so much

We have both experienced employees

so that, in 2014, Cassetto began to

who have been with us for over twenty

work exclusively for this American

years and new, very young employees

multinational.

who we are improving their skills with us, but above all we are seeing roles

In 2016, when Caterpillar decided to rationalise its sites and close one of the factories that Cassetto had been supplying for some time, the Turin-based

From left to right: Andrea Spinelli, Gianfranco Calabrese, and Francesca Marabotti.

being passed on from father to son,” adds Calabrese. “Now, Cassetto is a major supplier to leading companies in the ACE sector such as Caterpillar, CNH,

company suffered a bigger crisis than the one that had just passed in 2009. However, it is in moments like these

Liebherr, Manitou, Mecalac, and Merlo. Our target market is that of

that true entrepreneurs unleash their skills: in 2017, Cassetto decided

agricultural, earthmoving, and road paving machinery. We have greatly

to change its industrial target. “We have embarked on a completely new

expanded our production range, focussing on machine components

path, which has led us to a different customer base from the previous

and avoiding bodywork or large parts, which are not in our industrial

one, although still concentrated in a particular industrial sector,” states

DNA. Our manufacturing process is complete, from 2D-cutting sheet

Gianfranco Calabrese, the Plant Director of Cassetto Srl. “As a result,

metal to selling assembled and coated workpieces to customers. For

we have experienced very significant growth. This has entailed a series

each machine, we produce several hundred components, all of which

of strategic changes involving all areas of our company, from logistics

are welded or bent metal parts.

to technology, with substantial investment in new machinery and

“We have equipped ourselves with a station including numerically

production equipment.”

controlled machining centres to meet customisation requirements and

Such progress was crowned by an increase in turnover and the doubling

we have adopted management software that takes care of the entire

The coating plant.

international PAINT&COATING magazine - NOVEMBER/DECEMBER 2021 - N. 72

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manufacturing process, from acquisition of the raw material to delivery

solvent-based liquid systems, which were later replaced by water-

of the end parts. We work with external partners for the galvanising

based ones. It was in 2014, with the advent of Caterpillar, that we

operations, but we have chosen to manage the coating process in-

switched to powder finishing and converted our existing water-based

house. This accounts for just over half of our production, the remainder

paint line into a powder application one – first with one booth and

being sold raw to customers.”

then with two, applying black and yellow, respectively. The latest step

Coating: a very important sales lever

was the implementation of a two-coat powder system to meet the growing demand for this technology, able to give a more durable finish

“For Cassetto, finishes have a mainly functional purpose, protecting

to components,” explains Gianfranco Calabrese. “It was a challenging

components and extending their service life,” states Purchasing

transition, which meant we had to upgrade our plant to maintain high

Manager Andrea Spinelli. “However, the expansion of our product range

productivity and coating quality degrees. LEM Impianti Srl managed the

has also increased the number of colours we apply from our classic

line upgrade. After analysing our new work cycle, they introduced us to

3 (black, yellow, and grey) to around 15. While acting as an important

Infragas Srl (Mappano, Turin), which worked four-handedly in synergy

market lever, this choice of aesthetic customisation has brought a

with the manufacturer and helped us remove the bottleneck that had

number of critical issues to manage, such as the timing of colour

been created in the coating phase and that was slowing down our

change operations and the optimisation of work shifts. In addition to

entire production process.”

these requirements, we also switched from a one-coat to a two-coat

“The problem was that, in the absence of a suitable coating plant, after

powder coating system (epoxy primer + polyester top coat) in order to

the application of the epoxy primer the parts had to move around the

increase our components’ outdoor durability and corrosion resistance.”

entire chain to reach the curing area, then returned to the same booth

The evolution of coating systems and a few necessary plant upgrades

to apply the polyester top coat, and finally went back to the oven for the final curing stage,” explains Spinelli. “Productivity was practically halved, even when one of the two booths was assigned solely to

Cassetto’s path in coating faithfully reflects the evolution of finishing in

primer application and the other to top coat application. This, in turn,

the ACE sector over the last twenty years. “We started with conventional

forced us to manage all colour change operations on an outdated

Workpieces entering one of the powder application booths.

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The powder centre.

FOCUS ON TECHNOLOGY

booth. With the advent of new customers and new colours, even this solution was no longer manageable. The first step, therefore, was to dismantle our old application booths in favour of two new fibreglass booths with a semi-automated colour change process, which we are now able to complete in an average time of 7 minutes.” “In order to overcome the bottleneck that had reduced our productivity by 50%, together with the manufacturer we decided to integrate a tunnel with gas catalytic infrared panels provided by Infragas Srl, which gels and pre-cures the primer and prevents the parts from having to move around the chain twice,” says Calabrese. “With LEM and Infragas, we carried out various tests and analysed our production dynamics in detail. We then concluded that a 1.5-metre IR tunnel was the right choice for our needs. Infragas also tested different temperatures in order to find the ideal one for gelling our epoxy primer. At the end of such research process, we started up our IR tunnel, which now enables us to paint our products with two coats of powder in a single run while, at the same time, providing durable products that can pass the stringent cyclic corrosion tests of the American standard ASTM D1654.” “As the parts leave the IR tunnel at a temperature of almost 150 °C, in order to cool them down before the application of the polyester top coat, Infragas and LEM suggested we install a series of fans at

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The gas catalytic panels of the primer gelling oven.

After pre-curing with IR, the parts pass through the cooling zone before entering the booth for the application of the second coat.

Some components at the end of the coating cycle.

the exit of the tunnel itself, which lower their surface temperature to

on the powder coating to be cured, without stressing the component:

around 60 °C before they reach the entrance to the finishing booth,”

indeed, the radiation is completely absorbed by the organic material

adds Spinelli. “After application of the second layer, the coating process

and the treatment times are short to optimise the process and save

ends with the curing stage at 180/200 °C for 12 to 15 minutes.”

energy. The Infracat® 16.40 panels installed at Cassetto’s premises by

Infragas Srl has been manufacturing catalytic panels and gas radiant

manufacturer LEM Impianti, in particular, are 1000 mm x 400 mm in

systems for industrial ovens since 1971. Its main strength is its R&D

size.”

laboratory, where it tests the most suitable plant solutions for each requirement together with customers.

Future projects

“We supplied Cassetto with static infrared panels, called Infracat

“The installation of the tunnel with Infracat® infrared panels has

to emphasise the combination of INFRAred energy and CATalytic

enabled us to maintain the same coating times as we had before

technology and characterised by a surface temperature that can

we started using a two-coat powder system,” comments Gianfranco

be adjusted from 180 to 550 °C,” explains Francesca Marabotti, the

Calabrese. “Our future goal is to further expand both our clientele and

Marketing Manager of Infragas.

our product range. Today, however, we are still in the consolidation

“With the catalytic technology, the gas is converted into infrared energy

phase of what we have achieved so far: we aim at concluding it in 2023,

without developing flame. The Infracat® panels allow IR irradiation with

when we intend to be efficient enough to trigger a development phase.

a medium to long wavelength, between 2 and 10 microns. The infrared

The investment in our coating plant and the optimisation achieved with

rays are concentrated on the surface of the exposed workpiece, i.e.

Infragas’ technology have been a significant step in this direction.”

N. 72 - NOVEMBER/DECEMBER 2021 - international PAINT&COATING magazine

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When Automatic Shot Blasting is a Recipe for Quality: Ideal System’s Automatic Mechanical Surface Preparation Line for Maximum Finishing Quality of Earthmoving Machinery Components Alessia Venturi ipcm®

In order to increase productivity by eliminating a bottleneck upstream of its painting process, but above all to improve the quality degree of its coating systems – combining cataphoresis and powder primers and top coats – Ideal System (Gambettola, Italy) has created an independent, automatic mechanical surface preparation line. This includes a new-generation, automatic tunnel shot blasting machine supplied by OMSG (Villa Cortese, Italy) and a manual sandblasting and blow-off chamber, connected by a Power&Free conveyor designed by Futura Convogliatori Aerei (Robecco Pavese, Italy) with a 2.5 tonne capacity. The result? The removal of the production bottleneck and the achievement of smooth, pit-free surfaces that guarantee excellent coating film distension.

Ideal System has specialised in the one, two, and three-coat finishing of components for heavy and construction machinery.

N. 72 - NOVEMBER/DECEMBER 2021 - international PAINT&COATING magazine

FOCUS ON TECHNOLOGY

includes micro, small, and medium-sized companies with very

History and evolution of one of Italy’s largest contractors

different specialisations in terms of processes, products, and

This company was founded in 1989 by dynamic entrepreneur Marco

he Italian contract coating sector is a highly diverse market that

target industries.

Sfienti, its current owner, as a Technogym supplier. It has then grew

Unlike in other European markets, especially those of Central

rapidly, soon replacing liquid coating with the powder technology and

and Eastern Europe, in Italy there are only a few large, structured

implementing cataphoresis processes.

businesses that offer contract coating services alone. These are the

Since the beginning of its activity, Ideal System has provided not only

companies that were the first to focus on providing more than mere

high quality-coated products, but also complementary services, such

labour, by offering services for which they had developed technical

as pre-assembly and packaging of parts with their related assembly

skills, made continuous investments in technology, implemented highly

kits. In short, it can manage its customers’ entire orders.

automated procedures, and even experimented with and developed

Over the last ten years, at the same time, this company has never

processes capable of subverting traditional treatment technologies

ceased to evolve, gradually growing by upgrading its coating systems,

– for example, by replacing liquid with powder paints even in those

offering new services, and even expanding its factory. What has

markets where it seemed they could have never taken hold.

determined its success, however, is its passion and will to experiment

In other words, these firms have become not only market but also

with new processes towards a goal shared by its whole staff, from

opinion leaders in the field of liquid and powder coating. One of them

managers to operators: guaranteeing a visible, tangible, measurable,

is Ideal System (Gambettola, Forlì-Cesena, Italy), already featured in an

and lasting quality level. Meanwhile, Ideal System’s core business

ipcm® report in 20161.

has moved from the finishing of sports equipment to that of heavy machinery. Currently, it treats large components, frames, rotating turrets, telescopic booms, and other parts of earthmoving and construction

Monica Fumagalli, “The Development Of Nanotechnology Processes: A Plus For Optimising Painting Cycles” in ipcm® 40, Vol. VII, July-August 2016

machines, which it paints with three different coating systems: two

A general view of the new automatic mechanical surface preparation line.

international PAINT&COATING magazine - NOVEMBER/DECEMBER 2021 - N. 72

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two-coat systems (epoxy primer + polyester powder top coat or cataphoresis + polyester top coat) and, for maximum outdoor durability, a three-coat system including cataphoresis, an epoxy primer, and a polyester top coat.

Surface preparation: the magic word for perfect coating It is obvious to anyone with a basic knowledge of industrial finishing that, in order for complex coating cycles such as those used by Ideal System to be of high quality and resistant, surface preparation is of the essence. This does not only ensure excellent adhesion and durability of the coatings when subjected to mechanical and chemical stresses, but it also produces smooth, homogenous, and glossy finishes. © ipcm

In fact, such aesthetic features are now also a must in the off-road vehicle sector. Ideal System’s latest technological investment was aimed at maximising quality precisely in this area: an automatic shot blasting and sandblasting line that treats every product to be painted before it reaches the chemical pre-treatment phase. “With the help of OMSG, which supplied us with a new automatic shot blasting machine, we have solved a major bottleneck,” explains Ideal System production manager Angelo Baldacci. “Today, the market demands mechanical surface preparation by shot blasting or sandblasting for all the components we are asked to coat. The old set-up of our mechanical preparation department, equipped with an old generation automatic hanger machine and a manual sandblasting chamber, did not allow us to meet such demand despite working in three shifts. Our coating plant often had to

stop because it was not being adequately fed

The loading and unloading elevator of the Futura Power&Free conveyor connected to the shot blasting line (top photo). Within the OMSG machine and the blow-off chamber, the parts are handled by the Futura overhead Power&Free conveyor using the same load bars as the coating line’s conveyor.

N. 72 - NOVEMBER/DECEMBER 2021 - international PAINT&COATING magazine

by the shot blasting department, which, on the contrary, was constantly overworked.” “Not to mention that the quality of our manual shot blasting operation was not

FOCUS ON TECHNOLOGY

even remotely comparable to that offered by our new OMSG automatic tunnel machine with 12 direct drive turbines, in terms of both treatment uniformity and surface roughness,” adds Marco Sfienti. “In other words, such major investment has both increased our productivity and raised our treatment quality degree.”

The layout of the new mechanical surface preparation department With this investment, Ideal System did not just install a new automatic shot blast machine, but it rather created a truly independent and autonomous mechanical preparation line, which integrated all existing equipment with the new OMSG plant through a Futura Convogliatori Aerei tworail conveyor with a loading and unloading © ipcm

elevator. The line is structured as follows: • Power&Free conveyor with 5 loading units storage buffer with 3 spaces before the tunnel • shot blasting machine • manual sandblasting and blow-off chamber (created by upgrading the existing manual chamber) • hoist and tumble shot-blasting system. “With the creation of this department, separate but perfectly integrated with the coating plant’s flow, we have improved our product quality, our overall productivity, and even the quality of the operators’ work,” comments Angelo Baldacci. “This does not mean that we have replaced our workers or reduced our staff, but that our operators can now carry out cleaner and more comfortable operations.” “Two key aspects of increasing our powder

finishing quality level were the improvement of metal surfaces after shot blasting, i.e. the creation of less rough and pitted surfaces, and the achievement of more complete and consistent treatment coverage,” notes Sfienti.

Hung workpieces entering the OMSG automatic tunnel shot blasting machine type TUNNELBLAST 1525/12 SP. OMSG’s 12-turbine machine is combined with a 20,000 m3/h self-cleaning filter and it has wear-resistant rubber slats at both the inlet and outlet to prevent metal abrasive from escaping.

international PAINT&COATING magazine - NOVEMBER/DECEMBER 2021 - N. 72

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“Indeed, we have also seen a noticeable improvement in terms of film distension. Therefore, we are very pleased with the investment in our shot blasting department. OMSG’s machine is easy to use, effective and efficient, sturdy, and fully digitalised. The choice of the Futura Power&Free conveyor was a winning one as well, because it enabled us to replicate our coating line’s part coupling device, thus being able to use the same load bars. “We have maintained our existing manual chamber, of course after retrofitting it and integrating it on the line, to perform three operations: cleaning all parts by blow-off after the automatic shot blasting treatment, treating any oversized parts, and helping handle any maintenance-related downtime needed by the OMSG ‘s shot

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Vespa Sabbiatrici’s manual blow-off and sandblasting chamber placed in line with the shot blasting machine.

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FOCUS ON TECHNOLOGY

blasting machine and the Futura’s conveyor” Stenti ends. In fact, we have made it automatic in its operation, as it receives all commands from the OMSG automatic shot blast machine. Finally, we have maintained the historic hoist and tumble shot blasting machine, which was installed in 2003, and treats all small parts that can be processed in groups.”

Features of the new automatic shot blasting machine OMSG supplied Ideal System with a tunnel shot blasting machine type TUNNELBLAST 1525/12 SP, with a maximum workpiece size of 1500 mm in width and 2500 mm in height. The plant is equipped with 12 7.5-kW turbines with one-disc

WHEN IT HAS TO BE

PERFECT CHOOSE

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PERFORMANCE POWDER COATINGS

Ideal System is currently testing the implementation of a pair of Lesta articulated robots on its powder coating booth.

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impeller and self-locking vane insertion

more articulated robots supplied by Lesta.

system.

This continues the powder application

The shot blasting machine is combined

automation project we have started a while

with a 20,000 m3/h self-cleaning filter with

ago by testing two opposing Lesta robots

24 antistatic polyester cartridges, which

on one of our two existing coating booths.

guarantee a maximum emission of less than

In future, each booth is going to feature one

5 mg/Nm3.

robot at the entrance and one at the exit,

The workpieces are moved inside the

with the aim of further improving the powder

machine by an overhead handling system

coating application. The first robot will carry

made by Futura. At both the entry and exit

out the initial 3D painting operation, then

of the shot blasting machine, wear-resistant

the 16 guns mounted on the reciprocators

rubber slats with a steel core prevent metal

will coat the parts’ entire exterior, and

abrasive from escaping. A Vespa Sabbiatrici

finally the second robot will carry out the

manual blow-off and touch-up booth is

post-retouching phase, while the manual

placed downstream of it. The whole flow is

workstation will be used mainly for quality

controlled by a PLC and the shot blasting

control.”

plant is Industry 4.0-ready.

“However, the most important news I want to

All turbines are controlled by individual

share with you is that Ideal System is going

inverters and special two-pneumatic piston

to expand to a new production plant, located

feed valves to guarantee as follows:

500 m from the current site, where we will

• avoiding possible deformation of the most

install a new powder coating plant. The

delicate parts;

semi-automatic line with manual application booths and a static oven will coat even

• if needed, reducing the grit’s impact on the workpieces (milder shot blasting);

larger parts, with masses of up to 3 tonnes, which we currently cannot treat because

saving energy.

our cataphoresis + powder coating line can

A bright future for Ideal System

handle a maximum of 50 parts weighing up

As mentioned at the beginning of this article,

to 2.5 tonnes,” announces Marco Sfienti.

Ideal System has never stopped evolving

“It will be an autonomous plant, which will

since 1989.

carry out a paint treatment from A to Z like

In fact, after the investment described

the current one, with its own shot blasting

here, two others are in the pipeline: one is

line, a chemical pre-treatment unit, and an

already underway and the second, much

independent application and curing area. We

larger one is due to be completed in 2023,

are very proud of this achievement, because

when ipcm® will visit Ideal System again.

it shows that what has always seemed

“The first investment will be completed

unfeasible, that is, powder coating parts

early next year,” says Marco Sfienti. “We

with such large masses, is actually a piece of

are building a new car park with 90 spaces

cake… if you know how to do it!”

and a new warehouse to have our loading and unloading yard finally cleared and made fully operational. With the second, most significant one, we will replace the current coating booth for applying the corrosion protection primer with a new full recovery one, which will be equipped with last-generation applicators, and four

N. 72 - NOVEMBER/DECEMBER 2021 - international PAINT&COATING magazine

In the operational configuration of the booth, the Lesta robot at the entrance will apply a layer of paint, which will then be completed by the automatic guns mounted on the reciprocators and touched up by the second Lesta robot at the exit.

FOCUS ON TECHNOLOGY

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Emiliana Serbatoi’s New Water-Based Top Coat Halved Drying Times and Increased Production Throughput Monica Fumagalli ipcm®

Reducing the duration of coating processes is one of the most frequent requests received by paint manufacturers from applicators. Emiliana Serbatoi turned to Inver, belonging to multinational group Sherwin-Williams, for the development of INVERPUR/R, a water-based top coat capable of halving drying times even at room temperature and thus doubling its production capacity related to its world-famous tanks.

roduction times are among the biggest costs of a company.

that can reduce our products’ delivery times to increasingly demanding

Emiliana Serbatoi (Campogalliano, Modena, Italy), a company

local and international markets.” Moreover, in 2015, the firm switched

known globally for the production of tanks for the storage,

from solvent-based to water-based paints and, since then, the drying

transport, and dispensing of fuels and liquids in general for agricultural

times of its tanks have increased due to the inherent peculiarities of this

and industrial use. “This is why,” states Gian Lauro Morselli, the founder

particular coating technology. Based on a well-considered management

of the company in 1983 together with his father Giancarlo and its

decision aimed at sustainability, however, it chose not to install a drying

current president, “we are always on the lookout for innovative solutions

oven in its coating department, which would have certainly reduced

One of the latest products made by Emiliana Serbatoi (Campogalliano, Modena) and coated with INVERPUR/R.

N. 72 - NOVEMBER/DECEMBER 2021 - international PAINT&COATING magazine

FOCUS ON TECHNOLOGY

processing times. As the President explains, “this would have had a significant evintonmental impact, in contradiction with the green principles that have always been pursued by Emiliana Serbatoi, which considers environmental friendliness a priority – as is also demonstrated by the recent installation of a photovoltaic system, aimed at meeting our company’s energy needs.” The company, on the other hand, chose to continue to believe in the ability of its water-based coatings’ supplier to find the right solution for its needs and, in the end, it did. INVERPUR/R, the top coat developed by Inver1’s laboratory during the pandemic, meets the demand of all those applicators that, like Emiliana Serbatoi, choose to let their products dry at ambient © ipcm

temperatures, which are not always optimal because they are difficult to control, thus avoiding the oven. Since the 1960s, when the path that would have led to the foundation of the company in 1983 began, “Emiliana Serbatoi has stood out for its non-conformist choices such as this one,” the president says, “which have led it to become an international benchmark” to the extent that it has been called upon by governments all over the world to offer its expertise in the development of regulations for the complex sector of the manufacture and securing of tanks for petroleum products and liquids in general.

Emiliana Serbatoi: from farmland to oil tankers Emiliana Serbatoi started its business with the construction of gravity tanks for diesel fuel (now no longer legally compliant) intended mainly for farms, quarries, and construction sites © ipcm

that needed fuel dispensers for their work vehicles in easily accessible areas. Hence, the urgent need to especially regulate the production of agricultural tanks, which at that time could reach a volume of up to 9,000 litres: the risk of accidents that would cause potential harm not only to people but also, in the event of a spill, to the soil and the surrounding environment was unacceptable. “Emiliana Serbatoi was the first company to obtain ministerial approval for its single-walled steel tanks equipped with a containment basin for the storage of diesel fuel,” says Paolo Cinquegrana from the firm’s marketing department. “These tanks were the initial core business of our company, which since then has also continued to collaborate with the Italian ministry of the interior first and then with foreign governments as well to make a technical contribution in the drafting of new environmental safety regulations.”

From top to bottom: - Some tanks waiting for mechanical pre-treatment before painting. - Brushed tanks.

A brand of The Sherwin-Williams Company.

- The coating booth.

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An INVERPUR/R top coat application phase.

In the 1990s, a new figure emerged in the agricultural sector, that of the

Emiliana Serbatoi was no longer able to cope with increased market

contractors who used their own machinery to work the fields to order.

demands. Therefore, we decided to insource some processes such as

“With this came the need to build transportable tanks that followed the

the construction of tank casings and to acquire another company in

contractors’ vehicles and were capable of safely transporting diesel fuel.

