ipcm® n. 51 - May/June 2018 by ipcm® International Paint&Coating Magazine

The first international magazine for surface treatments

ISSN 2280-6083

ipcm digital on In this issue :

SPECIAL AUTOMOTIVE

INDUSTRIAL CLEANING TECHNOLOGIES

INTERNATIONAL PAINT&COATING MAGAZINE

www.myipcm.com 2018

9th Year - Bimonthly N° 51 - MAY/JUNE

Drylac®

3D Metallics

A NEW DIMENSION IN EFFECT POWDER COATINGS • Liquid paint-like 3D effects in one-coat • Brilliant and bright effects • Easy-to-apply: minimal equipment inﬂuence

www.tiger-coatings.com

Ace the test: Thanks to innovative corrosion protection for the entire chassis. JUNE

5– 7 th

Safety for the entire chassis: our zinc lamella systems can perfectly protect large and geometrically challenging components – even when subjected to stone chipping and a subsequent salt spray test. This is high-performance corrosion protection at a new quality level: Dörken MKS –The Corrosion Experts. Learn more about our automotive competences at www.doerken-mks.com

echno Surface T rt a g in Stutt 7 0 1C th o Bo

log y

Reliability and Experience at your Service Tosca srl is a leading company for over 50 years in the design and construction of shot blasting machines and shot blasting plants for surface treatment. In a site area of 30.000 mq and a reference of over 4.000 worldwide shot blasting machines installations, Tosca srl produces in accordance with Industry 4.0 ensuring extremely reliable products thanks to high engineering skills and advanced know-how where the details make a difference.

FATI

NOVITÀ

srl

NEW NEUHEIT

CATENE PER TRASPORTATORI - CUSCINETTI A SFERA

CATENE AD ALTE PRESTAZIONI HIGH PERFORMANCE CHAINS | LEISTUNGSFÄHIGE KETTEN

HPCOAT

con | with | mit HPCOAT

FATI srl

Resistenza alla corrosione Corrosion protection | Korrosionsfestigkeit Durata alle alte temperature Life-time at high | Beständigkeit gegen temperatures | hohen Temperaturen Autolubrifcazione Self lubrification | Selbstschmierung Produttività Productivity | Produktivität

senza | without | ohne HPCOAT

LESS

Particolare are dei d cuscinetti n con HPCOATT Detail D t il off bbearing i with ithh HPCOAT AT Ausschnitt der Lager mit HPCOAT

Aspetto dopo 200 ore in nebbia salina Surface after 200 hours of salt spray test Aussehen nach 200 Stunden in Salzsprühtest

CONTENTS MAY/JUNE 2018

SPECIAL AUTOMOTIVE

FOCUS ON TECHNOLOGY

SUCCESS STORIES

Ferrari: The Italian Automaker Revolutionises the Car Painting Process with a Low Cure Clear Coat System

Coating Gas Cylinders Uniformly

SP EC IA L A U TOMO T IVE

SP ECIAL AUTOMOTIVE

FOCUS ON TECHNOLOGY

56 05 06 14

Highly Automated Coating at the Service of Italian-Made Automotive Luxury

EDITOR’S LETTER BRAND-NEW HIGHLIGHT OF THE MONTH Next Generation of Powder Coating: WAGNER Presented IPS Coating Centre at PaintExpo 2018

16 18

29 30 50 64

HIGHLIGHT OF THE MONTH

BRAND-NEW BUSINESS CARDS

Smart Service Solutions for Factory 4.0. Data-Based Services Secure Rapid and Effective Customer Service

SPE C IAL AU TOMO TIVE

BRAND-NEW

84 106

BRAND-NEW FOCUS ON TECHNOLOGY Gestamp’s New Cataphoretic Coating Plant Enables 4.0-Oriented Communication

BRAND-NEW

No Chance For Legionella

20 26

INNOVATIONS: PRESENT&FUTURE

HIGHLIGHT OF THE MONTH Biomass Balance Approach, Functional Coatings for Energy Management, and New Colour Trends to Emphasize The New Mobility: BASF’s Answers for Present and Future Requirements of the Automotive Industry

BRAND-NEW STANDARD & LEGISLATION - UCIF INFORMS Industry 4.0: the Challenges of 2018

108 110 118

TRADE FAIRS & CONFERENCES ZOOM ON EVENTS ICT - ANALYSIS The Future for Solvent Vapour Degreasing Equipment. Innovation Driven by Legislation

studiocolore.it

the Power of Colour P O W D E R

C O A T I N G S

TECHNOLOGY INNOVATION SERVICE PERFORMANCE

www.ripol.com

CONTENTS MAY/JUNE 2018

FOCUS ON TECHNOLOGY

INNOVATIONS: PRESENT&FUTURE

Why Automate your Paint Booth?

104 122

INNOVATIONS: PRESENT&FUTURE

Innovative Spray Stripping Systems: Alit’s New Products Presented at PaintExpo 2018

ICT - HIGHLIGHT OF THE MONTH

144

Economical Cleaning Solutions Are the Factor for Success

124 126

ICT - CASE STUDY

132

ICT - CASE STUDY A Low Emission Cleaning Machine for a High Quality Production: SATA’s Commitment to the Environment and Production Flexibility

138

ICT - CASE STUDY

Parts Cleaning Ensures Added Value

ICT - TECHNOLOGY OVERVIEW Sustainability at Service of the Customer: Biokavitus Solutions for Recovering and Reusing Emulsions and Water from Industrial Processes

ICT - INDUSTRY NEWS

Cleaning With Fixed Jets to Effectively Remove Swarf from Aluminium Components for Steering Systems

Full Automation ‘Batch 1’ – Powder Coating for Production of Entrance Door Panels

146

150 152

ICT - HIGHLIGHT OF THE MONTH High Quality, Eco-Friendliness, and Research in Contracting Cleaning Services

ICT - TECHNOLOGY OVERVIEW In-Line CO2 Snow-Jet Cleaning Process to Clean Lighting Components Before Coating. Reject Rate Significantly Lower Since Changing Over to Different Cleaning System

ICT - TECHNOLOGY OVERVIEW How to Overcome Aluminum Parts Cleaning Challenges

158

ICT - INDUSTRY NEWS

Top Quality Coil coatings Since 1978 coil coatings for building, industry, and packaging for

Aluminium closures

for for

TAB stock

Indoor

for for

Valve caps

Food containers

for

Pharma caps

• Antiﬁnger for stainless steel • High gloss PE coating • Laminated system

for

Outdoor • Anti-skid coating • Copper imitation • PE coating • PUR/PA cycle • PVdF cycle • Wood effect • Wrinkled coating

Innovative coil coatings Worldwide market presence High performance paints and inks Salchi Metalcoat Srl Viale dell’Industria 3/A-3/B - 20875 Burago di Molgora (MB) ITALY Ph. +39 039 6251824 Fax +39 039 6251829 E mail: info@salchirh.it - www.salchimetalcoat.com

EDITOR’S LETTER

Nowadays, quality is an imperative for any durable consumer good.

Richiedi la versione in italiano a info@ipcm.it

In a life of consumption subjected to the tyranny of the moment (from “Consuming life” by Zygmunt Baumann, 2007), the “fast” philosophy has imposed itself in some market segments (let us think about the spread of fast fashion), i.e. the consumption of goods that are easy and quick to produce as well as replace because they are cheap, conformed, and of poor quality. In other sectors, however, consumers prefer to purchase robust goods, based on sophisticated technologies, with durable, wellfinished, and aesthetically pleasing surfaces, and highly customised. One of these sectors is the automotive one. The car industry is going through a boom period, especially in Asian markets, and OEMs are making significant investments to offer vehicles with superior performance in any segment. Whereas driving performance and comfort are the first factors in the choice of a car, we know that its surface is the “emotional factor” that determines its purchase. In medium-high market segments, consumers increasingly tend to prefer specialeffect colours and multi-layered, iridescent, and matt surfaces. On the other hand, the choice of increasingly lighter construction materials, such as aluminium and carbon fibre, for greater consumption efficiency and lower environmental impact entails new challenges in terms of coating. Furthermore, the trend towards evergreater personalisation calls for the implementation of coating technologies combining speed, efficiency, quality, and extreme flexibility. The era of Industry 4.0 and production digitalisation helps meet all these needs, and the latest developments in chemistry enable the formulation of increasingly sophisticated coating products, with a much lower environmental impact than in the past. Water-based base coats and two-component clear coats are now a reality in the automotive industry, while the first low cure systems are starting to appear, allowing to simultaneously coat different substrates, e.g. aluminium and carbon. This issue of ipcm® includes a technological premiere: Ferrari, the Italian manufacturer of sports cars that are the dream of any passionate motorist, is the first OEM to have implemented a coating system curable at low temperatures for clear coat layers. This project required an 18-month old design and industrialisation process and the involvement of various technology partners, both for the plant and product aspects. It is an absolute novelty in the world of automotive coatings, as well as a solution to the long-standing problem of coating different substrates in-line with the same finishing quality. You will find this and much more in the issue of ipcm® you have in your hands, including a feature article about the technological trends in the auto industry, which has always determined colour trends and driven the development of advanced products and technologies that later reach other sectors…

Alessia Venturi

When the automotive one is already thinking about the next step.

Editor-in-chief Direttore Responsabile

international PAINT&COATING magazine - MAY/JUNE 2018 - N. 51

BRAND-NEW

Chemetall® Receives Airbus SQIP Award for the Fourth Consecutive Time

Figure 1: Chemetall has been awarded the highest supplier award in the Airbus Supply Chain & Quality Improvement Program called SQIP. The award was handed over to Christoph Hantschel, Global Product Manager Aircraft Sealants & CICs, Hendrik Becker, Global Aerospace Manager, and Nicholas Cush, Global SIOP Manager.

he Surface Treatment global

For the fourth consecutive year, Chemetall

Ardrox® products, which meet the

business unit of BASF’s Coatings

achieved the “Accredited Supplier” status

strict requirements of the international

division, operating under the

(Fig. 1). The award acknowledges sustained

aerospace industry.

Chemetall brand, has been awarded the

quality and delivery performance, strong

“We are extremely proud to once again

highest supplier award in the Airbus Supply

continuous improvement and customer-

receive this prestigious award, which

Chain & Quality Improvement Program

oriented approach. Chemetall supplies

values the dedication and commitment

called SQIP.

Airbus with high-quality Naftoseal and

of the Chemetall team in line with Airbus

N. 51 - MAY/JUNE 2018 - international PAINT&COATING magazine

BRAND-NEW

targets and expectations in 2017,” says Hendrik Becker, Chemetall’s Global Aerospace Manager. “Winning the award for the fourth consecutive year is a great honour for our long-lasting and successful business relationship with Airbus.” In 2017, Chemetall strengthened its supply chain. “We implemented several projects to further improve the performance of our European aerospace supply chain and strongly supports the ramp-up of the Airbus A320 and A350 programs,” says Ronald Hendriks, Quality Manager and SQIP Coordinator.

Airbus reviews the performance of its suppliers The aim of the Airbus Supply Chain & Quality Improvement Program, known as SQIP, is to advance the major strategic Airbus suppliers towards the goal of industrial excellence with regard to product quality and delivery reliability. In view of increasing production rates, this goal is of particular importance. Every year, the performance of each participating supplier is reviewed and either confirmed or – in case of non-conformity with the requested quality standards – downgraded or even rejected. “We are delighted about this supplier award from Airbus. It acknowledges the continuous efforts of the Chemetall team and our commitment to deliver high quality service and products. Operating as a brand of BASF’s Coatings division, we look forward to supporting the Airbus growth strategy even more now and in the future,” says Dr. Martin Jung, Senior Vice President Surface Treatment. “The combination of expertise and innovation power will accelerate innovation and drive even more success for our customer, Airbus.”

Chemetall has a long-term partnership with Airbus Over the past 25 years, Chemetall and Airbus have established a long-lasting and successful business relationship. From production sites in Langelsheim/Germany and Soissons/France, Chemetall supplies several Airbus sites with aircraft sealants, corrosion protection products, cleaners and pre-treatment technologies. In September 2017, Chemetall received the Airbus Best Performer Award for top level industrial performance and significant contributions in partnering with Airbus. Starting in spring 2018, Chemetall will expand its production site in Langelsheim, Germany, to fulfill the increasing global demands for aircrafts. For further information: www.basf-coatings.com

BRAND-NEW

DSM Launches Higher-Performance Matte Powder Coating Technology Resin

oyal DSM, a global science

for OSM matte powder coating solutions.

is a sustainable development partner

company active in health, nutrition

With the new Uralac OSM resins,

with global commitment. Specifically,

and materials, has launched a

manufacturers can more easily reproduce

powder paint manufacturers can now

new proprietary Uralac one shot matte

the same matte coating finish. Finally, the

offer lower cure OSM powder coatings,

(OSM) HAA powder coating resin system

new Uralac OSM HAA system also enables

with lower crosslinker content, better

that delivers better reproducibility and

lower crosslinker levels than other current

reproducibility, and excellent overall

enables lower crosslinker levels and curing

OSM alternative systems, driving the

performance properties. Over the coming

temperatures than current one shot matte

cost-effectiveness of matte powder

years, DSM will look to further broaden its

alternatives (Fig. 1).