San Donà di Piave (Venice, Italy), which carried out the same production

In addition to our established line of storage tanks, we therefore started

as us and had an in-house coating department, but was no longer able

manufacturing transport tanks, which have in turn evolved into a series

to cope with manufacturing costs. We then decided to only perform

of plastic transportable tanks. Actually, polyethylene products now

our sheet metal processing operations there and close the paint shop,

account for 50% of our production, with sheet metal tanks accounting

in order to concentrate the finishing processes in Campogalliano

for the other 50%,” indicates Cinquegrana.

and thus have greater control over our coating quality, while avoiding

The company has now achieved an annual production of 18,000

unnecessary additional handling and, consequently, longer delivery

plastic transportable tanks made with 25 proprietary moulds and

times. This decision also led us to expand our product portfolio, which

4,500 iron tanks. It has also significantly diversified its target markets

now range from 50-litre to 80-m3 tanks, with no limit on customisation.”

beyond agriculture, which still remains among the priority sectors, to

The acquired Venice-based company took the name of Espa Enerlab

include the industries of construction, oil and gas – for example, it was

and it now manufactures finished tanks that it then sends to the

approached to supply a container station to be mounted on an oil

Campogalliano plant. “However, it is thanks to the experience that

tanker – automotive, transport, shipping, aviation, industrial equipment,

San Donà’s technical staff had in the field of painting that we heard

gardening, and food. “We have also developed a department devoted to

about Inver and its water-based paints for the first time,” adds Filippo

special tanks, particularly for the chemical and pharmaceutical sectors,

Cucchierato, the technical manager of Emiliana Serbatoi. “Before

for which we are receiving more and more requests,” notes Gian Lauro

employing these products into our coating process, we carried out

Morselli. “This is further proof that we are not afraid to go against the

a number of tests that gave very good quality results compared with

tide: our competitors are currently focusing on standardising their

the products we were using at the time and with which we were

production, while we are going in exactly the opposite direction with

experiencing durability problems. In fact, we needed paints that

our constant search for innovative products.”

would give the coatings a high degree of resistance not only against

The production structure In the second decade of the 2000s, the company revised its production structure. As Morselli explains, “with the Campogalliano site alone,

N. 72 - NOVEMBER/DECEMBER 2021 - international PAINT&COATING magazine

the chemicals present in the fuels contained in our tanks, but also against the severe weather conditions to which our products are often subjected.”

FOCUS ON TECHNOLOGY

Fast. Powerful. Consistent. © ipcm

Coated tanks in the drying phase.

The competitive edge provided by the fast-drying top coat Once the tanks reach the Campogalliano plant, they are degreased and mechanically pre-treated to remove any residues of dust and contaminants left by previous processes and then sent for painting. “In our manual coating booth, we use an airless gun to apply two coats of primer, also supplied by Inver: one on the most difficultto-reach areas such as welds and undercuts and one on the entire surface of the tank,” says Cucchierato. “The product is then left to dry at room temperature and, once dry, it receives a coat of INVERPUR/R, followed by drying in the booth at room temperature,

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aided if necessary by mechanical ventilation. While the entire cycle used to take 48 hours, thanks to the coating developed by Inver it now takes just 24 hours, leaving the tank to dry overnight. We can thus cope with a high production rate of 15 to 25 tanks per day, with delivery times of 3 days. We apply different colours, but the predominant one is a green shade called “Emiliana” because it is the typical tint of our products: it accounts for 80% of the paints we use, whereas customised colours on request account for the rest. Inver’s cooperation has also proved to be optimal in the management of batches, from the largest ones to the smallest ones needed to meet the most particular requirements.”

Features of INVERPUR/R

• Fast powder paint removal • Simplified operation and control with Master Remover® ESPRIT plug and play equipment • Consistent performance, all day everyday • Efficient use of energy and space

“The top coat developed in our laboratory,” says Sherwin-Williams’ sales representative Michael Benedini, “is a water-based, twocomponent polyurethane acrylic resin. The main challenge faced Atotech Group info@atotech.com

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Table 1: INVERPUR/R speed of drying.

100 µM WFT (≈ 50 µM DFT) Drying conditions INVERPUR 25% 72870

INVERPUR/R 30% 40301

150 µM WFT (≈ 70 µM DFT)

40 °C

60 °C

40 °C

60 °C

Tack-free time

>8 h

>1 h

30 min

>8 h

>1 h

35 min

Dry-to-handle time

>8 h

>2 h

35 min

>8 h

>3 h

40 min

Tack-free time

20 min

10 min

3.5 h

20 min

10 min

Dry-to-handle time

30 min

10 min

4.5 h

50 min

15 min

An example of a tank with customised colours.

Emiliana green is the most used tint.

when creating the most suitable coating system for Emiliana Serbatoi’s

fact that it stores in its warehouse the equivalent of the volume of

needs was its high quality standard, combined with its processing time

paints we need for one and a half months’ work is also indicative of

requirements to cope with peak production. We conceived a water-

our two-way, consolidated relationship of trust.”

based, two-component product that works perfectly both in optimal conditions such as those of a drying oven with pre-set temperature

Conclusions

parameters and in less than perfect conditions such as ambient ones.”

“INVERPUR/R’s development,” explains Cesare Bonora, the GI Italy

“Thanks to the development of INVERPUR/R,” emphasises the

area manager of Sherwin-Williams, “started in 2019 to respond to

Modenese company, whose headquarters are located just a stone’s

the market’s needs for optimisation of coating times and processes

throw from the A22 motorway exit, a genuine gateway to Europe,

following the switch from faster-drying solvent-based paints to water-

“we were able to increase production capacity without integrating a

based ones. Indeed, the limitation of this technology lied in its drying

drying oven, doubling shifts, or expanding our production space. We

time. Our R&D laboratory set out to researching new water-soluble,

appreciated the professionalism of Inver’s team in its consultancy

acrylic resins to develop this product, which, after being industrialised,

service and its willingness to carry out the many tests we needed.

has found one of its most successful applications in Emiliana Serbatoi.

We chose this supplier because of its large corporate structure

We have overcome one of the most difficult challenges: to create

that ensures an average daily production of 80,000 kg of paint, but

a top coat that, even in less than perfect ambient temperatures,

we would like to underline that we have never received a negative

guarantees drying characteristics comparable to those of conventional

response even when we ordered just a few cans of a tint. Lastly, the

technology. Objective achieved!”

N. 72 - NOVEMBER/DECEMBER 2021 - international PAINT&COATING magazine

FOCUS ON TECHNOLOGY

SPECIAL ISSUE ON ACE & OFF ROAD VEHICLES

A “Cartesian” Coating System and a New Pre-Treatment Process to Increase Corrosion Resistance Fivefold. Alpego: When Chemistry Matters. Alessia Venturi ipcm®

Providing a coating with corrosion resistance properties is never a one-man show, but rather teamwork involving all the different elements that make up a painting process. Alpego Spa, a global leading manufacturer of agricultural machinery, is well aware of this. Its new pre-treatment cycle developed by ALIT Technologies with Alufinish products, combined with an unconventional coating line that is perfectly suited to its needs, has increased its products’ salt spray resistance fivefold.

One of the agricultural machines included in Alpego’s range of products.

N. 72 - NOVEMBER/DECEMBER 2021 - international PAINT&COATING magazine

FOCUS ON TECHNOLOGY

he agricultural, construction, and construction machinery (ACE) sector is comparable to the automotive one in

terms of plant engineering, painting, outdoor resistance, and, last but not least, coating sustainability requirements. Not only does the heavy machinery and off-road vehicle market now demand finishes with a “bodywork” aesthetic quality degree comparable to those applied by automotive OEMs, but the issues of the durability and the mechanical, chemical, and corrosion resistance of coatings is also just as central as in the car industry. Although the coating departments typically set up in the two industries are not comparable, not least because in the ACE sector the metal masses involved are very large and therefore require very different plant arrangements than in a classic automotive paintshop, the issues of sustainability, energy efficiency, and the environmental impact of paint systems are

equally important. For both sectors, the key process for guaranteeing the durability of coatings is surface pre-treatment. Only a perfectly deoxidised, clean, passivated surface with the correct surface roughness value can guarantee excellent adhesion of the paint film and increase its resistance to corrosion. Clearly, once the ideal pre-treatment has been found, it must also be integrated in a process context where the coating products and their application are handled as efficiently and effectively as possible. Alpego Spa (Almisano, Vicenza, Italy) is a company aiming at optimising agricultural production with its machines by listening to the needs of a constantly evolving sector. Its experience in this respect is paradigmatic. After years of intensive study of all possible coating system solutions, which required seven visits to the PaintExpo trade fair in Germany and countless trips around Europe to analyse its competitors’ choices, Alpego spent four years planning its perfect painting

General view of the pre-treatment tunnel and the drying oven after the pre-treatment stage.

plant, which was finally completed in 2014.

international PAINT&COATING magazine - NOVEMBER/DECEMBER 2021 - N. 72

SPECIAL ISSUE ON ACE & OFF ROAD VEHICLES

Components of agricultural machinery being powder coated.

Its collaboration with Alit Technologies (San Bonifacio, Verona, Italy),

pickled sheets are purchased in Sweden, which is a leading producer

a supplier of pre-treatment products that is the Italian distributor of

in the sector, and the remaining 10% of purchased parts are made in

German Alufinish products, was strategic in achieving its corrosion

Germany and the United States.

resistance targets.

Since its foundation, Alpego has boasted constant growth in all

About Alpego

international markets, with double-digit increases in terms of both number of machines produced and turnover, reaching the threshold of

It is in the middle of the Veneto region, one of the richest and most

40 million Euros in 2021 with 190 employees.

industrialised areas in Italy, covered in vineyards and surrounded by the

Today, the company has three plants with a total area of 41,000 m2, of

splendid Dolomite Alps, that Alpego was founded in the 1980s as a small

which 15,000 are covered:

family business. It is still 100% owned by the Pegoraro family, now in its

• Almisano: the new headquarters since 2012, covering over 21,000

third generation. Flail mowers, subsoilers, tillers, rotary cultivators, seed

m2. It houses the administrative, technical, and sales offices, a large

drills, fertilisers, vineyard equipment, power harrows, and cultivators

assembly department, the coating line, a machine dispatch area, and a

make up the vast product range of Alpego, which manufactures 4000

spare parts warehouse.

machines a year.

• Gambellara: the company’s first headquarters, now housing a

All products continue to be conceived and designed in-house in

carpentry shop with advanced laser cutting systems, press brakes, and

order to maintain the complete know-how of each individual project.

welding robots.

The company always reinvests 4% of its turnover in research and

• Lonigo: an assembly service plant that was recently acquired in order

development and it has 40 active patents and trademarks. For the

to increase production capacity.

sake of quality and reliability, Alpego’s machines also continue to be

Alpego has a wide sales network consisting of numerous importers and

produced in-house or with the help of high quality Italian suppliers. 80%

dealers, as well as two European subsidiaries, Alpego France and Alpego

of the components purchased are produced in Italy, while high-strength

UK.

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FOCUS ON TECHNOLOGY

The development of an unusual coating system

were collaborating with Alit Technologies, which

“Alpego has always coated its machines in-house,”

workpieces, mainly made of thick (8-10 mm) black

states Luciano Pegoraro, the current owner of

iron sheets, called for an aggressive pickling process

Alpego together with his brother Giovanni. “Painting

in order to obtain surfaces suitable for high quality

is too important to be assigned to an external

painting. The only alternative would have been to

supplier. At our original Gambellara site, we had a

combine chemical pre-treatment with a controlled

conventional liquid coating line with an overhead

shot blasting phase. However, once again, our line

conveyor, a classic “ring” with a phosphodegreasing

did not allow us to do that.”

and a drying station, two painting booths for primer

“Despite several adjustments to the pre-treatment

and top coat application, and a final baking oven.

cycle, with the coating products and plant conditions

We used to apply a high-solids coating system but,

of the time, we could not make Alpego’s products

although we complied with atmospheric emission

achieve a salt spray resistance value over 170 hours,”

limits, we wanted to switch to water-soluble

says Loris Rossi, the CEO of Alit Technologies, the

products. However, our plant’s design did not enable

Italian distributor of Alufinish products. “The pre-

us to do so. Too many parameters would have had

treatment tunnel presented a major problem of

to be monitored and adjusted to achieve high quality

rinsing water pollution and the quality of surface

coating results with water-soluble products: the

preparation could not be further improved without

process was incompatible with the installation itself.

modifying the plant.”

In addition, we needed to increase the corrosion

“Based on all these reasons, in the early 2000s we

resistance of our machines, as many of them were

decided that it was necessary to invest in a new

exported by sea. Already with that old plant, we

coating line,” adds Luciano Pegoraro. “However, I did

supplied us with phosphodegreasing products. Our

Finished components hanged onto the coating line designed by Tekimp of Castelfranco Veneto, Italy.

SPECIAL ISSUE ON ACE & OFF ROAD VEHICLES

not want to install a traditional

with the selected

line with a two-rail conveyor

coatings, Alpego has

again. I found the layout of those

been able to achieve

lines too rigid for our production

a salt spray resistance

flow. Moreover, this type of plants

value of 500 to 700 hours

takes up too much space: in fact,

but, above all, it has

the first project submitted to us

achieved excellent quality

covered more than half of our

consistency.

new Almisano plant.

“This was a great team

“We therefore decided on a

effort,” comments

clear change in several areas of

Luciano Pegoraro. “Alit

our production flow. First of all,

already made sure we

we changed our raw material:

achieved good pre-

from black iron, we switched

treatment results despite

to buying only pickled sheet

the difficult conditions of

metal, mainly from Sweden. Secondly, we implemented laser cutting operations on sheet metal in order to eliminate

Luciano Pegoraro (left) with Loris Rossi in front of several Alpego’s agricultural machines ready to be shipped all over the world.

the previous line: with the new plant, the results are top notch!”. “Alpego placed great trust

as much as possible the problem of oxidation on high thicknesses.

in Alit. We already had a good business relationship that had started

Thirdly, we specified a water-based coating system consisting of an

when working on the old line, also thanks to the proximity between

epoxy primer and a two-component acrylic top coat and we started

their factory and Alit’s,” says Loris Rossi. “Then, the four years spent

considering using powder coatings, which we then actually did. Finally,

on designing this plant were years of mutual technical growth and

at PaintExpo we were inspired to no longer design a ring system but a

exchange of knowledge and experience. Alit felt valued by Alpego and

line of stations, based on a concept that is completely different from

we worked closely to fine-tune all chemical aspects.”

conventional plants.”

“Although a few changes were made during the construction phase, the path mapped out in the design phase proved to be correct, in

Quintupling corrosion resistance with the right chemicals, applied with the right equipment

terms of both plant engineering and chemistry,” notes Pegoraro.

Tekimp (Treviso, Italy), part of Rimor Group, designed for Alpego a

A new, challenging scenario

compact, functional plant that Pegoraro defines as “Cartesian” and

Working with the new system entailed a total change of paradigm

storage buffer-free, to emphasise the absence of a classic conveyor

for Alpego, from painting complete machines to coating individual

in favour of a handling process using trolleys that take the workpieces

components. “Initially, the system seemed gigantic compared to

to the relevant treatment stations, following pre-set routes that

what we had before, so we had a few problems making it work well,”

are independent of each other. The plant also includes an in-line

indicates Pegoraro.

modular shot blasting machine, which performs fine shot blasting

“For the first four years, we only applied liquid coatings. Then, in 2018,

of high thickness (8-10 mm) parts. These components undergo two

we implemented a one-coat powder finishing process by installing

pre-treatment phases, first mechanical and then chemical with the

a Gema automatic booth, separating the components that could be

new Alufinish system, while thin sheet metal parts only undergo

powder coated from those that could not. The new painting line is

the chemical pre-treatment process. Each load bar can be assigned

very complex in terms of production scheduling software: start-up and

a different shot blasting grade. The Alufinish pre-treatment cycle

industrialisation were difficult. Now, almost eight years later, the plant’s

supplied by Alit Technologies includes a strongly alkaline degreasing

capacity is saturated and we would need a new one. Over the last

stage at 55 °C for 10 minutes, two rinses with mains water, a

few years, in addition to the painting plant, we have invested 7 million

nanotechnology passivation stage, a rinse with demineralised water,

Euros in Industry 4.0-oriented production machinery. Now, we are

and a drying stage. With this new pre-treatment process, combined

ready for new coating challenges!”

N. 72 - NOVEMBER/DECEMBER 2021 - international PAINT&COATING magazine

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

INNOVATIONS: PRESENT&FUTURE

SPECIAL ISSUE ON ACE & OFF ROAD VEHICLES

Protect and Beautify Farm Machinery, a High-Tech Challenge Edited by SAMES KREMLIN Meylan – France

marketing@sames-kremlin.com

Agricultural machinery manufacturers design machines that are able to withstand the weather, chemical and mechanical aggression. Today, they must also offer paints with finishes as meticulous as those on cars. This dual challenge requires the use of high-tech application equipment.

ho would have thought that metallic paints would one day

Sales Director for Industry in France. “The acquisition of a piece of

make their appearance on agricultural machinery? But

agricultural machinery is an investment over several decades. The

that’s what we’re seeing now: light grey, anthracite grey and

quality of the finish is a guarantee of seriousness, a reassurance about

metallic red are being used on tractors and trailers, which can even be

the lifespan of the machine and ... a way of enjoying it, quite simply”.

customised. The shine of their painted surfaces is on a par with that of

These requirements led to the development of new references by paint

car bodies.

manufacturers who could not offer their usual products dedicated to

Combining durability and aesthetics, a challenge for paint manufacturers This quest for aesthetics also affects, to a lesser extent, combine harvesters, sprayers, soil preparation and planting equipment.

the automotive market. Indeed, the chemical composition would not have withstood the harsh life of the fields. They expanded their ranges for agricultural machinery by introducing metallic colours, mainly in the form of liquid paints.

Agricultural machinery has always been required to be robust and

Hardeners, zinc or titanium particles...

durable to withstand the sun, frost, rain, dust, shocks, vibrations,

However, the fundamentals of paints, those that ensure their durability,

chemical aggression and sometimes salt spray. Now they must also be

have not changed. These are mostly “two-component” paints. They

beautiful.

combine a base (for example, an epoxy if maximum durability is desired,

“It is understandable that farmers think like this”, says Gilles Valbrecq,

or a polyurethane for an impeccable finish) and a hardener. To reinforce

N. 72 - NOVEMBER/DECEMBER 2021 - international PAINT&COATING magazine

INNOVATIONS: PRESENT&FUTURE

the mechanical properties of the coating, microparticles of zinc or titanium are sometimes incorporated. This very specific market relies on application equipment that is just as specific. Their role is first to extract the products from their container, drum or barrel. It is then to mix and dose them, particularly for twocomponent base-hardeners. Finally, it is to spray them onto the parts, combining precision, productivity, homogeneity of thicknesses and colours, low environmental impact, etc. SAMES KREMLIN, one of the major players in this market, relies on

GLOBAL SOLUTIONS FOR WATER TREATMENT

a wide range of proven technologies from other industrial sectors: automotive of course, but also construction, aeronautics, railways, furnitures, household appliances, etc.

From manual guns to automated industrial lines In the agricultural machinery segment, SAMES KREMLIN equips from small-scale trailer manufacturers to world-class companies. For the former, it supplies manual electrostatic spray guns for painting large flat parts with high productivity (Airmix® range) or parts with complex geometry where the smallest gap must be protected

with a complete service that includes system design manufacturing installation technical support chemicals

(Airspray range). In the latter case, it sets up particularly innovative industrial lines. One example is an automated installation in Northern Europe that applies powder paint to beet harvesters. It includes a conveyor belt, a powder booth, a powder conveying and recycling system, a colour change module, pre-touch and touch-up stations and an oven. “Such a line paints simple shaped parts at a very high rate,” says Christophe Denis-Bosio, Global Business Development Manager. “In addition, a part recognition and measurement system place the guns at the optimum distance, without human intervention”. Another example of a SAMES KREMLIN installation for the application of liquid paints is the four booths installed on platforms for the top-down treatment of large elements. From these gondolas, the operators monitor their movements as well as the complete control of the paint lines, without having to return to the ground.

Pumping, mixing, spraying, the key links in the paint chain To measure the high technical nature of the painting installations, it is best to describe their three main components: pumping, mixing and spraying. Bases and hardeners are transported from their original storage to

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

a mixer by pumps. The hardener must be kept away from humid environments; it would crystallize, attack the pump seals and clog the injectors. SAMES KREMLIN has eliminated this risk with its Flowmax® technology, which has been on the market for over 25 years in its range of pumps. A patented bellow completely isolates the hardener from the air. Via E. Torricelli, 79 - Z.I. Fossatone 40059 MEDICINA (BO) Tel +39 051 856263 info@hydroitalia.com www.hydroitalia.com

SPECIAL ISSUE ON ACE & OFF ROAD VEHICLES

The second step is the mixer where the base is combined with a hardener. Just like in the kitchen, the correct dosing of the ingredients and the quality of the mixing are decisive for the final result. The Cyclomix™ electronic dosing machine from SAMES KREMLIN meets these requirements. It prepares the required volume of paint in the right proportions. Compared to manual mixing, the advantages are major: repeatability of parameters, no risk of human error, and product losses reduced to a strict minimum. The resulting paint retains constant characteristics. This guarantees the stability of the colour and mechanical properties of the tractors or trailers that come off the line.

Paint droplets and grains charged at 80,000 volts

Finally, spraying uses electrostatic technology: the droplets or paint particles, electrically charged by a high-voltage unit that can reach 80,000 volts, are attracted to the metal parts to be coated and are deposited there. The resulting layer is more even than with a non-electrostatic hand gun, because the charged paint particles repel each other and do not clump together. Most of the paint ends up on the workpiece, without dispersing as it would with a compressed air spray gun. This “transfer rate” - as it is called - is a record 93% for the Nanogun Airmix® manual electrostatic spray gun from SAMES KREMLIN. This low product loss reduces costs, waste volumes and VOC emissions, which improves the environmental balance of the industrial tool. Sames Kremlin is also working on this

issue with installations for water-borne paints. “We have already equipped several customers. They generally apply a solvent-based primer for durability, followed by a waterbased topcoat,” concludes Gilles Valbrecq, Sales Director for Industry in France.

From top to bottom: - Application with manual electrostatic spray gun for painting large parts with Airmix® high productivity technology. - Automatic application of powder coatings. - Electrostatic application.

N. 72 - NOVEMBER/DECEMBER 2021 - international PAINT&COATING magazine

SUCCESS STORIES

Dürr Builds Two Paint Shops for Sinotruk Dürr is currently building two state-of-the-art paint shops in China for manufacturer of heavy trucks, Sinotruk.

ürr is building two paint shops in Laiwu and Zhangqiu, in the eastern Chinese province of Shandong, for the manufacturer of heavy trucks, Sinotruk. The paint shops, equipped with

state-of-the-art technology, will be used to coat Sinotruk subsidiaries Ji’nan Truck and Ji’nan Commercial Vehicle’s truck cabs and pickups, including flagship brands such as Yellow River, SITRAK, and HOWO, with which Sinotruk aims to enter the league of world-class manufacturers. The Sinotruk plants are scheduled to start production in 2021 and 2022, respectively.

Flexible conveyor technology with AGVs At Sinotruk, Dürr’s automated guided vehicles (AGVs) will transport truck cabs for the first time. In order to move the heavy loads, the EcoProFleet has been designed

with an unladen weight of 850 kg in good proportion with the maximum load capacity of 1,000 kg. The fleet is intelligently controlled by the DXQcontrol software, making sure that all AGVs execute their transport assignments and are permanently on the move. The energy concept with supercap technology also contributes: AGVs are charged within just 1.5 minutes, and at charging points where the AGV is stationary anyway for picking up or setting down the bodies.