coating solutions.

matte powder coating product portfolio,

The new Uralac OSM HAA powder coating

Marten Houweling, Global Product

in line with consumer trends and market

resins are being rolled out globally and can

Manager Powder Coating Resins, DSM: “By

demands.”

be used for a wide range of industrial matte

addressing the growing market demand

applications.

for higher-performance matte powder

For further information:

Thanks to DSM’s R&D efforts, the innovative

coating solutions; it shows that DSM truly

www.dsm.com

Uralac OSM P8014 and P8019 resins © DSM Engineering Plastics

enable a step change in performance for OSM powder coatings for industrial applications, delivering several important user advantages. In particular, unlike other commercially available OSM low-gloss powder coating solutions, which usually offer cure temperatures of 200°C, DSM’s newly launched Uralac OSM resin system can be cured for 10 minutes at 180°C or 20 minutes at 160°C, enabling a lower manufacturing carbon footprint. In addition, the new Uralac OSM resins successfully tackles the common drawback of poor reproducibility

Figure 1: Royal DSM has launched a new proprietary Uralac® one shot matte (OSM) HAA powder coating resin system that delivers better reproducibility and enables lower crosslinker levels and curing temperatures.

N. 51 - MAY/JUNE 2018 - international PAINT&COATING magazine

Paint Engineering

Premium quality Formulation, design and manufacture adapted to technical requirements, and highly complex facilities.

Anticorrosive systems

Coil Coating Superdurable Superdurable coatings for sublimation effect Metallic bonding

www.titanpowdercoatings.com

BRAND-NEW

Ecopure® CCF Removes Three Pollutants from Exhaust Air Simultaneously

he Ecopure® CCF from Dürr is

generation. The heart of Dürr’s new

the strongest warning level for polluted air in

a combination technology that

technology is the Catalytic Candle

China. The manufacturing processes do not

simultaneously filters dust, sulfur

Filters (CCF). The catalytically coated

have to be interrupted even during service

dioxides, and nitrogen oxides from

filter candles, which can withstand

work on the filters, since their modular

exhaust air. Three individual processes

temperatures of up to 716°F,

design means that they can be individually

are combined into one system for this

simultaneously remove dust, sulfur

shut off. During maintenance, the exhaust

to occur. The compact design of the

dioxides (SOx), and nitrogen dioxides

air of the module to be serviced can be

Ecopure CCF means that even existing

(NOx) from the exhaust air.

easily distributed to the other modules.

industrial plants with limited space can be

This method makes it possible to

The Ecopure® CCF is already proving its

retrofitted. The Clean Air Alliance of China

achieve clean gas values up to 50%

performance in practice in China. Glass

has presented Dürr the Bluetech Award

below the current Chinese emission

producer Libbey is the first manufacturer

for this technology, which recognizes high

limits. This gives leeway for tighter

to use the new exhaust air purification

standards in air pollution control (Fig. 1).

limit values in the future and today

technology in its plant in Beijing.

For the last three years, the Clean Air

makes it possible to continue

Alliance of China (CAAC) has been giving

production without restrictions even

For further information:

awards to international emission reduction

when there is “Level 1 Alarm” in effect,

www.durr.com

be used to improve air quality in China. Above all, the Alliance assesses real measurement

methods which can

results, the environmental benefits, the technological contribution, and the financial sustainability of the technology. There were 63 applications from 13 countries for the latest Bluetech Award. Dürr received the coveted award for its newly developed Ecopure® CCF technology. The Ecopure® CCF can help to reduce air pollution in all energyintensive industries with high levels of pollutant emissions, such as glass making or the use of coalfired boilers for electricity

Figure 1: Harald Zysk, Director of the Clean Technology Systems Division of Dürr China, with N. Bruce Pickering, Vice President of the Asia Society and committee member of the BlueTech Award during the Award ceremony.

N. 51 - MAY/JUNE 2018 - international PAINT&COATING magazine

BRAND-NEW

Brand New Palette for 5L4 Matt Series

uropolveri is always careful to

excellent durability and high resistance

- gives Europolveri a range of around

understand and anticipate its

to atmospheric agents as they are

1.000 different products, with very short

customersâ&#x20AC;&#x2122; needs and to realize

formulated in compliance with Qualicoat

delivery time that grants high quality

the most appropriate tools to help them

Class 1 technical requirements and were

service to the final customer.

choosing correctly.

implemented for the architectural market.

The products available on stock are RAL ÂŠ Europolveri

By the end of 2017 Europolveri announced the arrival of a â&#x20AC;&#x153;mysteryâ&#x20AC;? object that is a new palette

colors - in compliance with C.E.P.E. (05-05-2014) - with gloss level of 25 Âą 5; there

developed with the intent to ease

is availability also of the 17

and speed up customersâ&#x20AC;&#x2122; choices.

pearled colors present in the

This new tool is now available and it is

K7 RAL Chart.

able to amaze for its unique format,

Using correct coating cycles,

its chromaticity and the ability to

the final user can reach the

attract for its originality. This new tool

highest protection to corrosion

is made up by a carton box with two

C5M-H (EN ISO 12944-2) in

palettes that compose the new 5L4

compliance with Qualisteelcoat

Matt Series.

(QSC) requirements.

The new collection of powder

Europolveri technical support

coatings 5L4 Matt features all the

is always available to give practical and technical

207 RAL Colors in matt version. The products are applied on

information to recommend the

aluminium panels and each of them

Figure 1: The new palette of the collection Europolvei 5L4 Matt.

has its own description with technical

best coating cycles that involve specific Primer homologated for QSC cycles.

characteristics and data on the back (Fig. 1).

These 207 products of the 5L4 Matt

It emerges from Europolveri vision its

The new 5L4 Matt Collection is part of

Collection are all available on stock, with

willingness to innovate through the

the 5L Pural Series, Polyester Qualicoat

a minimum order of 25kg, as to show the

research and the development of new

without TGIC, suitable for aluminum

willingness to widen the product range

and astonishing solutions.

profiles or steel application and wherever

and to increase the presence on the

high resistance to weathering is

market. This new Collection - together

For further information:

required. Indeed, all the products ensure

with the 750 products already on stock

www.europolveri.it

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BRAND-NEW

oyal DSM, a global science

DSM Launches Uralac® Ultra Website to Mark New Stage of Powder Coating Solutions for Heat-Sensitive Substrates company active in health, nutrition and materials,

has launched a dedicated Uralac® Ultra website – www.dsm.com/ ultra – to mark a new chapter for this breakthrough technology, which enables first-time-right powder coating of heat-sensitive substrates such as mediumdensity fiberboard (MDF – Fig. 1). DSM has pioneered the development of polyester resins for powder coatings since the 1960s. Uralac® Ultra was developed specifically for use on MDF and other heat-sensitive wood products. While other commercially available resins cure for longer periods of time at

temperatures of around 170°C, Uralac® Ultra resins can be cured at around 130°C in three minutes.