The coating process The Sinotruk paint shops feature the RoDip rotational dip process, which provides the optimal prerequisites for subsequent processes. The electric variant RoDip E permits individual dip curves for pretreatment (PT) and cathodic electrocoating (EC), which optimize the coating quality when dealing with different cab models. With this method, each cab is transported through the complete PT and

EC process using a freely programmable trolley. Each trolley has a conveying drive and a rotating drive, which enable horizontal and rotating movements to be controlled independently of each other for each cab. The immersion tanks for the rotational process are smaller than with a traditional pendulum conveyor, which means that less energy and chemicals are required, saving resources and reducing operating costs. In each of the two paint shops, two EcoRS sealing robots seal the inner seams and another two apply liquid sound deadener in a fully automatic process. The base coat and clear coat in each paint shop are applied by 19 of the latest generation of EcoRP painting robots, which are equipped

N. 72 - NOVEMBER/DECEMBER 2021 - international PAINT&COATING magazine

SPECIAL ISSUE ON ACE & OFF ROAD VEHICLES

with EcoBell3 high rotation atomizers, which ensure optima painting results in terms of colour shade and flow values, as well as particularly uniform layer thicknesses. At the same time, the Dürr application technology creates less of an impact on the environment thanks to high rotation atomizers with electrostatic charging that are extremely efficient in their material use. With the colour change technology and the EcoBell Cleaner

INDEPENDENT MANUFACTURER OF PROTECTIVE COATINGS

D2 for cleaning atomizers, paint loss during colour changes and consumption of flushing agent and solvent (and thus VOC emissions) are also minimized. The EcoDry X dry separation system, which doesn’t require water or chemicals, is another technology used in the new Sinotruk paint shops. The system uses inexpensive cardboard filter boxes

HMG Specialise in

to efficiently separate overspray and, if necessary, saturated filter boxes can even be replaced during production time. At the end of the painting process, the body surface is checked

Bespoke Product Development

at a fully automatic quality control station. Here, a robot follows defined checkpoints on the truck cabs and uses sensors to record data about colour variations, surface texture, and layer thickness. This automation saves time compared to manual

measurement. This data is transferred to the database and

visualized digitally for the worker. This way, the worker always has

an eye on the quality.

Testing technology Dürr has also implemented end-of-line testing technology. In Laiwu, four x-wheel truck d test stands equipped with highprecision 3D measurement technology are used to measure and adjust the vehicle axis geometry. Dürr meets the specific requirements of the heavy trucks in terms of load carrying capacity, wheelbases, and tracks widths with components specially developed for this area of application. The safetyrelevant driver assistance systems of the trucks are precisely adjusted using Dürr test technology. With the modular test stand concept x-DASalign, the sensor technology for the lane departure warning system and the advanced emergency braking system are perfectly aligned in relation to the geometric driving axle of the respective vehicle. Sinotruk also ordered additional test stands for another plant in Zhangqiu in August 2021. The production plant for light trucks will use the x-wheel wheel alignment stand with the latest x-3Dsurface measurement technology and the multifunctional roll, brake and ABS test stand x-road medium truck. For further information: www.durr.com

Market Leading Technical Support Colour Matching & Development

CMY

Book a meeting or request product information by emailing sales@hmgpaint.com

www.hmgpaint.com

A single-track crane trolley manufactured by ABUS.

FOCUS ON TECHNOLOGY

SPECIAL ISSUE ON ACE & OFF ROAD VEHICLES

Cranes with Perfect Surfaces Ulf Kapitza AGTOS GmbH, Emsdetten – Germany

info@agtos.de

When crane systems and lifting gear with a load capacity of 80 kg to 120 t are constructed, the surface also needs to be perfect. ABUS, one of the most important European manufacturers of indoor cranes, erected a completely new plant in Gummersbach and works there since 2019 with AGTOS shot blast machines. These embody special functions and have been adapted to meet high ergonomic and safety requirements.

or over 50 years, ABUS has been finding efficient and well thought

Gummersbach, it is represented globally by seven further locations as well

through crane solutions for all kinds of industrial buildings and

as an international sales and service network.

factory floors. Where a variety of heavy loads are moved daily,

“The high-quality standards achieved by ABUS crane systems are

quality and precision down to the smallest component is sought after,

only possible because of the extreme care taken in production. Our

and this is exactly what makes ABUS one of the leading indoor crane

production facilities represent the state of the art, from the preparation

manufacturers in Europe.

of steel plate using high-performance blast cleaning systems and

In addition to the company headquarters and the production site in

welding using machinery with automated weld sequences through to

N. 72 - NOVEMBER/DECEMBER 2021 - international PAINT&COATING magazine

FOCUS ON TECHNOLOGY

the application of the high-quality paint system,” says Michael Wirths,

change requests. Design changes were also realised efficiently by AGTOS

Component Plant Manager at ABUS.

Project Managers U. Wietkamp (Design) and Christian Remmes (Sales).

When it came to choose the most suitable devices to renovate the shot

We were very impressed by the project work”.

blasting department, ABUS had no doubts. “Our contact with AGTOS,“ Wirths continues, “arose in the early 2000s in relation to spare parts for

Special features of both shot blast machines

the Schlick shot blast machines we then operated. We were very pleased

Both shot blast machines are installed on vibration isolation mats that

with the cooperation, as AGTOS had speedy response times and offered

reduce vibration and noise. The two machines are also equipped with

excellent service. For us, it was apparent that AGTOS would also be the

a generously dimensioned Type TP 1500 touch-panel to ensure that

company to approach when it came to new investments. Cooperation

personnel enjoy optimum operating conditions. Swivel arms facilitate

in the project was marked by a spirit of partnership, commencing with

flexible positioning, contributing to optimum machine operation.

the definition of requirements, compilation of a specification and the

Batches are recorded through barcodes, triggering the appropriate

offer and continuing through explanations and speedy consideration of

predefined blasting program in each case.

From top left, clockwise: Loading the AGTOS Type BS wire mesh conveyor shot blast machine; A large panel with a swivel arm facilitates optimum machine operation; AGTOS wire mesh conveyor shot blast machine outlet; Behind the acoustic insulation: the blasting chamber is at the heart of the wire mesh conveyor shot blast machine.

international PAINT&COATING magazine - NOVEMBER/DECEMBER 2021 - N. 72

SPECIAL ISSUE ON ACE & OFF ROAD VEHICLES

Maintenance hatches and doors were enlarged, adapting them to ABUS

high-grade weld quality. The welding process is followed by coating with

requirements with regard to ergonomics.

waterborne and solvent based 2-components paints, depending on

In the event of a service assignment inside the blasting cabin, the

customer requirements and wishes.

dedusting system which normally leads to the associated cartridge filter mobile extraction units can be dispensed with. Nevertheless, the filter

AGTOS wire mesh conveyor shot blast machine features and process

systems are equipped with fire detection equipment and extinguishers.

Wire mesh conveyor shot blast machines are, essentially, extremely

The performance of filter systems is set to separation efficiency levels far

flexible in terms of their use. The fact that workpieces are simultaneously

higher than statutory requirements.

shot blasted from above and below considerably broadens the

The first wire mesh conveyor shot blast machine delivered was used for

spectrum of workpieces that can be processed. The machines are used

processing flame-cut blanks for single-track crane trolleys. Blasting in

for applications such as deburring, descaling and cleaning of cast and

this case achieves optimum cleaning of the parts prior to welding. Rust

laser-cut parts.

and scale need to be effectively removed through blasting to achieve

Automatic workpiece detection upstream of the inlet sluice starts

switches to indoor extraction. The advantage here is that additional

From top left, clockwise: Simple abrasive filling with the refill hopper mounted directly on the bucket elevator; AGTOS roller conveyor blast machine intake for profiles; Christopher Fritz Dietrich, Project Engineer for factory planning and organisation, demonstrates the ease of operation on the clearly arranged panel; AGTOS wire mesh conveyor shot blast machine.

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FOCUS ON TECHNOLOGY

the needs-based abrasive supply to the four active AGTOS high-

organisation, emphasises the compact design of the machine, a feature

performance turbines. These are equipped with 11.0 kW motors at

not available in this form from other manufacturers. ABUS placed

ABUS, enabling the achievement of blasting speeds of up to 2.0 m/min.

particular importance on a few special features, including installation of

Workpiece detection ensures that shot blasting only occurs when the

a perspex safety pane on the working platform to protect any worker on

workpieces are in the shot blasting area.

the platform from a crane passing close by. In addition to hearing the

This reduces the stress on wear parts in the machine and saves energy.

noise of the approaching crane, the worker can also see it.

The inlet sluice is equipped with wear-resistant rubber curtains for

Dietrich is impressed. “The blasting performance exceeded the

sealing purposes. Workpieces that have passed through the shot

demands stipulated by us in the specification, enabling an expansion in

blasting zone move to a blower unit. Abrasive remaining on the

the product range”.

workpiece surface is removed here and fed back into the abrasive

The most recently delivered AGTOS system, a roller conveyor blast

circuit.

machine, blasts undercarriage supports for travelling cranes. Points of

The abrasive keeps circulating and is cleaned for continuous use.

particular importance to ABUS in the first project were implemented

Cleaning is realised in a special air separation system. It cascades here

here from the outset.

over an edge, while a finely adjustable air flow is fed through at the same fines to the impact separator where coarser particles are separated.

AGTOS roller conveyor blast machine features and process

The abrasive continues to the cartridge filter system which eliminates

This machine type is used for descaling and rust removal on sections/

undersized particles and dust. An abrasive dosing device is used to

profiles and sheet metal. The rollers convey the deposited workpieces

convey the cleaned abrasive from the storage hopper to the high-

through the blasting chamber and upstream brush blower unit. The

performance turbines.

machines can be integrated in production lines with sawing, drilling,

Christopher Fritz Dietrich, Project Engineer for factory planning and

blasting and conservation stations.

time. This is generated by the cartridge filter system fan. It guides the

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 ACE & OFF ROAD VEHICLES

Michael Wirths, Component Plant Manager at ABUS, in front of the AGTOS wire mesh conveyor shot blasting machine.

Undercarriage support for ABUS travelling cranes.

The workpieces actuate the switching threshold upstream of the inlet

workpieces are also cleaned using a blower unit.

sluice for the automatic abrasive supply of the high-performance turbines.

A further detail is the maintenance platform tailored to special customer

This also ensures that shot blasting in this machine only occurs when the

requirements. It improves accessing during service assignments.

workpieces are in the shot blasting area.

The quality of the blasting process on both machines is assured through

The machine at ABUS has four high-performance turbines, each with a

abrasive analyses conducted by AGTOS.

drive power of 15.0 kW. This ensures that a high blasting speed can also

Cycles are initially shorter, being extended as experience is gained and

be achieved with this machine.

the machines are run in. The operating mix is analysed and compared

The inlet sluice is equipped with wear-resistant rubber curtains and other

with previous values. What is important in this context is checking to see if

sealing elements for sealing purposes. Workpieces that have passed

too many fines are present, as these contribute significantly to wear inside

through the blasting zone move to a combined brush blower unit.

the machine.

Abrasive remaining on the workpiece surface is fed back here into the

Conversely, consistent quantities of coarse particles are necessary for

abrasive circuit. Cleaning of the abrasive is also achieved through an air

the blasting performance, and consistent quantities of fine particles for

separation system on this machine.

the blasting overlap. A consistent operating mix achieves the consistent

The unique feature of this machine is the brush station. As workpieces

blasting performance desired and an efficient process.

with differing heights are processed on this blast machine, the cleaning

Maintenance is achieved with the support of a plan compiled by ABUS

brush also has bristles of differing lengths to follow the individual profiles

that, simply and clearly, depicts the steps to be realised and confirmation

of workpieces. This ensures that the bristles are not pressed down too far

notations provided by personnel.

during lowering in the case of taller workpieces, as this would accelerate

Positive collaboration and a coherent service concept bode well for future

wear. This measure also ensures the efficiency of the process. The

cooperation between ABUS Kransysteme GmbH and AGTOS.

N. 72 - NOVEMBER/DECEMBER 2021 - international PAINT&COATING magazine

Your fast efficiency. 5/5

We care. Surface cleaners

dn-chemicals.com

BRAND-NEW

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A Look Inside the Paint Shop of Tesla Gigafactory in Shanghai Tesla Shanghai has released a rare video that shows its completely automated paint shop and reveals Tesla’s focus on paint, which has increased since talk about Giga Berlin’s advanced paint shop started.

esla released a short video which shows the step-by-step

Moreover, in the months following Tesla’s announcement of the

automated painting process that all Made in China Tesla vehicles

Gigafactory in Germany, Elon Musk teased about Giga Berlin’s

go through at the company’s Gigafactory in Shanghai.

advanced paint shop, stating that “Giga Berlin will have world’s most

The clip shows that most of the painting process is automated.

advanced paint shop, with more layers of stunning colours that subtly

The car body undergoes a rotational dip process, through which

change with curvature”.

an anti-corrosive primer is applied by dipping the car body in an

To build Giga Berlin’s paint shop, Tesla partnered with Geico Taikisha

electrically conductive bath.

and it appears that the company plans to retrofit Giga Shanghai with

The topcoat is then applied with fully automated robots that feature

Geico Taikisha machines once the technology has been tested at Giga

rotary atomizers with electrostatic technology.

Berlin.

The paint shop features advanced process technologies, including an exhaust gas centralized combustion system. The paints employed are VOC free. All this ensures that the coating process is highly efficient, energy-saving and environmentally friendly. The footage also reveals some of the different colour options available to Tesla customers, including Tesla China’s Deep Sea Blue, China Red, Pearl White, Cold Light Silver and Pure Black colour options. This video comes after a Tesla app update, which teased new colour options available for cars produced at Giga Berlin, similar to the ones seen in the Tesla China video.

N. 72 - NOVEMBER/DECEMBER 2021 - international PAINT&COATING magazine

Scan the code to take a look inside the paint shop

BRAND-NEW

SPECIAL ISSUE ON ACE & OFF ROAD VEHICLES

HMG Improves Its Acrythane 4G Topcoat

www.cmautomazione.it

he Research and Development section at

the ones in the new HMG ColourBase Colour Box, a

HMG Paints has added a new thinner to

multi-function tool containing chromatic codes that

its Acrythane 4G, in order to speed up the

identify existing colours on the market for reference.

application process of the topcoat specifically

It presents over 2400 colour chips displayed in

intended for commercial vehicles. “The major

chromatic order within 20 fan decks.

benefit for applicators is the ease of use of

“The unique properties Acrythane 4G provide us

Acrythane 4G. Our customers are complimenting

easy application, fast drying and a superior finish,

us on a daily basis about how easy Acrythane 4G is

it’s so nice to use I can just put it on and walk away.

to use and produce high quality results, especially

I love it, the depth of image on jobs is fantastic and

when compared to competitor products,” stated

customers are now specifying it for their whole

Martyn Binnington, the Distribution Manager for

fleet,” added Paul Rafferty of Rafferty Coachworks.

HMG Paints.

Acrythane 4G is also being used in other industries

Launched in 2019, Acrythane 4G is a high solids

as a VOC and REACH compliant topcoat to provide

acrylic polyurethane coating developed to satisfy

excellent gloss final appearance and durability. Its

the strict requirements of the commercial vehicle

advanced properties and thinner options allow to

sector. The optimised balance of early hardness, fast

use the paint in cold and warm weather conditions.

hi-tech

The topcoat Acrythane 4G developed by HMG is now faster to apply.

conveyors

cure and long pot life makes the topcoat particularly suitable for OEM, repairers and builder.

For further information:

Acrythane 4G is available in several colours, including

www.hmgpaint.com

CM AUTOMAZIONE srl - FA Ganci

Via Monte Bianco 20 - 20833 Giussano (MB) - IT p. +39.0362.314075 - f. +39.0362.861222 info@cmautomazione.it

Tough Love We’re setting new benchmarks in the agricultural and construction equipment (ACE) market. ACE vehicles and their various components help create the realities of tomorrow; from the food we harvest to the buildings in which we live. Which means they need to perform. With a performance proposition and proven track record, an array of high-quality finishes, and environmental, chemical protection, the ACE range of powder coatings is the ultimate partner for vehicles often pushed to the limit of their endurance. We’re driving the current to power your future

automotive.interpon.com

BRAND-NEW

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PPG Teamed Up with Toyota to Reimagine the Iconic Toyota Chinook Camper Experts of PPG’s automotive OEM coatings and refinish businesses collaborated with Toyota Motorsports Garage to bring back to life the vintage colour scheme of the iconic Toyota Chinook camper for a reimagined version of vehicle.

PG unveiled the new colours developed for the Toyota “Tacozilla”

white basecoat and vintage yellow, orange and bronze accents.

4x4 overlander concept vehicle – a reimagination of the iconic

“This was a very fast-paced, exciting project that demonstrated our

Toyota Chinook camper of the 1970s and 1980s – during

team’s unique ability to create and execute a colour scheme that helped

the 2021 Specialty Equipment Market Association (SEMA) Show in

bring our customer’s concept to life,” said Misty Yoemans, PPG colour

Las Vegas. Tacozilla is an off-road-ready Toyota Tacoma TRD Sport

styling manager, Americas.

featuring a fully insulated “micro-house” with modern conveniences

Complete Customs in McKinney, Texas, applied all three PPG colours

that can comfortably accommodate two people for on- and off-road

with support from PPG distributor English Colour and Supply in

adventures. The Chinook was introduced by Toyota in 1972 as a fuel-

Richardson, Texas.

efficient alternative to conventional motorhomes. Experts from PPG’s automotive OEM and refinish businesses collaborated with Toyota Motorsports Garage in selecting the vehicle’s

For further information: http://corporate.ppg.com

N. 72 - NOVEMBER/DECEMBER 2021 - international PAINT&COATING magazine

INNOVATIONS: PRESENT&FUTURE

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Fully Automatic Coating System for Complex Gear Components Kornelius Berg VENJAKOB Maschinenbau GmbH & Co.KG - Rheda-Wiedenbrück, Germany

kberg@venjakob.de

Fully automatic coating in serial production is part of many companies’ everyday operations. Order-specific production, on the other hand, is a different matter, because small batch sizes and the variety of parts requiring coating create significant challenges for the automation system. The following is a description of a system developed by Venjakob that permits fully automatic coating of complex gear components from a batch size of 1.

he components requiring coating are fully machined and pre-

who managed the project. “Each of these components got their own

cleaned components for planetary and angular gears made of

programs in the plant control system. They are differentiated by

steel and aluminium. The varied range of components comprises

diameter, length, geometry, coating parameters and colour. Once the

15 different gear types of different sizes. Measurements range from

component has been identified, the system selects the corresponding

an exterior diameter of 50 mm to 350 mm, a length of 40 mm to 420

coating program and automatically completes the associated set-up,”

mm and a weight of 0.5 kg to 30 kg. The outer surface of the gear

Kornelius Berg describes the process.

component requires coating.

Component identification by bar code

Crucial controls and mechanical components

The only manual work involved is loading and removal. For each

“The particular challenge in this case was that the system had to be

requirement, a suitable number of workpiece carriers is available, on

designed for batch sizes as low as 1 and had to adapt to different

which the machine operator can place the gear components with a

gear components automatically,” explains Kornelius Berg of Venjakob,

jig for areas that should not be coated. It is not necessary to position

Fully automated and compact robotic coating solution for complex gear components (left) and paint supply system with integrated 2 K technology for 4 different colour cycles.

N. 72 - NOVEMBER/DECEMBER 2021 - international PAINT&COATING magazine

EPISTOLIO EPISTOLIO

INNOVATIONS: PRESENT&FUTURE

towards the future

the components in a specific way. “Everything was supposed to be quick and simple. In response to this request by the customer, we implemented suitable safety mechanisms,” explains Berg. After placement the operator scans the bar code of the gear component,

SOLUZIONI ROBOTIZZATE DI ROBOTIC PAINTING SOLUTIONS VERNICIATURA

the control system activates the associated coating program and pressing a release button starts the program. After release, the system automatically detects the position of the workpiece on the carrier. This means incorrectly positioned components can be detected. During this process the system also checks whether the data transmitted by the bar code matches the workpiece dimensions. If the bar code does not match the component, the system immediately enters malfunction mode and signals the error. If the scanned bar code information matches the workpiece, the workpieces are transported through the coating process by a chain conveyor system in a clock-controlled manner.

Coating results with consistently high quality After position detection, the workpieces are transported into the closed coating booth containing the coating robot. To ensure that a wide variety of gear parts (with and without connecting flanges), and rotationally symmetrical and asymmetrical parts, can be coated fully automatically with a spray gun, the coating robot was equipped with programs referred to as “master programs”. These programs are activated based on the component, taking the parameters into account. As previously described, the parameters are transferred to the control system when the bar code is scanned at the loading station. For the coating process this means that e.g. the coating speed or the coating angle of the spray gun are automatically adapted to the size and geometry of the gear part. Another important factor for consistently good coating results is the permanent air conditioning of the coating booth. The controlled air supply ensures that the temperature and air humidity are suitable for the coating process year-round.

Solutions for reduced material consumption The system is designed for multiple coating materials. Venjakob engineers used a variety of approaches to keep the material consumption as low as possible. The coating material supply is positioned directly next to the coating booth in a closed ventilation and venting booth. As the system is used for coating gear components of different sizes, it is possible for e.g. only every second workpiece

Epistolio Srl.

carrier to be filled. For this reason, a scanning unit checks whether

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

or not the spindle is empty during entry into the coating booth. If the spindle is empty, the coating process is paused. Use of the coating robot permits targeted spraying. This already reduces overspray, but any overspray that still remains is collected by a filter system and can

Publierre_Milano

be reused.

SPECIAL ISSUE ON ACE & OFF ROAD VEHICLES

View into air-conditioned robot coating spray booth.

View into drying section with continuously variable temperature setting from 50-90 °C.

Automatic cleaning of covers

into the evaporation channel, then into the jet drying channel. In this

After the coating process, the workpieces are first transported to the

section, the coating material is dried by recirculating air blowers. The

jig removal station. This station uses a horizontal and vertical axis

temperature is continuously adjustable. The air humidity is kept at a

system with grippers to remove the jigs that were put in place in the

consistent level. After the drying process the now fully coated gear

loading area and transport them to the cleaning station. Cleaning is

components are transported by the chain conveyor through the

performed in three steps: alkaline cleaning, rinsing with water, warm

cooling channel and returned to the loading and removal area from

air drying. Then a conveyor belt returns the jigs to the loading area,

the other end, in a manner of speaking.

where they can be reused.

Removal possible before drying

A quantum leap of change Where coating was previously performed manually in 3-shift operation,

The final important stations for the coating result are the evaporation

the fully automatic robot coating line with a spindle chain conveyor

channel and the jet drying channel. A removal point upstream of the

system achieves the same output in 2-shift operation, reducing

evaporation zone was created for cases in which a coated workpiece is

both the cost of labour and of coating material while simultaneously

not supposed to pass through the dryer.

ensuring consistently high coating quality. “The change from manual to

Heavy workpieces can be removed with a crane at this point.

fully automatic coating represents a quantum leap in this case,” says

Otherwise, the gear components on the spindles are first transported

Kornelius Berg.

N. 72 - NOVEMBER/DECEMBER 2021 - international PAINT&COATING magazine

SUSTAINABILITY

SPECIAL ISSUE ON ACE & OFF ROAD VEHICLES

AkzoNobel’s White Paper on the Importance of Powder Coating for EVs AkzoNobel has released a new white paper that explores how powder coating can help prevent EVs’ batteries from overheating and maximise performance.

owder coatings are essential for the future evolution of Electric

These are two of the many themes that are explored in the new

Vehicles (EVs), particularly to prevent batteries and other

White Paper recently published by the Powder Coatings business line

components from overheating, as well as insulate assets to

of AkzoNobel, entitled: “The critical importance of powder coatings

maximise performance.

in driving an electric future”. The White Paper explains how powder

Moreover, they are also supporting EV OEMs and tiers in developing

coatings can help to protect an electronic vehicle’s cooling systems

a more sustainable manufacturing process that meets strict

by electrically insulating and protecting its components, keeping the

international environmental regulations and directives.

battery within its optimal temperature range.

100

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SUSTAINABILITY

SPECIAL ISSUE ON ACE & OFF ROAD VEHICLES

Furthermore, it also reveals how powder coatings support the

waste and enable powder that has been over-sprayed to be re-used.

longer-term performance of the battery by protecting it against

Gustavo Carvalho, Automotive key account and Segment Director at

corrosion and other threats and how they protect the wider electric

AkzoNobel Powder Coatings and author of

ecosystem of the vehicle – its cooling plates and tubes, stator

the White Paper, states: “Global CO2 emission targets and changing

hairpins, bus bars, battery cell and housing – many of which have

consumer behaviours are driving change. Many manufacturers

long-term heat resistance requirements.

are now switching to powder coatings because of the technical

More specifically, the White Paper addresses the evolution of

performance and environmental credentials that a powder coating

Interpon and Resicoat powder coatings from AkzoNobel over the last

delivers. They are also switching because in becoming more

50 years and the benefits they can bring to current and future OEM

sustainable, they are also gaining in performance.”

designs. It details the environmental advantages of products that are free of Volatile Organic Compounds (VOCs), create no hazardous

For further information: automotive.interpon.com

2 0 ye a r s

Competence in Shot Blast Technology

As a full-range supplier, we design and manufacture shot blasting machines including filter and transport technology.

AGTOS | GmbH | D-48282 Emsdetten info@agtos.de | www.agtos.com © Adobe Stock

international PAINT&COATING magazine - NOVEMBER/DECEMBER 2021 - N. 72

304-01/21-4c-GB

➜ New shot blast machines ➜ Second hand machines ➜ Service and spare parts ➜ Reparation & maintenance ➜ Inspection & consulting ➜ Performance improvement

101

FOCUS ON TECHNOLOGY

Profilglass Choose Recycling and an Advanced Water Treatment System to Reduce the Environmental Impact of its Aluminium Processes Monica Fumagalli ipcm®

Is it possible to make aluminium processing more sustainable? The industry specialising in the processing of aluminium and aluminium alloy products has been wondering about this sensitive issue for some time. An international leader in this sector, Profilglass (Pesaro e Urbino, Italy) has decided to implement a recycling cycle and install a latest-generation water treatment technology developed by CIE (Milan, Italy) to handle organic and inorganic contaminants from various finishing processes.

102

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FOCUS ON TECHNOLOGY

ne of the main challenges that the aluminium industry is

7,000 m2 of aluminium to over 280,000 m2,” explains Profilglass general

facing and will have to face with greater urgency in the coming

manager Marco Sangiorgio. “We process an average of 200,000 tonnes

years is the need to reduce the environmental impact of its

per year and we have established ourselves as a global industry leader,

manufacturing processes while still meeting the ever-growing demand

exporting to over 85 countries. Not many Italian companies have seen

for this material. According to data reported by the International

a similar growth and have decided to concentrate their activities in a

Aluminium Institute , despite the economic scenario made uncertain by

single production site. This development has led owners Giancarlo and

the pandemic, aluminium production has reached 65,325 million tonnes

Stefano Paci to reflect on the possible consequences of such intensive

within a year. Faced with such high production volumes, the aluminium

processing on the environment and our company’s surrounding

processing and surface treatment industry is now looking for new ways

area, with which we have strong ties. An analysis of aluminium’s

to make its processes more sustainable. Profilglass Spa (Fano, Pesaro

main peculiarities offered us the answer: this particular material is

e Urbino, Italy), a manufacturer of profiles, coils, sheets, strips, discs,

environmentally friendly, light, strong, non-toxic, and highly formable

tubes, and rolled products in aluminium and its alloys since 1982, has

and mouldable and these qualities are preserved even when it is

chosen a scrap recycling cycle and the integration of highly efficient

recycled. In our recycling division, we now check and process hundreds

waste water treatment systems as its waste management solutions.

of tonnes of waste materials and cans every day, using the latest

“In almost forty years, our company has gone from a production area of

technology to sort, process, and transform them into new semi-finished

products. As a result, 80% of our aluminium is made from scrap, in line 1

https://international-aluminium.org/statistics/primary-aluminium-production/

with the principles of the circular economy.” Opening photo: Profilglass produces coils by continuous and/or discontinuous casting in aluminium and its alloys, with different physical states and surface finishes.

A section of the new alkaline cleaning and degreasing and flattening line for rolled metal.

The outside of the cleaning and degreasing tanks.

international PAINT&COATING magazine - NOVEMBER/DECEMBER 2021 - N. 72

103

The other area on which Profilglass focussed

to improve sustainability was the treatment of the waste water produced by its aluminium cleaning operations. “In order to guarantee excellent cleanliness of their aluminium surfaces, our products undergo several cleaning and degreasing stages aimed at ensuring optimal adhesion of the paints and films that our customers apply in subsequent processing phases. Between the end of 2019 and the beginning of 2020, we installed two water treatment plants supplied by CIE (San Zenone al Lambro, Milan, Italy), a company specialising precisely in the design, manufacture, and installation of waste treatment systems for finishing lines devoted to metals, and especially aluminium. The two systems filter waste water coming from two separate lines, one dedicated to cleaning rolled products and the other to hardening and passivating rolled metal intended for the automotive industry and produced in our specialised division, required to meet particularly strict cleaning standards.”

Profilglass: evolving aluminium since 1982 Profilglass started its activity by offering a new product on the market, a spacer profile for double glazing, in the production of which it has then specialised. “In the 2000s, we entered the field of rolled products,” says Sangiorgio, “to meet the ever-increasing demand for aluminium and differentiate the application fields of our products, which now range from the construction sector to the automotive industry, from electronics to household goods and mechanics. Double glazing profiles are the only products that are painted in our factory, whereas all the others are delivered as semi-finished parts; the final processing steps are then handled by our customers.” From top: Oil residue filtration devices and the demineralisation plant.

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FOCUS ON TECHNOLOGY

From scrap to semi-finished products The evolution of Profilglass has gone hand in hand with the vertical integration of its production system. “As our company was growing, we progressively insourced the processes and treatments that we considered most strategic, such as cutting, machining, and foundry operations with both continuous and discontinuous casting technology, up to the creation of an ad hoc division for the automotive sector, called LamiAL. Indeed, the most interesting aspect of our production and the one that sets us apart is the full integration of our manufacturing cycle. We start with the scrap that we recycle and end up with semi-finished parts, thanks to a production system divided into five macro-areas: • recovery and treatment of aluminium scrap and waste, produced both by us and by external companies; • foundry, where raw material is processed with a production capacity of 10,000 tonnes per month; • hot rolling, with a plant capable of rolling approximately 150,000 tonnes per year of aluminium plates with a thickness of up to 5 mm; • cold rolling, in 4 rolling mills with a production capacity of approximately 280,000 tonnes per year;

CIE’s chemical-physical plant for the treatment of waste water produced by the rolled metal cleaning process.

eosmarketing.it

A UT O M O TIVE

cataphoresis and liquid or powder spray applications

over 60 years of experience in surface finishing lines

www.trasmetal.net

• finishing in our flagship department devoted to the production of coils, strips, and discs, with 20 state-of-the-art machines that guarantee cutting accuracy and precise adherence to even the smallest tolerances imposed by our end customers.” The rolled metal’s finishing phase is preceded by heat treatments, which give the material the mechanical characteristics and the workability degree needed in the finishing stages, and by surface treatments, which improve the performance of aluminium, favouring the adhesion of paints and coatings, any subsequent decoration, or corrosion protection in order to maintain consistent exterior qualities over time.”

Cleaning automotive components Profilglass installed its first waste water treatment plant at its LamiAL division, equipped with a continuous-flow oven and a passivation line. As Alessio Guidi, the technical © ipcm

department manager, indicates, “this CIE plant is connected with the line carrying out continuous heat treatment of coils, upstream of which we installed a pre-cleaning station to prevent any machining oil residues exposed to the thermal treatment oven’s heat from leaving stains on surfaces. This additional spray cleaning step is performed with water heated to 60-70 °C. In the next step, the coils are heated and then quenched through rapid cooling with water, which becomes contaminated on contact with them. The waste water contaminated with aluminium and oil residues is collected and conveyed to the purification plant, which treats both solid and liquid waste. Unlike the rolled product degreasing line, where basic products are used, here we use hydrofluoric and sulphuric acids suitably formulated in pre-defined concentrations, in order to achieve surface deoxidation of the material. After this first

From top: The detail of the settling unit and filter press installed at the LamiAL division and the operational centre that manages and controls every stage of the production process.

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pickling phase, the coils can be subjected a passivation process with products based on zirconium and titanium, to protect them

FOCUS ON TECHNOLOGY

against future oxidation. Again, the water treatment plant collects process overflows and any solid contaminants.” “The waste produced,” says CIE project manager Antonella Monaco, “can basically be classified as acid concentrates from the pickling and passivation phases, alkaline concentrates from the degreasing phase, alkaline rinses, and acid rinses. Therefore these effluents, distinguished according to their conductivity (in rinses and concentrates) and their pH (acid or alkaline) are collected separately in different tanks.”

Different cleanliness degrees of rolled aluminium “Depending on the intended use of parts,” indicates Francesco Berti, a process engineering expert at Profilglass, “different specific requirements may apply in terms of cleanliness degree. The demand for

rolled products subjected to alkaline degreasing, together with ever-higher flatness requirements, which are crucial for perfect surface adhesion, has led us to install a new line in order to relieve our saturated department and streamline our production process. The new line actually integrates the processes of alkaline spray degreasing and tensioning (flattening of rolled metal under tension), previously carried out in separate steps. “The removal of rolling oils and surface residues is performed during the pre-cleaning stage, where a mechanical brushing action is combined with a chemical action to maintain the line’s subsequent sections in the best conditions and avoid the risk of marks or imprints being transferred to the metal surfaces, while also meeting any flatness requirements before the last process stage, that of degreasing, which takes place in a 40 m long section of the plant. Each chemical treatment step is followed by a rinse in demineralised water before drying. The water and alkaline solutions used are recovered

From top: The production department of the LamiAL division and a bird’s eye view of the CIE waste water treatment plant.

international PAINT&COATING magazine - NOVEMBER/DECEMBER 2021 - N. 72

107

The cleaning department of the LamiAL division.

A detail of the settler.

and fed back into the bath preparation system until they meet the

and discharged into the public water system), and that managing the

conductivity parameters. Overflow effluent is sent to the CIE purification

sludge created on the bottom of the lamella settler (which is sent to

plant for disposal.”

the thickener and then filter-pressed, so as to dehydrate it and reach a

“This plant,” says Monaco, “has a maximum treated flow rate of 10 m /h

dry percentage of between 35-40% in order to dispose of it as non-

and it treats the whole waste generated by the coil alkaline degreasing

hazardous special waste).”

line, divided into alkaline concentrates and rinses. The CIE treatment plant is also capable of filtering boiler purge water: since both lines use

Conclusions

hot process fluids, heating is carried out through steam generators into

“Having a water treatment system that automatically handles the

which chemicals are injected to preserve their operation and which

preparation and dosage of chemicals and allows us to manage the

must be purged periodically, once the water quality thresholds are

different types of organic and inorganic contaminants is fundamental

exceeded.”

for us, given the peculiarities of our production processes,” notes

Common features of the two CIE plants

Sangiorgio. “After purification, our water flow is conveyed into the public water

“The two chemical-physical treatment plants,” adds Monaco, “have some

system, whereas the filter-pressed sludge is disposed of as special

common features, such as the relaunch and accumulation section,

waste. Thanks to the specific products developed by MST Chemicals,

which includes the effluent collection sumps and tanks, and the actual

the two plants are optimised for the abatement of pollutants, mainly

treatment section, which performs the coagulation, neutralisation, and

aluminium, COD, sulphates, and fluorides, in full compliance with local

flocculation stages. The effluent in this section is treated with lime and

regulations, which are stricter than national ones, for both liquid and

three products developed by MST Chemicals, the company of the CIE

solid waste.

Group dedicated to chemical formulation: PUROSORB M31, a product

“CIE also helped us positioning the two systems, which are very

of fundamental importance for adsorbing oils and surfactants and

compact and, thanks to this particular configuration, enable us to

reducing the COD value so as to comply with the expected emission

manage transport and disposal logistics at best, with a flexibility

limit value; PURODEP A11, a coagulant that also helps reduce the final

that our previous plant did not offer. In addition, their complete

concentration of fluorides; and PUROFLOC A14, a polyelectrolyte that

automation and Industry 4.0 readiness put them among the most

allows the formation of flocs, which sediment more easily. The other

advanced systems implemented in our company. They demonstrate

sections common to both plants are the sludge settling section, the

Profilglass’ environmental commitment as one of the companies in this

section for the management of clarified water (which, after leaving

industry that are pushing the hardest towards a sustainable future for

the lamella settler, is collected in a specific tank and then filtered

aluminium processing.”

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Protection upgraded

Specialità chimiche per il trattamento delle superfici Lavaggio Industriale

Pretrattamento metalli alla verniciatura

Lavaggio di precisione

Processi di conversione esenti

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Fosfatanti a bassa temperatura

Protezione temporanea

Passivanti per acciaio zincato a caldo Passivazione conduttiva su Alluminio TCP

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Pretrattamento

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FOCUS ON TECHNOLOGY

SIGE S.p.A.’s Upgraded Coating Booths for Improved Product Quality and Reduced Environmental Impact Gabriele Lazzari ipcm®

The quality of metal accessories for storage furniture is the result of the right combination between their coatings’ aesthetic and functional, especially protective, characteristics. Active in this industry for over fifty years, SIGE has never stopped improving its production processes, up to expanding its market presence worldwide. Its latest investment in finishing, two Gema quick-colour change booths, has enabled it to achieve an 80% improvement in its finishes’ quality while reducing its manufacturing process’ costs and environmental impact.

s food has always been synonymous

Italian excellence abroad

with conviviality, it is not surprising

Over the years, this company has grown from

that the kitchen is one of the home

a small family business in the Marches region

environments that is given the most attention

to its current size: an industrial unit with an

when making decorating decisions. This

11,000 m2-wide covered space and a very

is why this rapidly growing sector is now

strong presence on the foreign market. “Like

committed to providing high quality furniture

many Italian companies, we started out as a

and accessories, in terms of not only

local business in 1969 and now we are known

aesthetics but also strength and durability.

worldwide: we are present in 57 countries and

SIGE S.p.A. (Polverigi, Ancona, Italy), a producer

over 90% of our production is exported. This

of metal accessories for storage furniture,

has enabled us to increase our turnover over

has therefore chosen to upgrade its coating

the years: in 2021, it should further grow by

department by installing two Gema quick-

around 30%,” states Mauro Galassi, the Chief

change colour booths that give its products

Executive Officer of SIGE. “The Italian kitchen

even higher finishing quality and reduce its

sector, and especially that of the Marches

production costs and environmental impact.

region, is synonymous with quality both in Italy

and abroad. We chose to focus on foreign markets during the 2007 crisis, when we suffered a 45% drop in turnover. We invested https://www.mordorintelligence.com/industry-reports/global-kitchen-furniture-and-fixtures-market 1

110

heavily in our foreign sales network, as well as in our products and technology. This gave us

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FOCUS ON TECHNOLOGY

Left photo: A storage furniture for kitchen equipped with metal accessories manufactured by Sige Spa of Polverigi, Ancona, Italy. In the last few years Sige has been introducing many new products to its range and new, unique finishes in metallic colours.

Uniqueness and quality to stay competitive In addition to the quality of its products, an important element that distinguishes SIGE is the continuous evolution of the technologies it adopts: “Our goal is to always improve in terms of quality, technology, and research, because we believe that these enable us to stand out and remain competitive on the foreign market.” The company’s continuous evolution and focus on technological developments is reflected in the investments made in its coating department, which have enabled it to constantly improve the quality of its range and reduce the environmental impact of its production activities. In the past, SIGE the impetus we needed to grow and reach our

used immersion plasticisation, but this had

current size.”

limitations in terms of available colours. “Until

SIGE started out as a manufacturer of kitchen

five years ago, coating did not play a major

storage furniture accessories in metal wire,

role in our industry, as galvanic finishing was

such as dish racks and crockery containers.

predominant. Then, many markets started to

“Then, however, the markets changed and

demand powder coating, along with a greater

so did customer demands. In order to meet

variety of colours, especially dark ones. We

them, we expanded our product range up to

therefore decided to differentiate ourselves

including all other kitchen accessories featuring

from our competitors by applying powder

guides, such as drawer storage baskets, bottle

coatings in order to offer high quality and

racks, pull-out tall units, and parcel containers.

exclusive products,” explains Galassi.

We have also started using materials other and wood – which is now a very important

Fewer coating booths but greater efficiency

part of our offer, so much so that we created

In order to ensure adequate preparation

a carpentry department. For a short time, we

prior to painting, the accessories produced

were also interested in expanding into the

by SIGE undergo a pre-treatment process

household appliances market too, but that

including two phospho-degreasing and

sector requires completely different coatings

two rinsing stages, one of which is done

from those we specialise in and, therefore, we

with demineralised water, followed by a

decided to focus exclusively on accessories for

nanotechnology conversion stage. “We

storage furniture.

implemented this less than two years ago

than metal wire, such as sheet metal, glass,

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111

and the difference in the treatment’s quality was immediately noticeable.” SIGE initially used three painting booths with triboelectric technology. Due to increased demand for finishes in different colours, in December 2020 the company decided to further upgrade its coating department by installing two Gema Magic Compact booths with a powder management unit for quick colour change operations, which replaced the three booths already in use. “When we decided to replace our booths, we looked at the various options available and tested some of them, including those from Gema. Having already used this supplier’s products, and being pleased with the results of the analyses carried out, we decided to invest in its MagicCompact® EquiFlow® booths,” explains Galassi. Initially, the second booth did not include a powder center. “However, after only one month of use, I requested that the new powder management unit OptiCenter All In One be added, because

their results were exceptional.” The intake air system keeps the surrounding area clean by means of a fan that sends air from outside the booth into the inside to prevent powder from escaping, while the permanent suction system integrated into the booth floor guarantees automatic cleaning and avoids any accumulation of overspray. The reduced amount of powder coating required and the presence of a cyclone make recovery and cleaning quick and easy: therefore, SIGE’s production times are also faster than before. SIGE typically applies five tints from two standard AkzoNobel series in the 80-120 µm range, but its new booths also enable it to customise its colour offer to meet any specific customer requirements. The plant comprising the two Gema booths, supplied by O.M.SA S.r.l., is also equipped with a one-rail conveyor and two curing ovens, which allow applying two coats of paint – if specifically requested by the

clients – without the parts having to repeat the same route twice. “In this case, after primer application and cross-linking in the dedicated oven, the components reach directly the second Gema booth, where the top coat is applied, and finally the second drying oven. This speeds up the whole process. We placed our trust in O.M.SA in 1995: they have always supported us in an excellent and quick way, whenever we wanted to upgrade our systems.

From top to bottom: - One of the two new power application booths MagicCompact® EquiFlow® by Gema installed by Sige in 2021. - The loading area of the coating system supplied by O.M.SA of Besana Brianza. The system is composed by a spray pretreatment tunnel, a mono-rail conveyor and two curing ovens. - Metal parts hanged on the coating line.

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FOCUS ON TECHNOLOGY

The entrance of the parts in the booth. On the right there is the powder center OptiCenter All In One.

It is also thanks to them that our production has reached its current volumes and timescales,” comments Galassi.

The right choice for part protection and sustainability About a year after upgrading its coating department, SIGE is finding a much higher quality degree of its finishes. “In the past, we had had a few qualification issues, especially with sheet metal, on which an uneven layer was created. Since when we started using the new booths, the quality of our coatings has improved by around 80%.” In addition to their ease of use, the Magic Compact booths reduce powder consumption by 15-20%. “We dispense less and recover more of it, whereas transfer efficiency has improved. As a result, our environmental impact and costs have decreased dramatically. This was a big investment, but we are completely satisfied with it.” As well as sustainability and cost savings, the thermosetting powder coatings used also provide protective properties that enable SIGE

to export its products abroad without any damage during transport. “The strength and durability characteristics of storage furniture accessories are often underestimated, but they are crucial. Some of our products are exported in containers on ships for oftenprolonged periods, in corrosive environments, and with temperatures sometimes exceeding 80 °C. This is compounded by the climate and humidity of the countries where they will be sold. It might seem irrelevant, but the location of a house in Milan, in China, or on the ocean shore can make all the difference to the durability of a product. The main advantage offered by Gema’s booths and AkzoNobel’s epoxy powders is that they provide greater resistance. They also allow obtaining smoother surfaces, which are important for any accessory intended to be placed on bearings made from soft materials such as polyethylene. Previously, we had

problems giving this feature to the products that required it, but the Magic Compact booths have enabled us to improve this aspect as well.” In over fifty years of business, SIGE has experimented with different manufacturing processes in order to always offer accessories for storage furniture that are strong, durable, and able to meet the demands of an everchanging market. Gema’s booths were the company’s latest investment aimed at remaining competitive in a globalised sector where product quality is of paramount importance.

Automatic application of the powder coatingand the MagicControl 4.0 module.

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Zaniolo CdA-01.21

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P O W D E R C O AT I N G S I N C E 1 9 8 2

The new QNix 9500 thickness gauge developed by Automation Dr. Nix.

INNOVATIONS: PRESENT&FUTURE

An Innovative, High-Tech, Easy-to-Use Portable Tool: The QNix 9500 Thickness Gauge Adriano Antonelli Tecno Supply - Ibix Srl, Santa Maria in Fabriago (Ravenna) – Italy

adriano.antonelli@tecnosupply.com

In the field of surface treatments, coating quality control has become essential to guarantee complete customer satisfaction. The engineers at Automation Dr. Nix – a German manufacturer of portable instruments for nondestructive thickness measurement on metal substrates, distributed in Italy by Tecno Supply, a division of Ibix Srl – have developed a new, innovative thickness gauge that meets even the most complex requirements, called QNix 9500.

n many industries, such as contract liquid and powder painting,

industries, for example. Especially in the automotive sector, quality

coatings are being required to meet increasingly high quality

assurance is particularly crucial because the layers of paint applied

standards in terms of aesthetics, durability, and reliability

are very thin and the tolerance range is relatively small. Thickness

while costs are simultaneously rising; quality assurance and order

gauges are therefore indispensable for the evaluation of a vehicle;

documentation are therefore indispensable for a coating process. In

they are essential for carrying out an assessment after an accident or

other sectors, including surface treatments, galvanising, and Eloxal,

estimating the value of a vehicle, for taking out a lease, buying a used

functional coatings give the processed surfaces precise anti-corrosion

car, or checking and documenting bodywork and paintwork.

and wear-resistant properties for use in the automotive or mechanical

QNix 9500, a thickness gauge that is robust, accurate, versatile,

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INNOVATIONS: PRESENT&FUTURE

and easy to understand, has been launched after a three-year

simple adjustment on rough, smooth, and curved substrates;

design phase. The engineers aimed at developing a state-of-the-art

• sturdiness and durability for reliable and long-lasting use even in

instrument that would meet any measurement requirement. Produced

adverse conditions;

by Automation Dr. Nix and distributed in Italy by Tecno Supply, a

• fibreglass-reinforced five-part body with IP65 dust and water

division of Ibix Srl, this thickness gauge stands out for its unrivalled

resistance properties;

robustness and ease of use combined with excellent quality, versatility,

• three-layer protection to absorb shock;

and precision.