Figure 1: Royal DSM has launched a dedicated Uralac® Ultra website – www.dsm.com/ultra – to mark a new chapter for this technology, which enables first-time-right powder coating of heat-sensitive substrates.

The new Uralac® Ultra website provides general information about the

Resins said: “In line with our customer-

said: “My company switched from using

various products in DSM’s expanding

centric approach, the new website

liquid paint to powder coatings, and we’ve

product portfolio, specific information

addresses the growing demand by

never looked back. Thanks to Uralac® Ultra

about the Ultra powder coatings,

OEMs, furniture coaters and designers

technology, we’ve achieved a ten-fold time

application results at leading brands, and

for information about the Uralac Ultra

reduction in our panel coating process – but

further details of DSM’s comprehensive

technology and DSM’s services. More than

make no mistake, this increased speed has

service package. Through the new

ever, Uralac Ultra is an attractive product

not impacted at all on quality. In addition,

website, samples can be requested,

because of its unique value proposition,

with Uralac® Ultra, our customers can

schedule test runs at the test facility in

addressing; environmental, practical and

achieve ‘green’ credentials in their proposed

Zwolle, the Netherlands, and calculate

aesthetic advantages. It’s the logical choice

tenders for local and national government

specific efficiency gains to experience the

when phasing out traditional solvent-

new builds.”

benefits of this exciting solution.

borne solutions.”

Martijn van Gurp, Business Director

Paul Maeyninckx, Owner, Kempa, a

For further information:

Innovation, Powder Can & Coil Coating

high-end kitchen cabinet manufacturer

www.dsm.com/ultra

N. 51 - MAY/JUNE 2018 - international PAINT&COATING magazine

ÂŠ Wagner

Opening photo: The IPS coating centre is an integrated complete solution that achieves consistently high coating results over a much longer period of time than conventional powder centres on the market.

HIGHLIGHT OF THE MONTH

Next Generation of Powder Coating: WAGNER Presented IPS Coating Centre at PaintExpo 2018 Katja Villnow Wagner Group, Markdorf, Germany

katja.villnow@wagner-group.com

AGNER Industrial Solutions

achieve perfect results. Powder preparation,

increase. At the same time, end customers

presented a revolutionary powder

feeding and dosing are accommodated in a

want more individual products, which leads

coating system at the PaintExpo

closed system, which automatically carries

to smaller batches and more frequent colour

trade fair in April: the IPS coating centre

out colour changes at the push of a button.

changes. In addition, there is the shortage

is an integrated complete solution that

The IPS coating centre thus opens up a new

of skilled workers, which is already having an

achieves consistently high coating results

dimension of system availability, productivity

impact on performance and quality in some

over a much longer period of time than

and user-friendliness.

countries. WAGNER Industrial Solutions will

conventional powder centres on the market

Globalization and digitalization are increasing

launch a revolutionary solution for these

(ref. Opening photo). All process steps can

the competitive pressure in the industry - also

diverse challenges. The IPS coating centre is a

be fully automated and centrally controlled,

in the field of powder coating. Plant availability

fully automated system that enables decisive

so that even less experienced operators can

and productivity must therefore continue to

improvements in the powder coating process.

N. 51 - MAY/JUNE 2018 - international PAINT&COATING magazine

HIGHLIGHT OF THE MONTH

Consistently high coating quality

live monitoring of key figures and an

basic concept of the new coating centre: Integrated Powder System. Only through

The automated colour change and easy

level of integration and automation of

an integrated approach, it is possible to

operation via a flexibly placeable touch

the IPS is unique in the market. This was

achieve increased productivity, consistently

screen also reduce the risk of operating

also confirmed to us by visitors at the

high quality and simple operation.

errors, which can quickly lead to rejects

PaintExpo. The enthusiasm was great,”

The result is a world premiere that

and renewed cleaning. “We know that

says Eric Gounon, President Sales EMEA

redefines powder coating and colour

many powder coating companies are

at WAGNER. “The IPS is one of this year’s

change processes,” explains Michael Topp,

faced with the question of how they can

highlights in the field of powder coating

Senior Product Manager at WAGNER.

achieve consistently high coating quality

and the numerous pre-orders show that

“In combination with a self-cleaning powder

without experienced specialists. For

we have struck a nerve with companies in

booth, a powder recovery system, guns and

us, the IPS coating centre is the answer

the powder coating business. With the IPS,

other components, the IPS is the first fully

because we have replaced manual

we react to their requirements and thus

automated powder coating system to be

activities with automated processes,”

we prove our PaintExpo motto – “Your

configured”.

explains Michael Topp. An example for

efficiency, our innovations”.

“The abbreviation IPS stands for the

Integration and automation for high system availability

interface to the WAGNER service. “The

this is the Smart Feeding Technology (SFT), which WAGNER has developed for

In the IPS coating centre, key functions

the powder feeding system: the powder

are interlinked: the SMART BOXER for

Several factors ensure high system

feeding with the aid of recovered fluid air

automatic, intelligent fresh powder supply

availability for the IPS: the IPS fresh powder

and an electronically controlled metering

directly from the box, the IPS MASTER

system SMART BOXER can hold two

valve with sensors creates an almost

for powder preparation, feeding and

powder boxes, which reduces the risk of

wear-free, high-performance system. This

dosing, the IPS system control, the flexibly

system downtime due to powder shortage.

offers the advantage that the parameters

placeable touch screen operating unit and

Integrated sensors also allow automatic

no longer have to be readjusted manually

interfaces to higher-level controls such as

powder consumption recording for each

- a task that repeatedly required the

MES and ERP.

coating batch. In the heart of the coating

attention of experienced operating

centre, the IPS MASTER, WAGNER has

personnel. The powder output is

In the IPS MASTER, powder preparation,

integrated powder preparation, feeding

permanently monitored by the sensors,

feeding and dosing are combined in a

and dosing in a closed system, including an

which guarantees high process reliability

closed system. Fully integrated ultrasonic

ultrasonic sieve as an important element

- up to a powder hose length of 30

screening and the Smart Feeding

for high coating quality. The system allows

meters. With these and other technical

Technology enable consistently high

the entire unit to change colour from five

innovations, the SFT powder feeding

coating results. The colour change is fully

minutes - depending on the colour tones.