• H6 chemical and scratch-resistant LCD screen;

The advantages of QNix 9500 are particularly clear in the fields of

• operating temperature from -20 °C to +70 °C;

heavy-duty corrosion protection, industrial coating, and surface

• stainless steel probes with an anti-dust membrane (IP65).

treatments for both in-house and contracting operations. Critical issues related to compliance with norms and standards, verification of

A systematic procedure and, often, impeccable documentation are

incoming and outgoing specifications, or internal controls related to

required for carrying out and monitoring coating operations in the

processes and quality are overcome thanks to its software package,

heavy-duty corrosion protection sector. Hardly any other application

which allows creating the necessary documents quickly and easily with

field has as many provisions, standards, and directives: here, demands

customised reports.

on people, machines, and tools are significantly high. For this reason,

The main features of QNix 9500

a great deal of importance was attached to making QNix 9500 particularly robust and ergonomic. Its five-part fibreglass-reinforced

The QNix 9500 thickness gauge guarantees high standards of accuracy

plastic body for reduced shock effects, its display, and its electronic

and correctness and it features as follows:

components are designed for this purpose, as is the cable, conceived

• high accuracy over the entire measurement range;

for use at an industry-standard distance and easily replaceable on site

• high repeatability of measurement results;

if required.

• thermal compensation directly in the sensor;

Numerous pre-configured parameters simplify the setting of limit

• precise measurements also on curved surfaces and small parts;

values and calibration in compliance with standards including, for

QNix 9500 can measure thicknesses on all ferrous and non-ferrous substrates. The analysis of user requirements enabled a thorough design development of the new measuring instrument.

international PAINT&COATING magazine - NOVEMBER/DECEMBER 2021 - N. 72

117

. Ni ation Dr

r. N

atio

tom

u ©A

The complete kit of the new QNix 9500 thickness gauge.

QNix 9500 comes complete with a cable and an interchangeable probe.

example, ISO 19840, SSPC PA2, and IMO SSPC. If the minimum limit

innovative instruments on the market. Some of the features that make

value is not reached or the maximum limit value is exceeded, this

it so are as follows:

is signalled by an acoustic alarm, an optical alarm (a sudden colour

• portable instrument for Fe, NFe, and Dual probes;

change on the display), and an RGB LED in the probe tip.

• quick switch to cable probes;

This enables the operator to concentrate fully on the points to be

• an integrated probe and a cable probe with one instrument;

measured. The high measurement speed (up to two measurements

• greater versatility thanks to the quick probe change operation;

per second) guarantees fast operations on large components. The

quick adaptability to different measuring tasks.

simple, user-friendly menu makes it easy to become familiar with the instrument.

Ergonomic design for fast measurement

A user-friendly configuration QNix 9500’s intuitive use saves time and costs thanks to the following features:

With the aim of saving time and effort at work, even with continuous

• simple calibration;

use, the QNix 9500 thickness gauge includes as follows:

• portable instrument and software user-friendly interface: only 3 clicks

• direct feedback through the probe’s RGB LED and the display

are required to get a report;

showing the limit values;

• one quick access button to customise with a chosen function;

• 2.4”, 600 lm, high light intensity IPS LCD colour screen with a reading

• pre-configured norms and standards.

angle of 70°; • excellent readability even under direct solar radiation. Automatic or

The QNix 9500 probes

manual brightness adjustment;

The new QNix® standard probes have been developed in a highly

• automatic or manual screen rotation by 0°, 90°, 180°, and 270°;

innovative way. Small and particularly robust, they are suitable for

large, soft touch keys and low centre of gravity.

measurements on iron and steel (Fe), non-ferrous materials (NFe), or

A flexible and interchangeable structure With its interchangeable probes, QNix 9500 is one of the most

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both (Dual). Some of their technical features are listed here below: • stainless steel probes with a protective membrane and IP65 dust and splash water resistance;

INNOVATIONS: PRESENT&FUTURE

• durable measuring head in polished ruby; • chemical resistant material, cleanable with solvents (acetone, nitro thinner); • limit value indication LED on the probe tip; • PUR adapter cable for use in cable drag chains. A digital copy of the last calibration certificate is stored software. All standard interchangeable probes of QNix 9500 can also be used with the new QNix 5500 tool for maximum

on each probe and can be integrated into a report via PC

customer flexibility.

The QNix 9500 software programme During the design process, particular attention was paid to the graphical user interface, which is user-friendly, easy

The new QNix® probes are small and particularly robust.

to understand, and quick to use. In the preliminary phase, numerous interviews were carried out with users from a wide range of industries in order to define the main practical requirements for the PC software package. This resulted in the creation of intuitive software that is easy to

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navigate, saves time, and optimises work. The QNix 9500 software programme is completely browser-based and requires no installation, making it independent of the Windows version being used. The operating logics of the new PC software package has also been applied to the user interface of the QNix 9500 portable instrument. All configurations made on the tool can also be set up via PC software. Thanks to the powerful statistical functions integrated, measurements can be checked and documented in just 3 clicks. Pre-configured and freely placeable text modules for tables and charts allow creating professional report templates with dragand-drop functionality. Logos, photos of the measured object, the last calibration certificate, the measured values history, statistical data, jobs, and areas can easily be included in the report. All these features make QNix 9500 an innovative, high-tech, convenient, and easy-to-use tool for all professionals in the coatings industry.

A measurement operation with QNix 9500 in the field of heavyduty corrosion protection and an application in the automotive sector.

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SUSTAINABILITY

Chemical Companies Team Up to Accelerate Net-Zero Climate Technologies Key players from the chemical industry, in collaboration with the World Economic Forum, are teaming up to move the Low-Carbon Emitting Technologies (LCET) initiative into its implementation stage by the end of 2023.

everal key players from the chemical industry – including Dow,

reason, most industries are customers of the chemical industry. Our

BASF, Solvay, Clariant, Air Liquide, Covestro Mitsubishi Chemical

role is to enable our customers to reduce their carbon footprint. In

Corp., Royal DSM, SABIC, and SIBUR – have joined forces to

order to address these challenges, we need to share technologies and

establish a breakthrough development platform by 2023, within the

common approaches,” said Conrad Keijzer, Chief Executive Officer at

LCET initiative framework.

Clariant.

Following a two-year period of analysis and collaboration between

A Project Development Company (PDC) will be designed as a

the industry players and the World Economic Forum, this agreement

new stand-alone entity operating on a pre-competitive basis and

represents the transition from a knowledge-sharing platform to an

supporting partners in setting set-up joint projects aiming to share

implementation tool aimed at accelerating greenhouse gas reductions

early-stage development risks and invest jointly in the development

in the chemical production chain.

and implementation of low-carbon technologies.

“Chemicals are present in almost all products of daily life. They are

“We are working together in the LCET initiative to jointly address

essential to more than 95% of the goods produced worldwide. For this

mission-critical technology challenges that cannot be tackled by one

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SUSTAINABILITY

company alone,” commented Martin Vollmer,

“This will require extraordinary business

Chief Technology Officer at Clariant. “We want

transformation, unprecedented partnerships

to actively contribute with our outstanding

and collaboration both within the private sector

research and development expertise in the fields

and across all stakeholders including society

of biomass valorisation focusing on agricultural

and governments”, commented Roberto Bocca,

waste streams for the production of advanced

member of the executive committee at the

biofuels and bio-based chemicals, as well as in

World Economic Forum.

the field of innovative, high-performance catalysts

“As the LCET initiative moves into the critical

to support the transformation of our industry

implementation stage, it will demonstrate the

towards net-zero emissions.”

ground-breaking innovation that our industry can achieve through

The companies add that the LCET initiative provides opportunities

collaboration. By working together to co-develop and upscale low

for co-marketing schemes that could encourage collaboration with

carbon-emitting technologies, we will accelerate our circular carbon

adjacent industries, such as electrical grids and pipelines, in order

economy journey to carbon neutrality”, added Yousef Al-Benyan, vice

to develop infrastructure for new technologies. The initiative is also

chairman and CEO of SABIC, and LCET Co-Chair.

aiming to facilitate coordination between academic institutions,

The companies and World Economic Forum are calling for more

governments, and civil society. The LCET initiative is aiming to achieve

producers, technology providers, and value chain partners from the

net-zero emissions in the chemical industry by 2050.

chemical industry to join the LCET initiative going forward.

We create chemistry that makes lines love curves. Coatings give a car more than just long-lasting protection. Brilliant gloss and innovative colors transform contours into dynamics and design into emotion. Lines and curves are united and edges and contours are brought to life. When color and shape come together, and paint evokes passion, it’s because at BASF, we create chemistry. www.basf-coatings.com

SUSTAINABILITY

Merck Establishes External Expert Advisory Panel for Sustainability As part of the sustainability strategy of Merck, the company has established The Merck Sustainability Advisory Panel (MSAP), which is made of six independent international experts who will advise the company on sustainability issues.

erck has established an

Merck’s sustainability strategy

external expert committee

Merck presented its sustainability

for sustainability, The Merck

strategy in November 2020, which aims

Sustainability Advisory Panel (MSAP).

at pursuing specific goals in the areas

The new committee consists of six

of science and technology and value

independent international experts

chains as well as climate change and the

on sustainability-related topics who

environment:

will advise Merck on selected issues

• Goal 1: In 2030, Merck will achieve

and critically assess its sustainability

human progress for more than one billion

performance as well as the company’s

people through sustainable science and

planned activities.

technology.

The experts will also apply their

• Goal 2: By 2030, the company will

knowledge to help address societal and

integrate sustainability into all its value

political challenges and developments

chains.

that could impact the businesses of

• Goal 3: By 2040, Merck will achieve

Merck, covering a wide range of topics:

climate neutrality and reduce its resource

from shaping and implementing ideas

consumption.

for environmental and climate protection to entrepreneurial sustainability

Merck also wants to make a clearly

principles, future-oriented business

recognizable contribution to the

leadership, and sustainability

The members of the Merck Sustainability Advisory Panel

transformation as well as ESG key figures

• Glynda Bathan-Baterina (Philippines): Deputy

Over the past several months, the

and sustainable finance.

Executive Director of Clean Air Asia

company has made clear progress in the

“As a science and technology company,

• Michael Braungart (Germany): Founder and CEO

implementation. For example, the most

we want to find answers to the most

of Braungart EPEA Internationale Umweltforschung,

recent Annual General Meeting agreed

pressing challenges of our time. That’s

Professor at Leuphana University Lüneburg

to a resolution to integrate sustainability

why we have embedded sustainability as

• Todd Cort (United States): Faculty Co-Director of both

aspects into the compensation system of

a key element of our corporate strategy

the Center for Business and Environment (CBEY) and

the Executive Board.

and set ourselves ambitious goals. The

the Initiative on Sustainable Finance (YISF) of the Yale

The company is working to systematically

internationally renowned experts of the

School of Management

incorporate sustainability into all company

Merck Sustainability Advisory Panel will

• Maja Göpel (Germany): Expert for sustainability

processes.

support us in achieving these goals,”

policies and transformation research, Honorary

said Herwig Buchholz, Head of Group

Professor at Leuphana University Lüneburg

For further information:

Corporate Sustainability, who chairs the

• Ioannis Ioannou (United Kingdom): Associate

www.merckgroup.com/en/

MSAP for Merck.

Professor for strategy and entrepreneurship at the

sustainability

The MSAP supplements the existing

London Business School

expert panels on bioethics and digital

• Huiyao (Henry) Wang (China): Founder and President

ethics.

of Center for China and Globalization (CCG).

and international trade, sustainable

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Sustainable Development Goals of the United Nations.

HIGHLIGHT OF THE MONTH

BASF`s Coatings Division presents Automotive Color Trends 2021-2022 Joerg Zumkley BASF Coatings GmbH – Münster, Germany

joerg.zumkley@basf.com

The designers of BASF’s Coatings division studied the uncountable number of world’s colour variations and based the new Automotive Color Trends collection on them.

esigners for BASF’s Coatings division have delved into new

EMEA – Eye-opening and thought-provoking colours

colour spaces for the 2021-2022 Automotive Color Trends

Colours designed for Europe, Middle East, and Africa (EMEA) use

collection. Borrowing a phenomenon from quantum mechanics,

familiar colour positions, but change them with the help of new effects,

this year’s collection is called SUPERPOSITION, which is a state where

subtle colour gradients, or a specific sparkle behaviour.

the limitation of binary systems is overcome.

Shades of grey change their colourfulness according to the angle of

In other words, things aren’t just black or white, heads or tails, one or

view. Shades of blue are light, reflective and structure the surface.

zero. The world has an uncountable number of variations, and this

“These eye-opening and thought-provoking colours are a superposition

collection immerses itself in those variations. The colours benefit from

of complex tones that challenge our perception,” said Mark Gutjahr,

an unlimited vocabulary of design, which can be playful and serious,

head of Automotive Color Design, EMEA.

comfortable and disturbing, or clear and chaotic all at the same time.

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HIGHLIGHT OF THE MONTH

Asia Pacific Recharge and think ahead

Asia Pacific saw societal change as its biggest trend for 2021. Many used the time they had to recharge, think ahead, and build energy for the future. Out of a uniformity in thoughts, products and materials of the past came flexibility and freedom. Everybody and everything should be accepted – not only people, but also products and materials. Everything can be flexible. “Asia Pacific’s key colours are light, clean shades evoking the exciting look of spring and the forward-looking hope it brings,” said

EMEA

Chiharu Matsuhara, head of Automotive Design for Asia Pacific. “They show a higher

level of understanding of our diverse world.”

North America The concept of balance North America’s future colour designs looked to the concept of balance that strikes a chord with human steadfastness. The colour spaces are anchored in optimism and resilience, and show the potential for humanity to move forward despite the challenges. “We found the equilibrium between the natural and the synthetic world to create calming, unwavering, and thought-provoking colours. They draw the viewer into unique

ASIA PACIFIC

sensations that operate on multiple nonbinary levels,” said Paul Czornij, head of

Automotive Design for the Americas.

Colour expertise of the Coatings division Every year, the designers of BASF’s Coatings division study future trends which they use as foundation for the development of surface, texture and colour positions. They draw inspiration from industry, fashion, consumer products, nature, and more. This research is shared with BASF’s customers, the automotive designers, to drive future mass production plans.

NORTH AMERICA

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ART WITHIN SURFACES

Graco’s Winning Team to Celebrate the Best Cyclists in the World Wim Belmans from Graco actively collaborated with street artist Thomas Daem, employing two Cordless 390 Classic units, to paint the portraits of famous cyclists along the road of the 2021 UCI Road World Championships.

im Belmans, District Manager CED of Graco, has cooperated

collective Puncheur searched for better equipment and finally chose

with the art collective Puncheur for a special street art

Graco airless machine to lift his art to a higher level. Belmans became

project on the famous Flander’s cycling roads. Aiming to

immediately fascinated with the projects, and after some initial tests

honour the greatest cyclists in history, they employed two Cordless

they both discovered that Graco cordless 390 classic units made their

390 Classic units to paint the faces of the athletes along the trail of the

work faster and easier.

2021 UCI Road World Championships, which took place in Belgium

In total, the team painted 16 portraits of 3.75 m x 2.55 m in just three

from 18th to 26th September 2021.

days, working tirelessly from 09:20 am until past midnight.

The original idea came to the Belgian graphic designer Thomas Daem

“Graco as a partner is very proud to cooperate in this very unique

for Tom Boonen’s last year as a professional cyclist in 2017. The artist

sports event and is even more proud that the lightweight and compact

and his dad created some basic stencils with spare cardboard from the

design of the new battery-powered sprayer, which was on top of that

grocery store and painted the face of Boonen on the road. Since then,

highly portable, turned out to be the ideal help for this paint jobs,”

Daem made several other portraits, such as the ones of Peter Sagan,

commented Belmans.

Frank Vandenbroucke, Johan Museeuw, Bradley Wiggins and Wout van Aert, becoming very renowned in the world of cycling and street art. For the 2021 UCI Road World Championships, he and the street-art

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For further information: www.graco.com

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Some of the products powder-coated by Sud-Ouest Laquage (Barbezieux, France).

FOCUS ON TECHNOLOGY

The Key Role of Multi-Metal Pre-Treatment in Improving Powder Coating Adhesion and Quality Monica Fumagalli ipcm®

The integration of a 5-stage automatic multi-metal pre-treatment tunnel in its powder coating department has enabled Sud-Ouest Laquage to improve paint adhesion on steel and aluminium substrates and, thanks to the faster production process, deliver high-quality products within just a few days, thus optimising its ability to penetrate markets other than its own.

or more than twenty years, the art of transforming metal has

of product quality, led this French company to create a new production

been one of the specialisations of Charente Pliage, a company

unit dedicated exclusively to powder coating small and large products.

based in Montboyer (France) machining and painting aluminium,

Charente Pliage thus founded Sud-Ouest Laquage in 2021. It set it up

stainless steel, galvanised steel, and other components, be they

with a shot blasting cabin, a metallisation cabin, a powder coating booth,

mass produced or made to measure for the architectural sector. The

and two curing ovens, all supplied by Industrie-Systèmes (Bouches du

continuous search for solutions capable of preempting the needs of

Rhône, France), which has been offering turnkey painting products and

the market and reducing process times, without of course losing sight

equipment since 1985.

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FOCUS ON TECHNOLOGY

“Although our company is young,” states Mickaël Matignon, Associate

its professionalism and in-depth experience in the supply of turnkey

General Manager at Sud-Ouest Laquage, “our team has many years of

plants,” says Emmanuel Lafon, General Manager at Sud-Ouest Laquage.

experience in powder coating. Thanks to this know-how, we are already

“Its collaboration with Italian company Eurotherm has given it an even

receiving more and more requests from both our local market, that

more international profile and enabled it to consolidate its business

is, the southwestern region of France, and the national market. This is

beyond France. We visited the Eurotherm factory in Volpiano (Italy) to

why we decided to speed up our preparation phase prior to painting

see the results of their solutions for ourselves. We were immediately

by integrating an automatic pre-treatment tunnel, and once again

convinced of the need to continue working with them in order to

we turned to our trusted supplier, Industrie-Systèmes.” Since 2010,

improve our paint adhesion and product quality levels and thus fully

Industrie-Systèmes has been working in partnership with Eurotherm

meet the demands of our partners – which, after only a few months

Spa, an Italian company specialising in the design, manufacture, and

since the start of our activity, are becoming not only more numerous,

installation of liquid and powder coating lines, whose commercial

but also highly varied in terms of industries.” The latest addition to this

activities conducted in France were managed by the former.

partnership was Aertech, specialising in supplying technical solutions for

An established team of suppliers

industrial coating and surface treatment departments, which provided the chemicals for the pre-treatment process. Aertech is the sister

Sud-Ouest Laquage worked with Industrie-Systèmes to design

company of the Chemtec Italian company which has been producing

and install its powder coating line from the outset. “We knew the

and distributing chemical products for the metal surface and water

reputation that Industrie-Systèmes had acquired in France thanks to

treatment for the coating industry since 2010.

The exterior of the pre-treatment tunnel, the powder coating booth, and the curing oven.

international PAINT&COATING magazine - NOVEMBER/DECEMBER 2021 - N. 72

131

The 5-stage pre-treatment tunnel, the latest system to be integrated into the coating department.

The inside of the pre-treatment chamber, where components of different materials can be cleaned.

“Our collaboration with Industrie-Systèmes and the team of companies

up to 4 m long, which we powder-coat in a large booth: the problem

working with it” - continues Lafon - proved to be a winning choice: they

was to find a pre-treatment system that would not only be effective on

understood what we needed and supported us very carefully through

any metal substrate, but would also provide optimal powder adhesion

every stage of the development and installation of our 5-stage pre-

results. We therefore worked with Industrie-Systèmes to develop a pre-

treatment tunnel.”

treatment tunnel capable of meeting all these requirements.”

The flexibility of the new pre-treatment tunnel

“The concept of this tunnel is unique,” states Mathieu Breton, General Manager of Industrie-Systèmes, “because it allows carrying out two

One of Sud-Ouest Laquage’s most pressing needs was to find a

different pre-treatment processes in the same chamber, depending on

pre-treatment solution that would be effective for different types of

the type of material to be treated. In the case of steel and galvanised

materials and components. “We process parts characterised by different

steel, we perform a phosphodegreasing or alkaline degreasing stage,

dimensions, materials, and shapes. We carry out metallising or shot

followed by three rinses, including two with mains water, and one with

blasting treatments on products that need extra corrosion protection.

osmosis water and nanometric conversion. In the case of aluminium,

However, for the other components, we were also looking for a solution

on the other hand, acid pickling is carried out first to remove the oxides

that would ensure greater resistance to weathering and corrosion and

that remain on the workpieces’ surfaces after welding and annealing,

excellent powder adhesion. Our plants are capable of treating products

followed by three rinses, including two with mains water and one with

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FOCUS ON TECHNOLOGY

The feeding system of the pre-treatment tunnel.

Electric recirculation pumps.

osmosis water, and nanometric conversion.”

“The possibility of choosing between these two processes,” notes

“The chemical products are formulated and manufactured by Chemtec

Mr. Matignon, “ensures we always achieve the best level of metal

in Italy and distributed by Aertech in France” - says Carlo Giudetti,

preparation prior to coating, in terms of both mechanical strength and

CEO of Chemtec. “This double pre-treatment cycle guarantees the

anti-corrosion resistance.” The tunnel has been designed to minimise

highest quality level for each type of metal. The formulations have

the risk of contamination of liquids during rinsing. “In addition, to avoid

been developed specifically for single-chamber tunnels, which always

contamination of the pre-treatment chamber due to the performance

represent particular applications due to the high contamination rate of

of different processes, we have equipped the plant with a zero-liquid

the rinsing tanks. The passivation applied to each surface is the latest

discharge water treatment system that filters the different chemicals

innovation available in the pre-treatment industry: the PRONORTEC

used during the cycles, purifies the liquid, and sends clean water back to

process developed by Chemtec is the only nanotechnological conversion

the machine.”

that exploits the chemical features of organic phosphorus compounds.

Thanks to this special system, entirely designed and supplied by Aertech,

It is totally free of heavy metals, does not require rinsing, has a very long

it is no longer necessary to drain water from the rinsing tanks to ensure

life and very simple application and is able to guarantee the same coat

the high quality of the processes: water consumption corresponds to

adhesion and corrosion resistance levels as the ones guaranteed by

the actual use of the system without drains or wastewater.

microcrystalline zinc phosphating”.