and dosing system ensures constant

automatic at the touch of a button and

Where the operator has to manually clean

conditions over a very long period of time.

achieves a very high cleaning efficiency

conventional powder centres, is exposed to

with the new Airblade cleaning unit in

is completely automatic. The cleaning

Innovative powder coating reduces production costs and shows optimization potential

intensity can be adjusted according to the

High system availability, fewer manual

on the colour tones. The cleaning intensity

colour change. The automated process

activities, simple operation, reliable

can be adapted.

offers companies clear advantages, as

coating quality, reduced wear and

the trend towards individualization and

energy consumption lead to lower

The SMART BOXER can optionally hold

smaller batch sizes is also having an impact

overall production costs. In addition,

two powder boxes. The powder supply

on the painting sector. Both trends result

companies that coat many workpieces

then switches automatically between

in more colour changes, which in turn

every day are ideally positioned for

the boxes. This reduces the risk of plant

reduces productivity. The IPS coating centre

production 4.0 with the IPS: The coating

downtime due to a lack of powder. The

counteracts this by enabling high system

centre can be connected to WAGNER’s

integrated automatic powder consumption

availability with the fast, fully automated

Internet of Things solution, which, for

measurement supports cost calculation

cleaning process.

example, provides graphically prepared

and allows extended quality monitoring.

powder dust and the powder contaminates the environment, the IPS cleaning process

combination with pulse cleaning. All in all, a colour change of the entire system can be carried out in five minutes, depending

international PAINT&COATING magazine - MAY/JUNE 2018 - N. 51

BRAND-NEW

SAT is All Around the World

AT is in the middle of spring: a very

with a coating line in every strategic

Finally, SAT has just finalized the

hectic period for the company.

warehouse.

installation of a vertical pre-

Its technicians are travelling all

Of course, they never forget their first

treatment plant in Wymondham

around the world, taking care of the

love, TREVISAN vertical powder coating

for the company Barley Chalu.

supervision and installation of several

plant: SAT’s technicians travelled to

All these are very important

vertical plants (Fig. 1).

Fougeres to supervise the installation of

and challenging projects for

Claudio and Daniele, their electrical

a new vertical powder coating line with

SAT, which wouldn’t be possible

technicians, brought to completion

2 CUBE powder coating booths for the

without “all the customers who

the start-up of the first FOX of the UK

French company SFPI. Then they have

chose SAT and last but not

market for the company Aluk. The line in

flown for more than 16.000 kilometres

least, its skilled and competent

Chepstow will be the 6th plant with flash

to Melbourne - Australia to follow the

technicians”, as declared by the

oxidation technology in the world since

start-up of a new vertical powder coating

company.

2010.

line with 2 CUBE powder coating booths

But what is FOX? FOX is an innovative

for the company APA (Aluminium Profiles

For further information:

technology entirely designed by SAT and

Australia).

www.sataluminium.com

patent approved in January 2014. It allows to perform

covered with a European

the flash anodizing process automatically and in-line along a vertical powder coating line. Moreover, the CUBE army is spreading everywhere: in Portugal for Aluminio Navarra and in Sri Lanka for Alumex. It appears clear that CUBE has a huge potential, since it gives the opportunity to get very high quality with low production cost, which makes the customer immediately competitive in the market. On the other side, the product also targets towards big companies, willing not to concentrate the production in one single headquarter but bringing the coating service closer to their end-customers,

Figure 1: A vertical plant supplied by SAT.

N. 51 - MAY/JUNE 2018 - international PAINT&COATING magazine

Meet the world’s most experienced rookie.

Say hello to a remarkable business partner: We combine decades of expertise with the enthusiasm and dedication of a start-up. With the united powers of Silica products, TEGO® additives, and specialty additives of former Air Products, we oﬀer innovative and tailor-made solutions that deliver real value for your coating formulations.

Coating Additives of Evonik. Home of ACEMATT®, AEROSIL®, SURFYNOL®, and TEGO®. And much more.

HIGHLIGHT OF THE MONTH

No Chance For Legionella Tina Müller Freudenberg Filtration Technologies, Weinheim, Germany

here is no reason to be alarmist”, said Jürgen Becker, who is globally responsible

“T

tina.mueller@freudenberg-ﬁlter.com

for surface treatment at Freudenberg

Filtration Technologies. Nevertheless, the new version of the Federal Emission Control Act (42nd BImSchV) is causing paint shop operators to fundamentally review their existing exhaust air treatment systems. If wet separators are used to separate the paint overspray, the amendment to the regulations will require stricter inspection and documentation to be carried out. Wet separation systems must now be designed in such a way that they exclude any contamination of the environment by Legionella via the exhaust air. A legally compliant, technically effective and economically efficient alternative is dry paint separation, for example using edrizzi® paint mist separators from Freudenberg Filtration Technologies. For smaller spray booths, the handy boxes are the first choice anyway. Thanks to new concepts from various plant manufacturers, this now also applies to large, permanently high-capacity plants (Fig. 1). To enable risk-free testing, Freudenberg Filtration Technologies will install individually designed demonstration systems directly at the customer’s plant, without having to uninstall the existing wet separation system beforehand. This service is offered in collaboration with renowned plant manufacturers. Caused by Legionella infection, Legionnaire’s disease can be fatal in humans. The pathogen is a waterborne bacterium. The source of infection is often the moist and droplet-laden exhaust air from cooling towers, recooling plants or wet separators. For this reason, the 42nd Ordinance to the Federal Emission Control Act seeks to minimize the risk of infection by microorganisms as much as possible.

“Wet separation plants are well established in the industry. They allow stationary operation with constant process parameters”, Becker explained. However, these systems have a number of

N. 51 - MAY/JUNE 2018 - international PAINT&COATING magazine

Figure 1: Example of a paint shop equipped with edrizzi® dry separators.

HIGHLIGHT OF THE MONTH

serious disadvantages, including considerable investment and operating costs as well as high energy consumption due to pressure drops. In addition, the environmental impact of water consumption, coagulation chemicals and the costly disposal of paint sludge all have a negative impact. Not to mention the noise and odor nuisance suffered by employees involved in the painting process, as well as the corrosion problem. Added to this are the hygiene challenges and health risks already mentioned. In the context of the current amendment to the Act, these risks necessitate considerable additional effort and costs for the operators. Particularly risky are systems with heat recovery systems, in which a suspected bacterial contamination of the water can be transferred to the supply air. An effect that has even gone unnoticed in the current revision of the Emission Control Act. The legally compliant, hygienically clean and resource-saving alternative is “dry instead of wet”. Dry separation of the overspray without using water at all is suitable for new investments as well as for conversions of existing plants. This applies equally to smaller installations as well as to large, high-capacity paint plants in the automotive industry.

High separation eﬃciency of up to 97 percent An ingeniously simple solution is offered by edrizzi® paint mist separators made of fire-retardant corrugated board from Freudenberg Filtration Technologies. Their intricate internal design gives them an enormous overspray absorption capacity, achieving separation efficiency of up to 97 percent together with a long service life. In addition, they can be disposed of inexpensively and in an environmentally friendly manner via incineration. Depending on the paint and requirement profile, six different edrizzi® variants are available. Up to now, some operators have been put off using dry separation because of the need to regularly change the filters. “We have developed solutions so that this change can take place during operation and without system downtime. Handling the edrizzi® paint mist separators is child’s play anyway and they have a long service life too”, Becker added. “With Viledon® filterCair, we have many years of experience in process analysis and optimization in the filter management of paint shops. We systematically examine all factors that influence the painting process from a qualitative and economic point of view. This analysis then forms the basis for conceptualizing and designing an optimal filtration solution”, explained Becker. To be on the safe side when switching from wet to dry, Freudenberg Filtration Technologies offers paint shop operators a risk-free trial run without having to uninstall the existing wet separation system beforehand. This service is offered in collaboration with renowned plant manufacturers.

BRAND-NEW

Combined Expertise: Dürr and LTB Offer a Complete Range of Energy-Efficient Exhaust Air Purification Systems © Dürr

ürr Systems AG and Luft- und

They differ, for example, in the design of the

Thermotechnik Bayreuth GmbH

air distribution systems or the regeneration

(LTB) presented their wide

chambers.

portfolio of exhaust air purification

Together with LTB, Dürr offers the right

systems and educated attendees about

exhaust air purification system for every

current developments in systems for

production process. They can also provide

cleaning polluted exhaust air at

custom services to address further

PaintExpo 2018.

customer requirements, such as building

When investing in legally required

site organization. For example, the largely

exhaust air purification technology, it is

pre-assembled RTO systems from LTB

not only the purchase costs but above

are ideal when a short assembly time is

all the actual operating and maintenance

required. Furthermore, the flexible system

costs that are crucial. With their complete

allows the customer to involve their own

range of exhaust air treatment and

personnel in the construction process if

energy recovery technology, Dürr

desired, saving additional installation costs

considers itself an important partner

(Fig. 2).

in the industrial coating industry. Their

Depending on the solvent concentration

portfolio is comprised of customized,

economical exhaust air purification solutions for all requirements. When

Figure 1: Eﬃcient exhaust air purification with the Ecopure® RTO in the coating industry.

combined with a Dürr heat recovery unit, these systems for treating contaminant-

in the exhaust air energy can be recovered using a suitably rated heat exchanger and directly used for pretreatment, supply-air conditioning, or building services, including factory air conditioning or supplying hot water. This significantly reduces

a way to return energy to the

the primary energy consumption

laden exhaust air can even provide process that previously went

and therefore the energy costs.

unused.

The combination of a RTO and a

Thermal exhaust air purification

heat recovery system transforms

systems remove organic

an exhaust air purification system

contaminants like solvents (VOCs)

into an energy supply for more

and odors from the exhaust air

economical air pollution control.

in order to ensure that the official

Dürr and LTB’s wide range of

emission limit values are safely

experience and products and

adhered to. Exhaust air purification

the knowledge of their experts

systems based on regenerative

guarantees the most efficient

thermal oxidation (RTO) come

solution for every painting

in different sizes and technical

process.

designs, such as how the air distribution system or regeneration chambers are engineered (Fig. 1).

2 1

Figure 2: ROxiTHERM’s compact design in the coating industry.

N. 51 - MAY/JUNE 2018 - international PAINT&COATING magazine

For further information: www.durr.com

Una nuova generazione di prodotti bucciati!

La nuova formulazione offre prodotti in grado di coprire con facilità i difetti del substrato metallico, grazie a una buccia più uniforme, un utilizzo industriale più versatile e un maggior risparmio energetico. La temperatura di reticolazione di 150° C ha permesso di diminuire il tempo di cottura dei pezzi e migliorato la produttività dei nostri clienti. • Bucciatura uniforme in tutte le tinte • Migliore copertura dei difetti, spigoli e punti di taglio • Versatilità d’impiego (diverse geometrie e dimensioni) • Temperatura di reticolazione rapida (150° C) • 50 nuovi colori • Ridotto impatto ambientale

www.interpon.it

I prodotti Interpon di AkzoNobel sono amici dell’ambiente

Le ﬁniture a polvere sono prodotti chimici vernicianti privi di solventi, di VOC (Composti Organici Volatili) e di metalli pesanti tossici, come cromo o piombo. Questi sono da considerarsi come requisiti standard per tutti i prodotti Interpon di AkzoNobel che sono formulati per rispettare l’ambiente e la salute dei loro utilizzatori. Inoltre sono riciclabili, poiché l’over-spray può essere recuperato ﬁno al 99%, e la maggior parte dei prodotti Interpon di AkzoNobel richiede un minor impiego energetico in fase di applicazione rispetto ad altri sistemi vernicianti.

www.interpon.it

BRAND-NEW

The HELM Handling Technology Presented at PaintExpo 2018

appreciated: it reliably prevents

of logistics activities, from individual

technology was presented at

conveyor hooks from moving forward

components to turnkey plants. Close

this year’s PaintExpo trade

and it is particularly important

cooperation, complete advice, and an

fair in Karlsruhe with an innovative

because it minimises equipment

excellent service are crucial,” states

stand (Fig. 1) and a new brochure.

wear.” But HELM’s range is wide.

Woelm. “Overall, I am very pleased

“We decided to give up a bigger stand

The Heiligenhaus-based company’s

to have attended the fair. There

and focus on consultancy and other

portfolio includes a modular system

were many interesting discussions

services,” says Woelm GmbH CEO

consisting of rails, hooks, suspensions,

and preliminary consultations. It

Karl Kristian Woelm. “We have also

connecting components, seals

is always nice to meet customers

created a new brochure offering a good

for sliding doors, tracks, circular

in person and get to know new

overview of the entire range of HELM

conveyors, and traversers, a Power

potential buyers. We look forward to

conveyors.” The firm, however, also

& Free plant, and the proven HELM

continuing our talks after the fair.”

displayed a few assembled products

combination conveyor system. “We

during the exhibition. “Our new direct

offer our customers smart and

For further information:

interlock device was particularly

customised solutions for a wide range

www.woelm.de

oelm GmbH’s HELM

Competence in Shot Blast Technology We offer new and second-hand wheel blast machines including conveyor and filter systems.