The 5-stage pre-treatment is followed by the drying phase and the

international PAINT&COATING magazine - NOVEMBER/DECEMBER 2021 - N. 72

133

Some special workpieces painted by Sud-Ouest Laquage.

application of powder primers and coats, in which Sud-Ouest Laquage

have improved the working conditions of our operators by making them

specialises. After curing, the coated products undergo a quality control

less burdensome, thanks to the elimination of sanding operations before

and then they are ready for packaging and delivery or collection by

painting, now replaced by chemical pre-treatment. Finally, thanks to the

customers.

water recovery and recirculation system, we have even minimised our

Conclusions

running costs. The latest plant innovations by Eurotherm and Industrie-Systèmes

“Thanks to this investment,” says Mr. Lafon, “and to the quality of service

combined with the technological development in the surface treatment of

provided by the team made up of Industrie-Systèmes, Eurotherm, and

Chemtec and in the water treatment of Aertech guarantee us to achieve

Aertech, Sud-Ouest Laquage now has the opportunity to increase its

excellent results in terms of coat adhesion and corrosion resistance

production capacity and respond more promptly to requests not only

without using technologies with a strong environmental impact, creating

from the architectural sector, with which we were started out thanks to

wastewater rich in toxic substances, and discharging polluted water, by

the reputation of Charente Pliage, but also from other industries, such

minimizing energy and water consumption. Technological innovations

as furniture and carpentry, without limitations on the materials treated

now guarantee the coating industry to achieve the objectives of the green

and with the certainty of offering a high quality service. Moreover, we

and circular economy”.

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ART WITHIN SURFACES

Sonic Bloom: Communicating Through Colourful Horns Yuri Suzuki’s colourful art installation at the centre of London allows visitors to listen to city sounds and communicate with each other in-person again, thanks to the antibacterial paintings used to coat the entire sculpture.

ringing people together through sound and facilitating their

any landscape. I have created sculptures in public realms before and

communication is the main goal of Sonic Bloom, the colourful

primary colours do not conflict with landscapes and environments.”

interactive, community-focused, multi-sensory art installation

The layout of the artwork was designed to be inclusive, so it features

created by the sound artist and designer Yuri Suzuki.

seats and horns in various positions, in order to make it possible

Located at Brown Hart Gardens in London’s Mayfair area, near the

for people with disabilities and elders to experience the sculpture. “I

Oxford shopping district, Sonic Bloom is open to the public from 23rd

personally think just a statue standing in public realms does not give

August 2021 and will be possible to visit it for a year. The artwork

enough function to the community. If people actively use it, then public

features a cluster of colourful horn-shaped speaking tubes through

art has a meaning,” explained Suzuki.

which people can communicate. Moreover, the ones at the top of

The art installation includes also digital elements for people that are

the sculpture capture the city’s sounds and amplify them. To ensure

unable to travel to the British capital: the voices of the users have been

the safety of the people and allow them to gather and experience

recorded and edited into flower animations that are freely accessible on

community life without risks, the entire sculpture has been painted

the neighbourhood’s website. This aspect further expands the important

using antibacterial coatings and is cleaned daily.

concept of accessibility and inclusiveness, especially during a period

The name of the installation derives from its form, a network of red,

national lockdowns and travel restrictions.

yellow and blue trumpets resembling a blooming flower. The choice

Sonic Bloom has been developed to be dismantled and then

of the painted colours has been dictated by the artist’s favourite

reassembled easily in other locations, avoiding waste.

colour palettes. “I chose primary colours because I am dyslexic and they help with reading. With these clear divisions, people can easily

For further information:

identify the passage of sound. Primary colours also will fit very well into

www.yurisuzuki.com and www.alter-projects.com

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THE MARKETING CORNER

2022 Social Media Trends: Everything There is to Know Barbara Pennati eos Mktg&Communication Srl

info@eosmarketing.it

In this article, we summarize the most important 2022 social media trends that will drive digital content and strategies next year.

e have reached that part of the year in which the major

experts – which help us fully understand the digital world and adjust

marketing players publish reports on the main trends in

the focus of our communication strategies.

the digital world for the following year. Important data

So, let’s inaugurate this series of articles on next year’s marketing

and insights – obtained through surveys and interviews with industry

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trends by talking about 2022 Social Media Trends.

THE MARKETING CORNER

TikTok will continue to grow and other apps will adapt

and easily, without redirecting to other sites.

TikTok was the first non-Facebook-owned app to reach 3 billion

For this reason, on the eve of 2022, brands that sell online should

downloads globally. Just by this we should understand the power of

re-evaluate their sales funnel and consider taking advantage of social

this social network, which is based on user-generated content (UGC),

selling opportunities through posts, stories, reels, etc. Clearly, the

leading to very high levels of engagement and cross-platform sharing.

rule always applies that the easier and faster the purchase process,

When we spoke of 2021 social media trends, we mentioned the

the more chances we will have of concluding the sale. Furthermore,

importance of such content, the role that TikTok plays in promoting

it will also be important to provide support through chatbots and

it and the fact that more and more apps will adapt to try to imitate

verify through analysis tools that the costumer journey is as smooth

TikTok, as Instagram has already done with Reels.

as possible.

Today, we can say that this trend has been confirmed and shows

To be successful in social selling we will have to speak the same

no signs of dying out, especially since TikTok is launching further

language as users and in particular that of our audience, by

innovations, including the e-commerce aspect, new monetization

creating content that attracts their attention but also by exploiting

models and #TikTokResumes, a new feature that will allow users to

user-generated content. In fact, UGC is an effective way to sell on

upload their CV and apply for a job directly through the platform.

social media as they generate trust in the brand, while increasing

The hashtag launched to promote the initiative is already attracting

engagement.

the attention of younger people who will surely use their creativity to

However, if on the one hand social networks have become the heart

apply and stand out in the eyes of employers.

of shopping, on the other, brands must commit to offering, through

Therefore, what we will see will be an even more widespread

social media, a punctual and efficient customer service.

dissemination of TikTok-style content, not only on TikTok itself but

In fact, consumers, tired of waiting, have discovered that the

also on all other platforms (as it already happens, to the point that

customer service provided via social media is immediate, convenient

Instagram has come to penalize the content reposted directly with

and effective, and they prefer it: in a Nielsen survey commissioned by

the TikTok watermark). For this reason, other apps will adapt to host

Facebook, 64% of people said they prefer to send messages rather

similar content, while inspiring users to create it.

than calling a company. The pressure on companies to adapt to as

Therefore, if our target is on TikTok, it’s more important than ever

many digital support channels as possible is therefore skyrocketing.

to follow this trend, abandoning the more traditional forms of

But it’s not just customers who expect their needs to be met

communication and embracing new formats but without distorting

on social media: some regulatory bodies, such as the Australian

the brand. The consequence of the success of TikTok-style content

Securities and Investments Commission, are starting to require

is also clearly visible at the advertising level: despite the fact that we

organizations to provide support through customer-preferred

come from reduced budget times, the largest increases in advertising

channels.

spending compared to last year were assigned to TikTok, Pinterest

In this context, it is also important to remember another factor: our

and Snapchat. Marketers are shifting their assets to where they

customers don’t make the distinction between customer service,

can make the most impact, and increasingly, this is happening on

marketing or sales team. For them, every interaction is simply an

platforms that weren’t prioritized in the marketing mix before.

experience with the brand. It is therefore important to ensure

Therefore, our creativity must not fail when it comes to advertising:

that the various teams work in tandem and communicate without

brands that want to stand out in 2022 will have to commit to creating

constraints, so that they can easily and immediately deal with

ads that reflect and enrich the experience offered by each social

requests and mitigate any problem.

network. accept the need of experimenting, without focusing too much on the

The way we advertise and manage the privacy narrative will change

metrics, making mistakes and trying again and again.

At the time of the war on cookies and the tracking policies adopted

To keep up with all these changes, it is clear that we will have to

Social Selling will take on a leading role

so far, learning to balance the need to offer personalized services and the need to obtain the consent of users, acting in accordance

Thanks to the collaboration with Shopify, Instagram introduced

with the new regulations, will be of primary importance.

Shoppable Posts in 2018, which allow users to purchase products

As we have already seen when talking about digital marketing trends

without leaving the app, with a simple touch. Since then, the goal of

of 2021, people are, in fact, worried about their online privacy.

the main social apps has been to offer users the ability to buy quickly

However, such concerns do not seem to translate into a more

international PAINT&COATING magazine - NOVEMBER/DECEMBER 2021 - N. 72

139

conscious behaviour for the time being. This was demonstrated by an

changing.

experiment by Security.org, which added the right to name the user’s

In addition to user-generated content, we can also take advantage of

first child in the consent form. 98% of users agreed to.

influencer marketing, which to date remains one of the promotional

The truth is that many times the language of privacy policies is too

forms with the highest return on investment, capable of generating

complicated and verbose and people have neither the time nor the

high engagement rates without being invasive, and increasing the

desire to read them. However, with privacy policies changing and

credibility of a brand.

the need to address user concerns, brands will need to take matters into their own hands and set a strategy. This presents a challenge as

The metaverse will be the future

well as an opportunity: that of rewriting the privacy narrative, using a

Driven by the world of gaming, the metaverse is a fusion of the

more concise and direct language and building a relationship of real

physical world, augmented reality and virtual and, according to Mark

trust with users.

Zuckerberg (and many others), it will be the future.

One of the ways to do this and advertise our brand at the same time

Many brands, from fashion to automotive, have already exploited the

is to recognize that consumers trust other consumers more than

metaverse to launch their products, offering the public an immersive

brands. Therefore, UGCs must once again be part of our strategy to

experience and investing heavily in this new technological challenge.

address both growing user concerns and the fact that advertising is

Then we have the recent launch of Meta, which brings together all

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THE MARKETING CORNER

by the apps and technologies owned by Zuckerberg under a new

MODlFIED ALCOHOL

corporate brand. Meta’s goal, as stated in the official press release, will be to bring the metaverse to life and help people connect, find communities and grow businesses. The metaverse will be a hybrid of today’s online social experiences, which will embrace both a three-dimensional and physical world, allowing users to live different immersive experiences, from social connection, to entertainment, to games, to fitness, to work, to education, right up to business. Considering that Zuckerberg owns some of the most widely used social apps in the world today, it is clear that this new project will have significant proportions and consequences for anyone who does online marketing. Having said that, we must always keep in mind that projects for their own sake lead nowhere: our audience will not be interested in our brand, our platform or our space if what we have built does

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reflect and gather information on consumers.

Brands will need to be attentive to social issues Environmental sustainability was perhaps the first major topic of social interest to be embraced also at a corporate level. To such an extent that in some cases we speak of greenwashing, a term that indicates all those marketing and communication strategies aimed at presenting a company as eco-sustainable when in reality it is not. Today, however, the time for bla bla bla – to put it as Greta Thunberg did – is over: whether we are talking about environmental sustainability, racial issues or gender inclusiveness,

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brands will have to have an opinion on it because that is what consumers expect and what they will be judged for. Having said that, one does not become socially aware and inclusive overnight. You need to devote time, research and commitment to seriously and sincerely engage not only your audience on the issues of greatest interest but also the entire company. Therefore, let’s not imitate the popular sentiment to keep our

DIVISIONS:

audience engaged but let’s strive to be a truly inclusive and aware brand.

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change, by networking and sharing online. All social networks are

communities to life. This means building trust by investing in partner

moving in this direction, just think of the aforementioned metaverse

creators, taking the lead in distributing their content and amplifying it

but also of the new Twitter Communities, which aims to offer people

across our channels.

a virtual place to connect, share and get closer to the discussions

So, instead of trying to create a community from scratch – which

they care about the most.

requires time and money that are not always available – it is better

Last year we wrote about how brands focused on listening and

to introduce ourselves and tap into existing creator communities

finding their place within the conversation before making their voices

to learn more about our customers, simplify content creation and

heard online.

increase brand awareness and affinity.

This year, we need to take it one step further: not only do we need to

What do you think of these trends? Let us know with a comment

listen to what people say within the online communities we address,

on our website www.eosmarketing.it and contact us for more

but also actively support the content creators who bring those

information on our social media management services.

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booths

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SPECIALIZED TRAINING

Shortage of Skilled Personnel: The Training Needs of Companies Gabriele Lazzari ipcm®

Our editorial team asked a few questions to company owners and coating managers in order to better understand the needs of the labour market and how the ipcm® Academy training course can match supply with demand.

he labour market is constantly changing. Moreover, it often

We are now witnessing a growing demand for soft skills to fill these

seems that schools and universities are excessively focused on

gaps in practical activities1.

theoretical knowledge and unable to prepare future professionals

However, on the other hand, the surface treatment industry is

to the possible challenges they will face. 1

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https://www.indeed.com/career-advice/finding-a-job/qualities-employers-want

SPECIALIZED TRAINING

Lack of training courses especially for young people

Italy) specialising in plastic and metal surface

of training courses enabling people to learn technical knowledge related to the activities

Countless companies report having

an extensive search for a resource capable

performed in the coating and surface

difficulties in finding adequately trained

of managing its entire painting department.

treatment world.

staff. Therefore, our editorial team decided

“The biggest challenge was to find people

This is why the ipcm Academy courses,

to ask specifically about recent experiences

with experience in the whole coating process

aimed at paint operators, paintshop

in recruiting new professionals and about

and in the management of all systems, from

managers, paint manufacturers’ sales

the knowledge and characteristics that

pre-treatment to manual and automatic

engineers, and quality control managers,

these professionals should have. “In my

application of various types of paint, through

give access to a training programme based

experience,” says Massimo Arcuri, the

to polymerisation. Ideally, we were looking

on the current demands and needs of the

industrialisation and coating technology

for an engineer or a technical graduate, with

labour market, through classroom lessons

manager of IMR Industries (Carate Brianza,

about two years’ experience in various coating-

with highly qualified teachers boasting many

Monza e Brianza, Italy), “I have noticed that

related activities. Alternatively, we were

years of experience in the field of surface

there is a preference for seeking out and

willing to also consider technical graduates

treatments, including both a theoretical and a

hiring resources with a technical background

with production experience. We were not

practical part.

but willing to be professionally trained by

looking for an expert, but for a resource to

the company itself. The lack of specific

keep training and making grow professionally

schooling and academics makes it difficult to

in our company. Unfortunately, there are

find people who are already professionals,

very few candidates with experience in the

especially among young people. In addition,

various processes involved in painting. We

the continuous evolution of our sector

have had feedback from some coaters, albeit

requires continuous training.

with difficulty, or from people who in the

“That is why I attended the ipcm® Academy

past also supervised coaters as part of their

course as well, although I already had

duties, but nobody experienced in running

some knowledge of the topics covered –

a whole painting department. Therefore, we

and I regret not having attended it earlier,

also considered a person who had managed

maybe even at the beginning of my career,

other types of processes and was willing to be

because it would have given me a better

trained in-house.”

understanding of many aspects of the coating

Massa only found out about the ipcm®

process. Therefore, I would also recommend

Academy courses after this lengthy research,

it to young people who have just entered

but he says they would have been a useful

the world of work and started out in this

reference to turn to for immediate feedback

sector, so that they can better understand

during the research phase. “As mentioned, our

the various processes and obtain training

difficulties were due to a lack of knowledge

that is perhaps ancillary to their specific

tout court. Therefore, courses such as those

tasks, but still necessary for their professional

run by ipcm® Academy would certainly have

development. The world of work certainly

helped in finding staff with the characteristics

needs more training, and a course of this kind

we were looking for. Moreover, for example,

can enable these professionals to mature

the possibility of participating in individual

quickly. In fact, the company I work for is also

modules could enable coaters to acquire

looking for a similar course that focuses on

technical expertise on further aspects of the

plastics.”

surface treatment field and expand their

experiencing the opposite problem: the lack

Comprehensive experience in paintshops and equipment

treatments, which has recently carried out

knowledge. The industry suffers from a lack of training paths of this kind.”

This is also exemplified by the testimony of Michael Massa, the general manager of

For further information:

SIVE SpA, a company based in Cirié (Turin,

www.ipcmacademy.com

international PAINT&COATING magazine - NOVEMBER/DECEMBER 2021 - N. 72

145

STANDARD & LEGISLATION - UCIF Informs

Is Corporate Sustainability a Mirage? Marcello Zinno UCIF – Italian Surface Treatment Equipment Manufacturers’ Association, Milan, Italy

info@ucif.net

hen we talk or read about

(global) markets. Precisely in order to better

different opportunities, such as, for example,

sustainability, we often come across

understand how to orient in the (green) jungle

the industrial symbiosis approach (waste from

slogans, marketing strategies

of environmental issues, UCIF started with the

one company could be turned into resources

with little substance, or even questionable

2030 Agenda for Sustainable Development

for another). In addition, there are measures

media phenomena and personalities. Hardly

and its seventeen macro goals, which, together

to promote the right to reuse and repair and

any thought is given to how companies

with the Paris Agreement on climate change,

there will be an increasing move towards

should and could concretely become more

constitutes the roadmap for a better world

disassemblable products to allow for the

sustainable – which would also give them a

and a global framework for international

proper disposal of each individual component

competitive advantage, as the two factors

cooperation on sustainable development

(eco-design). As if that were not enough,

are not exclusive, but complementary. In fact,

and its economic, social, environmental, and

sustainability will also become a part of each

transitioning to technologies with a reduced

governance aspects. In order to achieve

organisation’s “corporate culture”, aimed at

environmental impact does not just involve

the Agenda’s objectives, the European

creating engagement on different levels: with

the ability to tap into dedicated economic

Union has promoted a series of policies and

shareholders, because in future no one will

resources (often public), but it is also about

binding targets, such as the 55% reduction in

want to invest in a polluting company; with

changing one’s own production approach

greenhouse gas emissions by 2030 and the

employees, because the younger generations

and adopting a new business philosophy that

even more ambitious goal of the EU’s climate

are attentive to these issues and will not want

brings various benefits.

neutrality by 2050, which necessarily involves

to bring their skills to a non-green company;

It was with this in mind that, in the framework

a process of decarbonisation of each member

and in terms of corporate strategy, because no

of its We Talk format, UCIF organised a

state (based on their NECPs, national energy

corporate mission will be conceivable without

digital meeting that saw the participation of

and climate plans).

including respect for or protection of the

two experts who addressed this issue with

Nevertheless, why should companies go in this

environment that surrounds us.

a focus on companies and the business

direction not only due to social responsibility,

This and much more was discussed during

benefits of embracing sustainable choices.

but also on economic grounds? First of all,

the digital meeting, one of the many events

In fact, while it is true that citizens are often

because the national recovery and resilience

that our Association is organising to support

sensitive to these topics, it is also true that

plans (NRRPs) stipulate that 37% of the funds

companies – because, in order to be actually

many industrial sectors do not yet know how

should be allocated to green transition, which

sustainable, it is necessary to act together.

to harmonise attention to the environment

is one of the plans’ six missions. Secondly,

While useful, individual contribution remains

with the economic constraints imposed by

because circular business models can create

marginal.

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PPG Supported the “Leonardo da Vinci” National Museum of Science and Technology in the Construction of a new Chemistry Laboratory Ilaria Paolomelo ipcm®

he “Leonardo da Vinci” National Museum of Science and Technology in Milan (Italy) has recently renewed

its space dedicated to STEM (Science, Technology, Engineering, and Mathematics) education by creating a new chemistry laboratory: iLab Chimica. Created thanks to the support of coating, paint, and special material manufacturer PPG, the new laboratory is an innovative and interactive area mainly conceived for new generations and aimed at bringing people and, in particular, primary and secondary school students closer to scientific disciplines and chemical phenomena. Such important result has been the fruit of the synergy between the museum’s educational expertise and PPG’s technical and scientific know-how – for years, this company has been helping bring colour and brightness to communities in line with its purpose, “We protect and beautify the world”. During the creation of this laboratory, the paint manufacturer’s experts and researchers selected the most innovative and sustainable products and recommended the most suitable and high-performance technologies with the aim of giving the community a new symbol of beauty and culture, a project to be experienced, seen, and experiences. Inauguration of the new laboratory The inauguration of iLab Chimica, which took place on 7th October 2021 at the “Leonardo

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da Vinci” Museum, saw the participation

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of numerous speakers who explained the reasons behind the

and fall in love with this complex and invisible but unexpectedly

development of a new laboratory. Creativity and innovation were

beautiful world that is woven into all aspects of our lives,” stated Maria

the common keywords among their speeches. Indeed, the creativity

Xanthoudaki, the Museum’s Education Director.

of chemistry is expressed in the possibility of combining existing

“We are very proud to be an active part of this STEM project with

elements – chemical elements, molecules – with connections, links,

our expertise and innovations, alongside an important scientific and

and reactions and generating original associations that create new

educational organisation such as the “Leonardo da Vinci” National

products and knowledge. On the other hand, innovation is provided

Museum of Science and Technology. We believe that science and

by an innovatively designed space, an unconventional educational

chemistry are closely linked to our mission, which is to protect and

approach, and unusual instrumentation including thermal imaging

make the world more beautiful, with colour as an essential element.

cameras, microphones, and sensors that make chemistry perceptible

This has guided us and will continue to guide us in future: at PPG, we

through different senses.

have been committed for years to using it in all its forms, making it

“The new laboratory aims at introducing chemistry through

the protagonist of our business and of a path to spreading knowledge

educational experiences designed to bring out the creativity that lies

of its beauty. In particular, with this new iLab Chimica project, we

in the synthesis or transformation of elements. This is made possible

wanted to show how the intertwining of innovation, colour, and

by a space designed to encourage group work and the direct use

sustainability can give rise to valuable initiatives. We hope that this

of tools making this subject perceptible through the five senses,

educational resource we are inaugurating will bring children closer

also thanks to an approach that favours open and experimental

to the discovery of science, intrigue adults, and surprise enthusiasts,”

learning. Our goal is to create a context in which each person can

commented Andrea Giunta, PPG’s Vice President Science &

directly experience chemistry, explore and discover it, ask questions,

Technology, Color, Corporate.

UCIMU-SISTEMI PER PRODURRE

075/2018 BMXX18R

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The new iLab Chimica

• tables that can be rotated and stacked to

The laboratory extends longitudinally, looking

flexibly adapt the space to the activities to be

out onto the garden of one of the two

carried out;

cloisters of the former Olivetan monastery,

• light boxes in the centre of the tables

and is characterised by a succession of strips

that change colour as required, helping to

in different materials and with different

observe any surprising reaction and setting

shapes, colours, and surface finishes,

the ideal stage for the many recording

which give rise to a dynamic, creative, and

instruments connected to the monitors;

innovatively designed space.

• three showcases containing familiar or unfamiliar, historical or contemporary

This is completed as follows:

objects, engaging visitors with informal

• two large projections welcoming visitors

questions that trigger reactions of curiosity

with artistic images from the international

and a desire to play and marvel at the

Beautiful Chemistry project;

countless possibilities that chemistry offers.

• large closets containing tools useful for teaching activities;

The laboratory has been open to the public at the Museum since 9 October 2021.