Offriamo Granigliatrici nuove ed usate, compresi sistemi di trasporto e impianti di aspirazione-filtrazione.

Figure 1: Woelm GmbH’s HELM innovative stand at Paint Expo 2018.

AGTOS Gesellschaft für technische Oberflächensysteme mbH Gutenbergstraße 14 D-48282 Emsdetten Tel. +49(0)2572 96026-0 info@agtos.de

www.agtos.de

international PAINT&COATING magazine - MAY/JUNE 2018 - N. 51

228-02/17-4c-GB-I

SUCCESS STORIES

Coating Gas Cylinders Uniformly

Graco rotary bell atomizer and

When it comes to coating gas

proportioning system have reduced

cylinders so that they resist these

Time to upgrade the paint shop

paint waste, improved uniformity

In 2016 it became apparent that after

from Bad Hönningen in Germany are

ten years of faithful service, Carbo’s paint

testing and reduced cleaning time and

experts. Every year, this producer

shop was beginning to show signs of

costs.

and supplier of technical gases

aging and needed upgrading.

In a lifetime that can be ten years or

inspects and paints around 30,000

A temporary solution was put in place that

more, gas cylinders must be capable of

cylinders, from small cylinders

allowed painting to continue using a paint

withstanding a variety of stresses, such as

measuring 20 cm in height and 50

gun without electrostatic technology.

exposure to severe weather conditions,

mm in diameter, to large models as

However, its high amount of overspray

and resisting damage during transport and

tall as a man and of diameter 230

was increasing paint consumption and

storage.

mm (Fig. 1).

cleaning, which all added to the unit’s

stresses, Carbo Kohlensäurewerke

of paint distribution, improved ultrasonic

Figure 1: Carbo Kohlensäurewerke from Bad Hönningen in Germany produces and paints around 30,000 gas cylinders every year.

N. 51 - MAY/JUNE 2018 - international PAINT&COATING magazine

SUCCESS STORIES

Spare Parts for Industrial Plants Catalytic panel for ﬁxing oven Components for pre treatment tunnel Transport systems, Water treatment Electric Motors, Electrical components Filtering elements for Industrial Filters Gearboxes for various applications Normal and special Fans for high temperature Oven Burners, Pumps Spare parts for conveyor

2 1

Figure 2: To paint the gas cylinders, a high-performance Graco ProBell rotary atomizer system was installed.

operating costs. A new solution was needed and

In addition, the Graco M2K proportioning system

Graco was invited to propose a solution.

was installed at Carbo. This guarantees consistent

They recommended their

mix ratios, minimizes

ProBell high-speed rotary

flush times and material waste, and

bell, which was first put in use at Carbo on a trial basis for four months before being purchased. The painting of the gas cylinders involves a single colour – RAL 7037 dusty grey – and a 2K waterborne system. Different caps for the cylinders also have to be painted. For this application, a highperformance Graco ProBell

In a lifetime that can be ten years or more, gas cylinders must be capable of withstanding a variety of stresses, such as exposure to severe weather conditions, and resisting damage during transport and storage. When it comes to coating gas cylinders so that they resist these stresses, Carbo Kohlensäurewerke from Bad Hönningen in Germany are experts.”

offers a compact, user-friendly design. Since an insulated set-up was required, the pump was housed in the existing plastic cabinet to prevent the electrostatic system from malfunctioning.

Increased quality; reduced costs

rotary atomizer system was

Carbo are delighted

installed (Fig. 2). It offers

with the coating

a high spray output and high transfer efficiency.

results, because the ProBell rotary atomizer

Moreover, its light, compact design means that even

enables repeatable, uniform paint application

reciprocators with a low lifting capacity can be used.

on the rounded contours of the cylinders, thus

ANTARES S.r.l. Via F.lli Cervi 12/B - 37036 San Martino Buon Albergo (Vr) ITALY T. +39 045 8780567 F. +39 045 994606 email: info@anteresitaly.net WWW.ANTERESITALY.NET

SUCCESS STORIES

3 1

Figure 3: The ProBell rotary atomizer enables repeatable, uniform paint application on the rounded contours of the cylinders, thus achieving a uniform and correct coating thickness.

achieving a uniform and correct coating

The cylinder was painted in position 1, and

As to the high amount of overspray, this has

thickness (Fig. 3). This is vital. An overly

the base area was then painted in position 2.

been significantly reduced, as has the need for

thick coating could create problems during

The paint was applied without electrostatic

almost continuous cleaning of the ventilation

ultrasonic testing of the cylinders. On the

technology, which meant that the paint

system. Whereas previously up to 10 person-

other hand, a too thin coating could

hours were spent each week to clean

lead to mechanical damage during truck transportation as a result of the gas cylinders knocking against one another.

the interior walls and a weekly deep

The move to ProBell made it possible to permanently reduce the thickness of the paint coating on the base of the cylinders.”

The move to ProBell also made it

clean, now it only takes four personhours to clean the installation every two weeks. Overall, Carbo has been able to

possible to permanently reduce the

permanently reduce their costs while

thickness of the paint coating on the base of

coatings on the base of the cylinder were

the cylinders. Previously, the cylinders were

sometimes too thick. Now, the paint is

painted with two paint guns – one attached

applied to the base of the cylinder in even,

For further information:

to the reciprocator, the other stationary.

reduced thicknesses in a single process step.

www.graco.com

N. 51 - MAY/JUNE 2018 - international PAINT&COATING magazine

improving the quality of their painting process.

BUSINESS CARDS

N. 51 - MAY/JUNE 2018 - international PAINT&COATING magazine

... On the road to

ipcm

Â®

n. 51...