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Scan the code to watch the presentation of the new laboratory

PIROMAX Where effectiveness meets gentleness. With PIROMAX ovens thermal paint-stripping is performed only through heat, paint is incinerated without altering the piece dimensionally or mechanically.

ciroldi@ciroldi.it

+39 059 386012

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Axalta Opens its first Colour Experience Room in Italy Barbara Pennati ipcm®

Customers, architects, and stakeholders can visit and admire in person the colours and finishes of Axalta’s new Colour Experience Room, inaugurated in October at the group’s Italian offices in Cavenago, just outside Milan.

he choice of colours and finishes is a fundamental step in the

Colour Experience Room at its offices in Cavenago di Brianza (Monza e

creation of any product. This is even truer for architectural

Brianza, Italy).

structures, which do not only have to fulfil specific functions

This contemporary and bright area of 80 m2 has been designed to

and comply with safety standards, but are also increasingly seen as a

welcome all those interested and allow them to get a closer look at the

valuable aesthetic and stylistic element of urban skylines. In order to

range of colours and finishes offered by Axalta.

guide its customers, but also architects and designers, in the choice of

“This Colour Experience Room in Milan is the first in Italy and the sixth

effects and tints for their architectural projects, Axalta has created a

in Europe,” explains Cristian Palmieri, the Sales Manager Italy of Axalta,

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during the opening

member of the Green

walk-in of the exhibition

Building Council, a

space. “It is deliberately

non-profit association

all white to highlight the

active in more than

1200 colour variants

seventy countries

displayed in a chromatic

around the world

sequence, which also

for the sustainable

include several special

construction market,

effects such as wrinkled,

which promotes

metallic, or bonderised.

certification protocols

Customers, designers,

whose parameters

and architects visiting

establish precise

this space have the

criteria for the design

opportunity to assess

and construction

our range up close, pick

of healthy,

up the sheets they are

energy-efficient,

interested in, and create

environmentally

their own personal

friendly buildings.”

colour palette.

Customers, architects,

“The decision to open a

and designers are

Colour Experience Room

also guided in their

in Italy was driven by the

choice of tints and

desire to offer a high

finishes by Vibes, a magazine published

added value service to both our customers and our customers’ customers, that is, architects

by Axalta every year to collect all main colour trends identified by

and designers. In particular, Milan alone has the largest professional

analysing different sectors of our daily life, from fashion to automotive.

association of architects in Italy, with over 12,000 people.”

Finally, the Colour Experience Room is not the only way through

“The language of architecture is different from the industrial one: it

which customers and designers can approach Axalta’s paint range.

has its own specificity and an emotional component, intrinsic in colour,

The company has installed around 200 ColourSelectors in Europe,

which must be taken into account. This calls for someone who ‘speaks

including 23 in Italy.

the same language’ and has the same skills as our visitors. That is

“These are walls set up with sheets coated in our 490 most popular

why, in each country where there is a Colour Experience Room, Axalta

colours, belonging to the Alesta® AE, Architectural Polyester, and

works with different architects in order to both create and manage

Alesta® SD (Super Durable quality) collections. Wherever they are, our

the exhibition space and its guests. In Italy, we have welcomed to

customers have the opportunity to see these tints in person, feel the

our team Ana Cecilia Montel, an architect and a Colour Specialist and

texture of different finishes, and, by scanning the specific QR code,

Specification Leader at Axalta, who supports all visitors in the selection

send their order directly to Axalta,” explains Palmieri.

of tints and finishes. In the competitive market of architectural paints,

“The opening of the Colour Experience Room at Axalta’s Italian offices

this project, together with the possibility of benefiting from specific

was well received by local customers and architects. It is the result of

know-how in the field of design and architecture, has enabled us to

an internal restructuring work carried out by Axalta to manage this

diversify and gain a competitive edge by focussing on design and

venture and offer an additional service to the Italian market, which

finishing,” states Palmieri.

is very important for us. We are delighted that this exhibition space

“Sustainability also plays an important role, from the choice of raw

has finally been realised and that we can once again welcome our

materials to the manufacturing processes and the chemical nature of

customers in person. For the future, we have other projects aimed at

our products, be they powder or liquid coatings, which we try to make

the world of architecture, on which we are already working,” concludes

as environmentally friendly as possible. Since last year, we have been a

Cristian Palmieri.

international PAINT&COATING magazine - NOVEMBER/DECEMBER 2021 - N. 72

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Dürr Hosted Its First Virtual Open-House Focused on Intelligent Flexibility Gabriele Lazzari ipcm®

Dürr’s 12th open-house, focused on intelligent flexibility, presented smart solutions for the paint shop of the future, that will improve efficiency and profitability while reducing costs and environmental impact.

or the first time, Dürr held its open-house virtually. From 8th to

The 12th open-house included presentations, interviews and technical

12 November 2021, the company presented its new products

demonstrations focused on solutions that would replace the previous

to increase efficiency and profitability in manufacturing while

line concept with a future-oriented configuration based around flexible,

reducing resources for large volume manufacturers and small electric

intelligently connected process modules which can be scaled to meet

car start-ups.

customers’ requirements.

EcoProFleet AGV at Dürr’s test centre in Bietigheim-Bissingen (Germany).

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“What manufacturers need most these days from the painting process is flexibility, cost efficiency, and sustainability. We answer this need with our concept of the paint shop of the future, which overcomes the limitations of the inflexible production line. Instead, the 120 or so individual operations are executed in scalable modules or small sections, in parallel and timed precisely to the needs of the individual body,” stated the CEO of Dürr, Jochen Weyrauch. “This makes it easy to extend capacities and channel different vehicle types through the painting process. Ideally, even individual items can be handled while production is underway.”

The paint shop of the future: flexibility and artificial intelligence Single stations can be custom equipped using the automated guided vehicle EcoProFleet, the first AGV specifically developed for

paint shops. In combination with a high-bay

The automatic applicator EcoSealJet Pro allows to paint hard-to-reach surfaces.

storage, it lays the foundation for intelligent material flow control along the whole process. The DXQcontrol software controls each AGV, so all modules are always efficiently used directly from the pre-treatment phase. The new modular system design of EcoProWet PT, on the other hand, is based on standardized chambers instead of immersion tanks arranged one after another, in order to allow more flexibility and save space. Dürr has further automated the seam sealing phase with the new EcoSealJet Pro automatic applicator and the DXQ software powered by artificial intelligence. The box configuration for the painting process in the EcoProBooth combines the application of the primer and basecoat layers in one single spray booth, eliminating two of the three usual conveying operations. Moreover, it is also suitable as a standard spray booth with the same robot equipment for both basecoat and clearcoat. © Dürr

EcoPaintJet Pro can paint vertical surfaces without masking and avoiding overspray.

international PAINT&COATING magazine - NOVEMBER/DECEMBER 2021 - N. 72

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EcoProBooth allows to apply for several coating layers in a single painting booth.

The overspray-free EcoPaintJet Pro painting system is now able to

data, messages, and information, helping to identify correlations and

automatically apply two-component paints (2C), besides two-tone lines

avoid errors. A feedback feature constantly provides the algorithm with

for car roofs, colour changes, vertical surfaces and decorative paint

additional information, so predictions about the need for maintenance

applications. In addition to this, the atomizer generation EcoBell4 can

can become more and more precise.

deliver shorter colour change times and automated atomizer cleaning,

“The many participants from all over the world, well in excess of 1,000,

therefore allowing to paint more units at the same time. Low paint and

and all of the enthusiastic feedback are indicators of the great interest

solvent consumption help to make production more sustainable by

generated by the first virtual open house. Our concept for the paint

reducing VOC emissions.

shop of the future is a complete success. It delivers exactly what

The software belonging to Dürr’s DXQ series ensure that the processes

manufacturers need,” concluded Weyrauch.

interact smoothly in the modular concept, transforming the boxbased painting system into a smart factory. DXQplant.analytics uses AI algorithms and machine learning modules to collect and analyse sensor

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For further information: www.durr.com

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Neuce Powder Coatings’ XIII Technical Day: “Technical Evolution and State-of-the-Art of Powders”

n 18 November, Neuce Powder Coatings celebrated its XIII

• Thicknesses on edges / edges in profiles / aluminium sheets.

Technical Day entitled “Technical Evolution and State-of-

Comparison of painted profiles in Europe (powder) and the USA (liquid).

the-Art of Powders” at the Hotel Rafael Atocha in Madrid

Metallographic study. Guarantee - Patricia Saez-Torres

(Spain). This technical event, which Titan Powder Coating (now Neuce

• Structured coatings. How to maintain consistency and gloss in all

Powder Coatings) has been celebrating for several years now with

applications. Adhesion on anodised, galvanised, and polyamide surfaces -

great success in terms of both participation and content, is aimed at

José Arrieta Segura

illustrating the latest research studies, experiences, ideas, and projects

• Technical coordinates of the last forty years in powder coating

on the subject of powder coatings. The meeting was well attended by

development - José Manuel Azpeitia

customers, suppliers, engineering companies, application equipment manufacturers, and firms specialising in surface treatments – which,

A round table discussion was held after the speeches, presenting the

together with coatings, are decisive in obtaining sound industrial

experience of three top companies and enabling all those present

finishing systems that meet all kinds of technical requirements. The

to actively interact with the speakers and stimulate an interesting

day’s programme addressed some common application problems faced

debate. This saw the participation of as follows: Iván Ortiz from POWER

in powder finishing. One example is the delicate issue of thicknesses

ELECTRONICS, a leading designer and producer of inverters for the

applied on the edges/corners of many aluminium profiles, which tend

photovoltaic industry and for electrical stations; Roberto Mínguez

to be problematic when it comes to guaranteeing the durability of the

from ALUCOIL, a manufacturer of panels for the industry and the

coating, as happens with bent sheet metal. All these issues have been

construction sector; Diogo Barreto from LACOVIANA, the leading

incorporated in a framework of constant technical evolution over the

independent aluminium coating contractor on the Iberian Peninsula.

last forty years, both in the application and pre-treatment fields, which

At the end of the day, the highest representatives of AEA (the

has enabled powders to successfully overcome major changes, also

Spanish aluminium and surface treatments association) presented a

discussed during the conference.

commemorative plaque to José Manuel Azpeitia in recognition of his contribution to the powder coating sector.

Speeches of the day • Electron microscopy as a tool for characterising powder coatings

For further information: www.neuce.com

Daniel Arias (Technology Development and Control)

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Nuremberg, Germany

18 – 20.1. 2022

International Trade Fair for Die Casting: Technology, Processes, Products Detecting trends, getting inspired, sharing ideas – trade fairs are all that and more. Come and discover EUROGUSS and its possibilities on site. #ReExperienceLive

Honorary sponsors VDD Verband Deutscher Druckgießereien CEMAFON The European Foundry Equipment Suppliers Association

euroguss.com

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A demonstration of the Production Process 4.0 during the UCIF Members’ Meeting Gabriele Lazzari ipcm®

The latest Ordinary General Meeting of the Members of UCIF (the Italian Surface Treatment Equipment Manufacturers’ Association) allowed participants to discuss a few major issues relating to industrial finishing and witness a demonstration of the production process 4.0, from design to the end of the product’s life cycle.

ADE, the Industry 4.0-related competence centre created

UCIF association aims at gathering the players of the surface technology

within the Politecnico di Milano’s Bovisa campus, hosted the

sector (producers and users of surface technologies) to talk about how

2021 Ordinary General Assembly of the Members of UCIF

this industry can contribute to production process improvement and

(the Italian Surface Treatment Equipment Manufacturers’ Association)

sustainability.

on Wednesday 17 November. MADE is a digital and sustainable factory

This was followed by the traditional analysis of the final balance sheet

that supports manufacturing companies in their digital transformation

for 2020 and of the budget for 2021 and 2022, presented by treasurer

towards Industry 4.0. It provides a wealth of knowledge, methods, and

Claudio Minelli. The Assembly ended with the observations and

tools on digital technologies ranging from design to engineering, from

proposals of some Members and of the specialized magazines (including

production management to delivery and end-of-life management.

ipcm®) that are Associate Members.

With its large, 2,500 m -wide demo centre, training rooms, and co-

After a convivial lunch organised at the same premises in order to keep

working and meeting spaces, it is a truly unique solution. The special

on discussing and networking, a few qualified experts of MADE CC I4.0

growth path towards digital transformation it has developed is based

presented the mission and services of the large demo centre that was

on three phases: displaying and providing information about Industry

hosting the Assembly. The event also included a demonstration of the

4.0-oriented technologies, explaining them through ad hoc training

manufacturing process 4.0, from design to the end-of-life of a product.

activities, and transferring and implementing technological solutions

The tour involved 6 technology areas with 20 demonstrators: digital

through specific projects.

backbone, artificial intelligence, hybrid cloud, 5G, collaborative robotics,

It was a very good stage for the latest UCIF Annual Meeting, which

smart operator assistance systems, digital twin, virtual commissioning,

focussed on important topics such as process sustainability,

lean production 4.0, quality 4.0, product traceability, additive

digitalisation, and the transition towards a more efficient, respectful, and

manufacturing, big data analytics, IoT smart connected products, smart

ethical industry. The Assembly, which was not an elective one, began

monitoring and control of industrial processes, smart energy monitoring

with a welcome speech delivered by UCIF President, Daryush Arabnia,

and control, smart maintenance, virtual design and new product

who recalled the operational difficulties encountered over the last two

development, and logistics 4.0.

years due to the pandemic crisis: the lack of planning, the fluctuation of raw material prices, and the demand for just-in-time processing only are offering partial and short-term future readiness to all companies in the surface technology sector – which on the other hand are showing great resilience, despite everything. Arabnia then presented UCIF’s new image, which has brought with it a more precise definition of the association’s mission and vision as well as of the benefits offered to Members, summarised in a new presentation that will be used to expand the membership base in the coming years. Finally, the President presented the S.M.A.R.T.2 conference, which will be held on 18 May 2022 at Fondazione Cariplo’s offices in Milan. The main theme of this second edition of the UCIF conference will be “Technological Innovation and Sustainability for a New Start”. After the success of the first edition of S.M.A.R.T. (the acronym of Surface, Manufacturing, Advanced, Research, Trends) in 2019, the

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For further information: www.ucif.net

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ESTAL 2021 Virtual Congress “Taking aluminium to new Horizons” Explored Important Developments for Powder Coating and Anodizing The first virtual Congress hosted by ESTAL offered the opportunity to gain up-to-date information on the developments regarding the market of aluminium surface finishing during three sessions focused on powder coating and anodising industry.

he virtual congress “Taking aluminium to new Horizons” that took

of interest for both the anodising and the coating industry, such as

place on 6th and 7th October was organised around 3 half-day

how political actions and worldwide trade interventions impacted the

sessions and the digital platform offered participants the possibility

aluminium market and investigations on the effects of increased recycled

to network and to contact industry suppliers via the virtual exhibition. It

contents in aluminium alloys and on the corrosion susceptibility of coated

attracted over 430 registered participants from 44 different countries

profiles.

The first session was dedicated to powder coatings and started with

President Ivo Vermeeren announced satisfaction for the attendance

update on the colour and finishes trends for the architectural powder

and with the lively Questions & Answers sessions that followed the

coating market, followed by a lecture on powder coatings with added

presentations. He addressed his warmest thanks to the sponsors and

properties such as anti-microbial efficacy. After that, it included a scientific

exhibitors for their financial support, to the speakers and organisers. The

presentation on how to quantify global and local corrosion process in

2021 virtual Congress offered an excellent opportunity to be informed

some aluminium alloys.

about the developments on the market of aluminium surface finishing.

The Anodizing Session began with a presentation explaining how issues

He invited the participants to attend the next ESTAL Congress that should

emerging during the pre-treatment of high-alloyed and secondary

take place in Budapest in 2022 or 2023.

aluminium could be resolved by principles of chemical machining. In the

For registered congress participants, the congress platform gives access

late afternoon the session ended with a fascinating presentation on the

to all presentations on demand as well as the possibility to contact the

anodizing basics for aluminium surfaces that showcased the nature and

exhibiting companies until the end of November 2021.

mechanism for anodic aluminium oxide development and growth. The second day of ESTAL virtual congress was dedicated to topics

For further information: https://estalcongress2021.org/

President Ivo Vermeeren opening the virtual congress.

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March 29-31, 2022 Paris Expo - Hall 2.2 Porte de Versailles

International Exhibition & Congress

France

Dedicated to production & formulation of paints, varnishes, inks, glues and adhesives

Join the 1st European exhibition gathering the coatings community since 4 years!

FORMULATION RAW MATERIALS BIOBASED INGREDIENTS

PIGMENTS

SOLVENTS

POLYMERS RESINS...

PROCESS, PRODUCTION, LABORATORY EQUIPMENT MIXERS

MILLING An event co-organised by:

TINTING MACHINES

www.eurocoat-expo.com To exhibit: Cyril LADET +33 (0)1 77 92 96 84 cladet@infopro-digital.com

To visit : Aïda AMINE +33 (0)1 46 99 31 32 aamine@infopro-digital.com

PACKAGINGS...

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More Than 70 Companies Have Already Announced the Participation at Interlakokraska 2022 The organisers of Interlakokraska 2022 have opened the registrations for the next international trade fair dedicated to paints, coatings, raw materials and production technologies that will take place in Moscow from 1-4 March 2022. Over 150 companies from 15 countries are expected to participate.

he organisers of the 2022 edition of Interlakokraska have

The next edition is expected to allow even more business opportunities

announced that the registrations for the international trade

and the circulation of knowledge. Over 70 companies have already

fairs dedicated to paints, coatings, raw materials and production

booked a stand.

technologies are now open. The exhibition is planned to take place at

The 2022 edition of Interlakokraska trade fair is expected to include:

the EXPOCENTRE Fairgrounds (Krasnopresnenskaya nab., 14) in Moscow

• More than 150 companies from 15 countries;

from the 1st to the 4th of March 2022.

• Over 10,000 m2 of fair ground;

Traditionally, during the first week of March the EXPOCENTRE

• Around 6,000 professional visitors.

Fairgrounds becomes a meeting place for manufacturers and suppliers

Interlakokraska offers several participation formats. The trade fair can

of machinery, equipment and advanced technologies for the paint and

be reached with the underground, at Vystavochnaya and Delovoy Tsentr

coatings industry and consumers of finished products and services.

metro stations.

85 companies from Russia, Germany, China, Belgium, Luxembourg,

The opening hours are set to be from 10:00 am to 6:00 pm.

France, Switzerland, the Republic of Belarus, Turkey and Ukraine

Interlakokraska is held with support of the Russian Ministry of Industry

participated in the exhibition in 2021. Moreover, several foreign

and Trade, the Chimvest Scientific and Technical Centre, the Russian

companies were represented by their Russian partners.

Chemists Union, NIITEKHIM OAO, the Mendeleev Russian Chemical

The feedback from past participants and visitors proves quality of the

Society, the Centrlack Association, the Paint Quality Association, and

event, especially during these challenging times for the industry. Visitors

under auspices of the Russian Chamber of Commerce and Industry.

and exhibitors gained the most out of their participation: productive negotiations, concluded contracts and new business partners.

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For further information: www.interlak-expo.ru/en/

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ICT | EDITOR’S LETTER

uring the annual assembly of an Italian association of which ipcm® is a member,

I had the opportunity to talk to a leading representative of the industrial cleaning sector in Italy, a player who has made the history of this industry, a person who

has never stopped experimenting to find the best performing solution with the lowest environmental impact. In this exchange of views, his sentence that struck me the most was as follows: “Today’s customers are not asking for a cleaning machine, but for cleaning results.” This sentence perfectly encapsulates the editorial philosophy of ICT, which is aimed at presenting its readers with the cleaning results that can be achieved with the best technologies available on the market – without being pigeonholed into rigid currents of opinion in favour of one technology or another, one approach or another. Too easy? Perhaps. But the job of journalism, including technical journalism, is to

Francesco Stucchi Editor

investigate reality, understand it, and report on it, as precisely and objectively as possible. This means that ICT’s task is to tell about technologies, to show the results obtained and have them presented by those who have chosen these technologies, and even to collect dissatisfaction or discontent for such choice, while being well aware that issues such as sustainability, efficiency, low environmental impact, and ethical awareness are crucial for industrial production. This magazine and the editorial services it offers are a tool for companies to show their progress, their approach to technical issues, their services, and above all their strengths compared with competitors. It is democratic: it can and must give space to everyone within the scope of its editorial policy. At the same time, each magazine chooses its readers and advertisers by selecting what to publish or not to publish. Everything else is pure sales.

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NEWS

ICT | INDUSTRY NEWS

MicroCare Acquired Certol International to Expand Its Presence and Offerings The acquisition will allow MicroCare to fuel growth through the delivery of innovative, value-added solutions and services for the global critical cleaning industry. icroCare LLC, a global supplier of critical cleaning fluids and

solutions to our customers. With this acquisition, MicroCare will

materials used in the electronics, medical device manufacturing,

continue to be well-situated to capitalize on the many emerging trends

fibre-optic and metal finishing markets, has announced that it had

in the dental and medical markets. We view this important acquisition

acquired Certol International, a Denver-based manufacturer of

as an excellent step to position the business for continued growth

specialty cleaning and disinfecting products for the medical, dental and

as we work with customers to solve their cleaning and disinfecting

consumer marketplaces.

challenges.”

“We are very excited to announce this acquisition. Certol has a 40-

This acquisition is aligned with the MicroCare strategic goals and

year history of providing EPA registered high performance surface

priorities to fuel growth through the delivery of innovative, value-added

disinfectants and specialty cleaners engineered for use in dental

solutions and services into the global critical cleaning industry. The

offices, medical offices, and hospital settings. Certol also manufactures

Certol leading product and development initiatives will amplify the

specialty products used in industrial, marine and consumer cleaning

already strong programs in the MicroCare pipeline and will enable

applications,” stated Tom Tattersall, Chief Executive Officer at

continued focus on high growth segments, such as automotive,

MicroCare. “We believe that the Certol product lines, customer

medical, electronics and fibre-optic communications.

relationships, and centralized U.S. location will reinforce our position as a leading supplier to the industries we serve, and will allow us to more efficiently deliver an expanded range of complementary

For further information: www.microcare.com

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About MicroCare, LLC MicroCare, LLC is a global company based in New Britain, CT (USA). Since 1983 it has focused on manufacturing safe, environmentally progressive

EXPERIENCE TECHNICAL CLEANLINESS

chemistries and tools used by industry for critical cleaning. These products are supplied to industries as diverse as electronics, metal finishing, transportation, communications, medical devices and aerospace with the goal of helping companies improve the performance and service life of products they make. MicroCare has an ISO 9001:2015 registered quality system and is continually improving and expanding its range of products. MicroCare products include the MicroCare™ critical cleaning fluids, Sticklers™ fibre optic cleaners, MicroCare Medical™ lubricants and Certol™ disinfectants among its brands.

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NEWS

ICT | INDUSTRY NEWS

25 years of SITA Messtechnik GmbH In December, Sita will celebrate its 25 years of innovation for quality and economic efficiency for the industrial cleaning industry. ITA Messtechnik GmbH will celebrate its 25th anniversary

The company operates worldwide in over 64 countries thanks to its

in December 2021. The international operating company

network of global partners.

headquartered in Dresden (Germany) was founded in 1996 by Prof.

With its solution and products, SITA Messtechnik GmbH has a long-

Dr. Lothar Schulze, who developed with his team innovative technology

term and sustainable impact on the areas of industrial parts cleaning

for measuring the dynamic surface tension of liquids and gradually

and surfactant analytics. The company is also an active member of

established the company as a market leader for measurement and

FIT, the Association for Industrial Parts Cleaning and supports training

control technology, as well as for quality assurance in the parts

and qualification in order to strengthen as well as technically and

cleaning industry by offering customised solutions for qualified process

qualitatively drive the industry. The management and innovative

management.

development that was shaped for 25 years by the owner Prof. Dr.

At present day, the company employs 27 professionals that develop,

Lothar Schulze, is now continued by the Managing Director Juliane

produce and sell products used for cleanliness inspection of

Schulze, CFO Robert Scheurle and the entire team of SITA Messtechnik

components and surfaces, as well as for monitoring process media

GmbH.

in cleaning processes. Customers of various industries such as the

The future objective is to strengthen and expand the worldwide

automotive industry, medical technology, electrical engineering and

position as a leading provider of measurement and control technology

electronics, the chemical industry, machinery and plant engineering,

for quality assurance in industrial parts cleaning.

as well as the aerospace industry use the intuitive mobile measuring devices and the robust Inline measuring devices.

For further information: www.sita-process.com

From left, Robert Scheurle, Juliane Schulze and Prof. Dr. Lothar Schulze.

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ICT | INDUSTRY NEWS

NEWS

Dollmar Won the EcoVadis Silver Medal for Sustainability Dollmar joined the EcoVadis rating programme and won the 2021 Silver Medal for sustainability.

ollmar Spa has joined the EcoVadis rating programme for the year 2021 with the aim of constantly improving its

commitment in terms of corporate sustainability. EcoVadis is an international certification provider that assesses the performance of companies in the categories of environment, labour, human rights, ethics, and sustainable procurement, giving them a score from 0 to 100. This assessment provides a picture of a company’s current sustainability level and better understanding of what can be further improved. Thanks to several internal initiatives to drive its business towards

25 Years of Innovation for Quality and Economic Efficiency in Industrial Cleaning Processes

a high level of sustainability, Dollmar was awarded the silver medal. “This important milestone is proof of our strong social responsibility, our constant will to improve, and our care for our employees, business partners, and not least the environment,” the company states. For further information: www.dollmar.com/cms/

MANY THANKS TO OUR PARTNERS AND CUSTOMERS. SITA MESSTECHNIK GMBH | Phone: +49 (0)351 871 8041 | www.sita-process.com

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ICT | HIGHLIGHT OF THE MONTH

DORIS SCHULZ SCHULZ. PRESSE. TEXT., Korntal – Germany ds@pressetextschulz.de

Reduced unit costs thanks to higher cleaning performance and lower energy consumption

Ecoclean launches EcoCcompact, the new compact plug & play system for efficient solvent cleaning and preservation.

EcoCcompact accomplishes cleaning tasks ranging from pre-cleaning and intermediate cleaning to final cleaning and preservation - fast, needs-based manner and at minimized unit costs.

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ICT | HIGHLIGHT OF THE MONTH

ith features such as a large batch capacity, improved washing

On the one hand, the working chamber’s standard diameter of 550

mechanics and wash fluid reconditioning, as well as energy-

mm results in a batch capacity which is ten percent higher than that of

optimized system technology with effective heat recovery, the new

conventional systems in this segment.

generation of EcoCcompact machines keeps unit cleaning costs low

On the other hand, the high flooding volume means that parts are

even when cleanliness requirements are high.

fully immersed in the wash fluid during the process. In addition, the

The small footprint and flexible changeover between hydrocarbons

powerful, frequency-controlled flood pumps not only ensure that the

and modified alcohols also contribute to the excellent economic

working chamber is filled and emptied quickly; they also achieve a

efficiency and future-proof concept of the compact plug & play

high mechanical cleaning effect during the standard injection flood

cleaning system from Ecoclean.

washing step. This can be further enhanced by integrating an optional,

Ever-stricter demands on component quality and rising product

frequency-controlled rotary drive to rotate and position the parts to be

diversity are calling for increasingly complex and versatile solutions in

cleaned in a specific way.

the parts cleaning sector.

Besides the high capacity and effective washing mechanism, the

To keep production competitive, it is also essential to minimize

EcoCcompact’s energy-optimized system technology makes the

resource consumption and unit cleaning costs while maximizing

machine even more economically efficient. For example, the second

cleaning performance.

and third flood tanks are warmed by heat recovered from the

The latest generation of the cost-efficient EcoCcompact solvent-based

distillation process. Among other things, this has led to a significant

system has been adapted to meet these requirements. Requiring a

reduction in energy consumption. Thanks to the efficient distillation

space of just 3,200 x 1,600 x 2,450 mm (L x W x H), the compact plug

process, the machine also has impressively low solvent requirements.

& play solution allows you to switch easily between hydrocarbons

This has been attained by installing the distillation unit in a vertical

and modified alcohols (semi-polar solvents) during ongoing operation

position, which requires hardly any mounting fixtures. The design

without any conversion work.

reduces sump formation, prevents dirt build-up and results in an extended bath life.

Optimal cleaning results achieved faster and more cost-effectively

A seven-inch HMI touch panel and self-explanatory pictograms

The machine comes with two or three fully-integrated flood tanks,

visualization also makes process tracking and maintenance easier and

each fitted with a filtration system in the supply and return lines in

more intuitive.

the form of bag-type or high-performance filters and bypass filtration.

With these features, the EcoCcompact not only meets the

This flexibility enables optimum results to be achieved in short cycles,

requirements of factories with comparatively low production capacities

all the way from pre-cleaning and intermediate cleaning tasks to final

and varying cleaning requirements but also those of large factories

cleaning and preservation.

with decentralized cleaning stations.

guarantees simple, safe and fast operation. Integrated parts

DORIS SCHULZ

ICT | TECHNOLOGY OVERVIEW

SCHULZ. PRESSE. TEXT., Korntal – Germany ds@pressetextschulz.de

Optimal cleanliness for the next production step The surfaces of parts that are coated or measured after machining must be exceptionally clean. To ensure that even small workpieces such as valve components and indexable inserts are cleaned reliably, more and more manufacturers are turning to the quattroClean snow-jet technology. This cleans single parts effectively and efficiently in a fully automated and integrated process.

he demand for precision, process reliability and high efficiency is

costs. At the same time, the trend towards automating and digitizing

causing many companies to put the processes and technologies

processes is playing an ever-more important role. Consequently, even

they use to the test and parts cleaning is no exception. This involves

where it concerns smaller components, manufacturers prefer a dry and

achieving the necessary level of cleanliness for the next production

fully automated cleaning solution such as the quattroClean snow-jet

step, such as coating or measuring, reliably yet at reduced operating

technology from acp systems AG.

During the process, a robot uses a specific motion sequence to move the cleaning unit over the valve components at a defined distance. To ensure reliable cleaning results, the consistency of the jet is continuously monitored by a sensor system.

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ICT | TECHNOLOGY OVERVIEW

Partial cleaning to remove dried impurities before PVD process

This was also the case with a valve manufacturer. The valve in question is a rotationally symmetrical part made of steel with a diameter of approximately five millimeters and a length of around five millimeters, which is partially coated in a PVD process. After machining, which generates heat, the surface is soiled with a mixture of dried-on machining medium (oil) and particles that is difficult to clean off. Although the amount of dirt is comparatively small, it is essential that it is removed from certain areas in order to ensure optimum adhesion and a long-lasting coating. A wet-chemical cleaning process was ruled out because of the high effort, space requirements and energy consumption associated with drying.

CO2 snow process optimally prepares surfaces for coating

The workpiece carriers, which are loaded with around 150 parts, are fed into and out of the cleaning cabin via appropriately-sized locks.

Extensive cleaning tests in the acp systems technical center demonstrated that partial cleaning with the quattroClean snow jet technology achieves the cleanliness needed to obtain an optimal coating result. The process uses liquid carbon dioxide as a medium. CO2 is a by-product of chemical

manufacturing processes and biogas energy generation, thus making it climate neutral. In the cleaning process, liquid carbon dioxide is passed through the inner ring of a wear-free, two-component ring nozzle and expands on exiting to form fine CO2 crystals.

This jet of snow is then bundled by a separate jacket jet of compressed air (outer ring) and accelerated to supersonic speed. The easy-to-focus jet of snow and compressed air impacts on the surface to be cleaned at a temperature of minus 78.5°C, triggering a combination of thermal, mechanical, sublimation and solvent effects. The cleaning action brought about by the interaction of these four effects removes the dried-on mixture of machining oil and particles in a dependable and reproducible manner. The detached impurities are carried away by the aerodynamic force of the jet of compressed air and eliminated from the cleaning cell together with the sublimated CO2 in the gaseous phase. This

reliably prevents parts from becoming recontaminated.

Tailored fully-automated process To clean the valve components, acp built the fully-automated Jetcell cleaning system using standardized modules, tailoring it to the application and to the manufacturer’s production conditions. The workpiece carriers are used both for the cleaning step and for the partial PVD coating process. Process

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The Jetcell cleaning system, designed as a stand-alone solution, has an integrated extraction unit to efficiently remove impurities and sublimated carbon dioxide from the system.

ICT | TECHNOLOGY OVERVIEW

parameters, such as the volume flows for compressed air and carbon

parts have been cleaned, the lock on the output side opens and the

dioxide, type of jet nozzle, distance of jet away from the part, cleaning

workpiece carrier is advanced to the encapsulated unloading area.

time, as well as the motion sequence, are appropriately adapted. This enables the required cycle time of six minutes for cleaning a fully-loaded workpiece carrier with around 150 parts to be met.

CO2 cleaning process integrated into measuring cell

Indexable inserts, which are manufactured in small quantities with

To optimally integrate the cleaning system into the existing workflow,

individual geometries and dimensions varying between ten and twenty-

buffer that holds five workpiece carriers is located on the input and on

five millimeters, have extremely tight tolerances that may not exceed

the output side. The carriers, which are marked with a digital matrix

one to two micrometers. To ensure this high accuracy, the entire

code to ensure seamless documentation of the cleaning process, are

contour of the carbide parts is measured at the manufacturer’s after

fed one at a time into the cleaning cabin via an appropriately-sized

grinding. Since impurities on the surface from machining residues and

lock. As soon as the lock is closed, the cleaning process starts. Using

grinding dust can cause measurement errors, in the past the inserts

a specific motion sequence, a robot moves the cleaning unit with jet

were cleaned manually at great expense. The manufacturer wanted to

nozzle over the valve components at a defined distance. A sensor

integrate this process into the automated production line. Here, again,

system continuously monitors the consistency of the jet. Once all

after cleaning trials and defining process parameters, the decision was

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made in favor of the quattroClean technology. In this case, a cleaning module was integrated into the measuring cell, which is docked directly to the grinding machine. This solution allows the existing robot to remove the inserts from the grinding machine via a lock, move them in a defined short motion sequence under the snow jet and then set them down neatly in the measuring area. The motion sequences, jet-cleaning times and respective volume flows for the various indexable inserts are all stored in the control system as part-specific programs. By precisely tailoring the cleaning step to the application and cycle time specifications, as well as being able to operate the system as a stand-alone unit, inline and in interlinked manufacturing environments, the Industry 4.0-capable quattroClean snow jet technology can play a major role when it comes to automating and digitizing production processes. Thanks to standardized interfaces, it is no problem to integrate the cleaning system into higher-level host computers and control it via these. To ensure seamless documentation and traceability, all process parameters are automatically recorded and transmitted to the host computer.

To clean the indexable inserts, a quattroClean module is integrated into the measuring cell. The parts are handled by the existing robot.

DORIS SCHULZ

ICT | TECHNOLOGY OVERVIEW

SCHULZ. PRESSE. TEXT., Korntal – Germany ds@pressetextschulz.de

Meeting defined particulate and film-type cleanliness specifications that can be reproduced and at the lowest possible cost. These requirements can only be implemented with cleaning solutions that are optimally adapted to the task.

Ecoclean: efficient and reliable cleaning with the optimum solution Today, parts cleaning has become a quality critical manufacturing step in all industry sectors. Often it takes great effort to reproducibly meet particulate and film-type cleanliness specifications. At the same time cleaning is to be done at the lowest possible cost. These contradictory requirements imperatively call for processes and machines tailored to specific needs.

rom machine and plant engineering, electrical and power

Although the parts are manifold, they have one thing in common:

engineering to connecting elements, the so-called general industry

to ensure the quality of downstream processes such as machining,

contains a multitude of sectors. In these industry sectors, components

heat treatment, coating, bonding and assembly and to guarantee

of the most diverse materials like metals, plastics, ceramic and

lasting functionality, they necessitate cleanliness levels in line with

composite materials are manufactured and processed using very

requirements. In many areas, ever higher requirements concerning

different manufacturing technologies.

particulate and film-type cleanliness must be met. And there are often

Products include, for example, cast and machined parts, stamped, bent,

added challenges such as high throughput rates and weights, a strongly

pressed and deep-drawn parts, hydraulic parts and, more and more,

varying range of parts to be cleaned, short delivery times and also small

additively manufactured components.

margins in some cases.

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ICT | TECHNOLOGY OVERVIEW

Adapting cleaning processes to tasks on hand

A matching process technology minimizes cleaning cost

This means there are

In order to minimize

different requirements for

the cost per cleaned

part cleaning. As supplier of

part, it is necessary that

complete future-oriented,

the existing cleanliness

flexible and energy-efficient

specification is not only

solutions for industrial parts

reliable, but also quickly

cleaning, Ecoclean covers

reached. Therefore the

the complete range of

systems are equipped with

wet-chemical procedures.

various application-specific

Cleaning processes and

treatment technologies such

systems for batch or single-

as spray, high-pressure,

part cleaning can be optimally

immersion, ultrasonic and

adapted to the respective specifications. To do so the following factors have to be

Solvent-based systems for wash load sizes up to 1,250 x 840 x 970 mm and weight of one ton for high throughput requirements are available.

plasma cleaning, vapour decreasing, injection flood washing, deburring, pulsated

taken into consideration: Material, size, geometry and weight of the

pressure cleaning (PPC) as well as a passivation/preservation process

part, type and quantity of contaminants, downstream process and

as required.

the resulting cleanliness specifications and throughput requirements.

By combining these cleaning procedures, the cleaning result and

On this basis it can be determined whether the contaminants can

duration for the specific parts can be influenced in a pinpointed

be removed most effectively with a water-based detergent, an

manner. The PPC procedure in combination with an aqueous or

environment-friendly solvent or a modified alcohol with lipophilic

solvent-based immersion cleaning for example, reliably and quickly

and hydrophilic properties. What is more, this information enables

removes contaminations from small cavities. In case of complex and

engineers to define the best suited process and drying technology.

bulk parts, spray processes and injection flood washing with adjustable

Besides the right cleaning fluid, the process technology - ultrasonics in this case - plays a vital role to reliably and quickly reach cleanliness specifications.

By integrating two cleaning processes in one system, such as wet-chemical and low-pressure plasma cleaning, quality, cost and cycle times can be optimized.

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ICT | TECHNOLOGY OVERVIEW

nozzles between 10 and 16 bar also deliver markedly improved cleaning results and shorter process times in solvent cleaning processes. Quality and cost can be optimized by combining processes that formerly required several machines in one single cleaning system. Among them are chamber machines designed for solvent-based or aqueous batch cleaning with a subsequent low-pressure plasma process. Among other things, this method effectively and efficiently prepares the part surface for a subsequent coating or bonding. Ecoclean’s extensive product range also offers the respective solutions for pinpointed deburring and cleaning of single parts, for example hydraulic and motor components in one system.

Dry-cleaning - selective or whole surfaces Cleaning tasks also change along with changing manufacturing and joining technologies. The focus lies more © Ecoclean

and more on dry-cleaning processes, be it for removing film-type contaminations from joint surfaces in a pinpointed manner, cleaning electronic components and assemblies, removing powder residues from additively manufactured components or cleaning integrated in assembly. For this and many more applications, the equipment manufacturer has developed a special toolbox for cleaning processes with atmospheric pressure plasma, laser, CO2

snow, conditioned vacuum air as well as saturated and dry water vapour. Depending on the specific application, these ‘tools’ too are applied alone or combined. This extensive portfolio of cleaning solutions is supplemented by Technology Centres around the world.

They perform tests with original soiled parts under conditions similar to production for all the different tasks existing in part cleaning.

From top: - The combination of high-pressure water jet deburring and low-pressure part cleaning processes enables efficient and automated processing of single parts, for example hydraulic components, in conveyorized manufacturing lines. - Dry cleaning methods such as vacuum air cleaning can be integrated into assembly lines and used for depowdering of additively manufactured parts.

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ICT | ZOOM ON EVENTS

DeburringEXPO Announced Satisfaction for the Success of its 4th Edition The DeburringEXPO has successfully met the expectations of both exhibitors and visitors.

ore than 1.100 visitors and 105 exhibiting companies from 12

Quality leads and significant RFQs

different countries attended the 4th edition of the DeburringEXPO,

Almost all of the 105 exhibiting companies were satisfied after the

the trade fair dedicated to deburring technologies and precision

three-day event. The organisers reported that 94% of the exhibitors

surface finishing held from 12 to 14 October 2021 at the Karlsruhe

expect now very good to satisfactory post-fair business. The trade fair

Exhibition Centre in Germany.

generated top-quality leads and substantial RFQs, in fact about nearly

The exhibiting companies showcased their new developments

44% of the visitors of the trade fair prepared or finalised an investment

and technologies, while participants had the opportunity to gather

decision. “As expected, fewer visitors attended the trade fair this year

information and industry insights about current trends, latest

than in previous years, but the quality is very good. Visitors are coming

developments and best practice solutions. Over 82% of the visitors

to our booth from widely differing industries with very specific tasks and

said they were very satisfied to satisfied with the offerings and more

projects, “commented Michael Striebe, sales manager for barrel finishing

than 75% would recommend the trade fair to colleagues and business

technology at Rösler Oberflächen GmbH.

partners.

“DeburringEXPO is very specialised and fits together perfectly with the

“For us there was no question that if DeburringEXPO would be staged

products we offer and the work we do. The visitors who come to the

as an on-site event, we would exhibit and present ourselves as a

trade fair are seeking solutions in a targeted manner. The quality of the

solutions provider for tasks in the field of deburring and precision

leads is excellent as a result. Furthermore, participating at the event also

finishing. And it was the right decision, because we were able to talk

provided us with the opportunity of meeting our customers face-to-

to existing customers about upcoming projects and their plans, and

face once again,” confirmed Jaume Miras, head of analytics and global

generate interesting new leads. We’re quite satisfied with the way

marketing at GPAINNOVA.

things went at the trade fair,” stated Maria Loula, managing director of

“We’re pleasantly surprised – not only by the number of leads, but

Perfect Finish GmbH.

rather by their quality as well. Interest in ultrasonic deburring is very

“Fortunately, DeburringEXPO has remained with us as an up-to-date

strong and visitors come to us with highly detailed requirements for

information platform. Not only does it provide a quick and adequate

specific components,” added Iris Münz, commercial director of ultraTEC

overview of new products, trends and innovations in the industry,

Anlagentechnik Münz GmbH.

it also facilitates an effective exchange of information with other

The next DeburringEXPO will be held at the Karlsruhe Exhibition Centre

exhibitors. For me, there couldn’t have been a better way to start

from the 10th to 12th October 2023.

participation at the trade fair”, declared Igor Pleis, sales manager at For further information: www.deburring-expo.de/en/home/

ATL Anlagentechnik Luhden GmbH.

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ICT | ZOOM ON EVENTS

Successful Restart for parts2clean With more than 2,000 visitors from Germany and neighboring European Union countries, parts2clean restarted successfully after the pandemic-induced break. Approximately 130 exhibiting companies, one in five of them from outside Germany, presented new products and solutions for a wide variety of industry applications at the meeting point for parts and surface cleaning.

arts2clean in Stuttgart demonstrated the increasing

provided a unique knowledge platform for all topics related

importance of cleaning processes

to parts and surface cleaning.

in the age of Industrie 4.0 and

Hundreds attended the forum

AI. Steadily growing demand for

on-site and 1,500 participants

clean surfaces and components

joined online. Frank-Holm Rögner,

requires highly efficient cleaning

division manager at Fraunhofer,

technologies as well as seamless

reported, “We are extremely

integration of processes

satisfied with the high level of

throughout the production chain.

participation in our forum, where

Exhibitors from more than ten

we were able to welcome not only

countries informed the trade

national but also international

visitors about new products and

visitors. The number of visitors

solutions for clean parts and

is lower overall than in 2019,

surfaces. “We are delighted that

but the quality is very good. The

parts2clean restarted so successfully and confirmed its role as the

topics ‘challenges due to film contamination’ and ‘cleaning for medical

most important international platform for industrial parts and surface

and pharmaceutical technology’ were particularly well received. There

cleaning,” says Arno Reich, senior vice president at Deutsche Messe

was also strong interest in the areas of standardization and guidelines

AG. “We are very satisfied with the number of visitors under the given

and the exhibitor product presentations. The demand for up-to-date

conditions, especially since the quality was extremely high.”

information is huge, which is a great position for the parts2clean forum.”

Roughly 2,000 visitors came to parts2clean in Stuttgart, one in five

The exhibitors were also completely satisfied.

of them from abroad. The strongest visitor countries were Austria,

Samuel Wolf, Assistance to the Management, vapic GmbH:

France, Italy, and Switzerland. Visitor quality was excellent: every third

“As the leading trade fair for industrial parts cleaning, parts2clean has

visitor came from top management, every fifth from the department

been the most important of all trade shows for us for years. What makes

manager level. Every third visitor came to part2clean with specific

parts2clean special is that customers come with specific project ideas

investment plans. The strongest visitor industries were the automotive

and want to develop solutions together on-site. Visitors demand a wide

industry (33 percent) as well as mechanical and plant engineering,

range of specialist knowledge to meet their requirements. We rate this

followed by medical and semiconductor technology and the aerospace

year’s show just as successful as parts2clean 2019 and thank all visitors

industry.

for their interest. We look forward to starting the new projects.” Wolfgang Kaufmann, Head of Sales, Zippel GmbH:

Innovations and further developments

“We were pleasantly surprised that on the morning of the first day we

parts2clean featured numerous new and further developments. Trade

had many visitors at the exhibit. That was the best morning at the show

show premieres included plant, process and process technology,

so far. The other two days of the fair were also very well attended. Of

clean and cleaning rooms, cleaning media and containers, work piece

course, we cannot compare the absolute number with 2019, but the

carriers and washing baskets, degreasing and cleaning solutions,

visitors who were at parts2clean were specifically looking for solutions

ultrasonic devices for cleaning, bathroom maintenance, cleanliness

and were not only interested in our standard systems, but also in tailor-

control, corrosion protection, and packaging.

made solutions, which we manufacture completely customer-specific.”

Expert forum a magnet for visitors Fraunhofer’s cleaning division organized the parts2clean forum, which

For further information: www.parts2clean.de/en/

international PAINT&COATING magazine - NOVEMBER/DECEMBER 2021 - N. 72

187

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Department of Chemistry, Material and Chemical Engineering, Politecnico of Milan – Section of Applied Chemistry and Physics

The Powder Coating Research Group

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Dr. Fulvio Zocco:

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ipcm® n. 72 - November/December 2021

Articles inside

ICT - TECHNOLOGY OVERVIEW

SPECIALIZED TRAINING

ZOOM ON EVENTS

STANDARD & LEGISLATION

THE MARKETING CORNER

ART WITHIN SURFACES

ART WITHIN SURFACES

SUSTAINABILITY

SUSTAINABILITY

SUSTAINABILITY

INNOVATION: PRESENT&FUTURE

INNOVATION: PRESENT&FUTURE

BRAND NEW

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HOW IT’S COATED

MARKET CLOSE UP

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IPCM IN REVIEW

EDITOR’S LETTER

HIGHLIGHT OF THE MONTH