Zaniolo CdA - 1.18

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SP EC IA L AUTOMOTIVE

BRAND NEW

FOCUS ON TECHNOLOGY

BRAND NEW

FOCUS ON TECHNOLOGY

INNOVATIONS: PRESENT&FUTURE

HIGHLIGHT OF THE MONTH

Ferrari: The Italian Automaker Revolutionises the Car Painting Process with a Low Temperature Clear Coat System

Highly Automated Coating at the Service of Italian-Made Automotive Luxury

Gestamp’s New Cataphoretic Coating Plant Enables 4.0-Oriented Communication

Smart Service Solutions for Factory 4.0. Data-Based Services Secure Rapid and Effective Customer Service

Biomass Balance Approach, Functional Coatings for Energy Management, and New Colour Trends to Emphasize The New Mobility: BASF’s Answers for Present and Future Requirements of the Automotive Industry

BRAND-NEW

S P E C I A L AU TOMOTIV E

Award-Winning Coating Technology from BASF Improves Energy Efficiency of Vehicles

ASF’s Coatings division has

range of a vehicle, particularly in the

opportunity to accentuate the shape

won the internationally

field of electromobility. Our technology

of the vehicle and to give the model

coveted iF Design Award in the

reduces energy consumption and

its unique character. Our temperature

category “Automobiles/Vehicles” for its

thus optimizes the vehicle’s efficiency,”

management system covers a wide

functional paint technology for passive

explained Stephan Schwarte, head of

colour spectrum that incorporates

temperature management (Fig. 1). The

Pigments, Dispersions & Innovative

both light and dark colours – without

jury of the iF Design Award honoured the

Colours EMEA at BASF.

compromising product quality,” said

specific properties of the paint system

In addition to the functionality, the

Mark Gutjahr, head of Automotive Color

and its design potential for mobility of

jury of the iF Design Award was also

Design EMEA at BASF.

the future – a successful combination of

won over by the design potential of

functionality and design. The prize was

the paint technology. “Colours and

For further information:

presented during the iF Design Award

special effects offer carmakers the

www.basf-coatings.com

The functionality of paints is playing an increasing role

Night at “BMW Welt” in Munich.

in the field of automotive OEM coatings. Due to a special formulation, the new temperature management system from BASF not only provides protection and creates a high-level finish for vehicles, it also ensures additional comfort and greater efficiency. The paint system utilizes a basecoat, which is transparent to high-energy near infrared (NIR) radiation, and an NIR reflecting filler. In this combination, the paint reduces the vehicle surface temperature by up to 20°C on hot summer days, which has a positive effect on the temperature inside the vehicle. This means the air conditioning system is used less to control the temperature in the car. “Factors such as A/C regulation have a major impact on the

Figure 1: BASF’s Coatings division has won the iF Design Award in the category “Automobiles/Vehicles” for its functional paint technology for passive temperature management.

N. 51 - MAY/JUNE 2018 - international PAINT&COATING magazine

BRAND-NEW

S P E C I A L A UTOMO TI VE

BASF’s Colors & Effects Brand Launches Pioneering Stir-In Pigment for Automotive Coatings

of the strategic partnership with Landa

Infinite styling options, reduced production time and costs

Labs. The new pigment technology

The blue-shade red pigment features both high

dimension was presented at the American

transparency and high tinting strength for unique,

Coatings Show.

more intensive shades with lower scattering.

BASF announced a pioneering stir-in pigment

Compatible with modern automotive coating

for automotive coatings, that provides enhanced

systems, eXpand!™ Red is the first of its kind suitable

colour depth, flop, and sparkle. eXpand!™ Red (EH

for outdoor applications. The small particle sized

3427), marketed under the Colors & Effects brand,

stir-in pigment is easily dispersible and cuts the

is the first pigment to result from the strategic

time involved in the production process as opposed

partnership between BASF and Landa Labs

to conventional milling methods; this lowers costs

that was established last year (Fig. 1). BASF has

significantly.

showcased the pigment at the American Coatings

Other featured pigments include Lumina® Royal

Show (ACS), held in Indianapolis, April 10 – 12.

Exterior Dragon Gold EH 0907 (S2823D), a brilliant

“We are excited to introduce the first pigment

greenish-golden, semitransparent effect pigment.

in our eXpand!™ line,” said Paul Verhoeven,

It extends the colour space potential for high chroma

eXpand!™ business leader at BASF. “By bringing

shades in automotive OEM / refinish, aerospace,

this technology to our customers, we continue

building & construction, powder coatings and

to demonstrate our commitment to offering

consumer electronics applications.

Xpand!™ Red (EH 3427) is the first result

a revolutionary generation of Colors & Effects For further information:

automotive coatings industry.”

www.basf.com

pigments that meet the requirements of the

Figure 1: eXpand!™ Red (EH 3427), marketed under the Colors & Eﬀects brand, is the first pigment to result from the strategic partnership between BASF and Landa Labs.

BRAND-NEW

S P E C I A L AU TOMOTIV E

AkzoNobel’s Coatings Technology Revives Mclaren F1 Team’s Racing Heritage

Figure 1: The new McLaren MCL33 was created using the latest coatings technology supplied by AkzoNobel.

ans of Formula 1 are revving up with excitement after the

new F1 car (Fig. 1). McLaren first used Papaya in 1968 – the

McLaren Formula 1 team unveiled its racing livery for the 2018

decision of founder Bruce McLaren.

season, which was created using the latest superior coatings

“This reveal is another milestone in our commitment to delivering

technology supplied by AkzoNobel.

cutting-edge innovation,” said Peter Tomlinson, Director of

The new MCL33’s eye-catching primary colour, Papaya Spark –

AkzoNobel’s Automotive and Specialty Coatings business. “It’s

first seen during the team’s official launch in Navarra, Spain – was

fantastic to work together with a partner like McLaren, who we are

developed in collaboration with McLaren. Reflective of McLaren’s

proud to have partnered with for ten years in our shared passion

racing heritage, Burton Blue and Cerulean Blue also feature on the

for technology and high performance.”

N. 51 - MAY/JUNE 2018 - international PAINT&COATING magazine

BRAND-NEW

S P E C I A L AU TOMOTIV E

significant weight and time-savings and a

McLaren become a leader in the

coatings technology to provide colour,

water-based, more sustainable livery.”

sustainability race for the new F1

protection and performance – all

Added Neale: “We are constantly chasing

season.

essential elements for F1 racing.

marginal gains. From working together

The two companies have been working

The innovative coating systems supplied

with AkzoNobel for ten years now, we

closely together since 2008, when

by the company have enabled the

have the knowledge and trust to co-

AkzoNobel first became the official

McLaren Formula 1 team to significantly

develop innovative ideas, driving our

supplier of paint solutions to the

reduce the total weight of paint and

technical teams to explore the bravest

McLaren F1 team. McLaren has used

decrease processing time by more

solutions and create a quality finish in F1

AkzoNobel’s premium Sikkens brand for

than 50%.

which embodies our relentless pursuit of

its F1 cars ever since.

“Working together with AkzoNobel is an

excellence.”

During the season – which started

example of how a long-term partnership

AkzoNobel’s new coating systems offer

in Melbourne, Australia on March

can continue to challenge and inspire

numerous performance and sustainability

25 – McLaren Racing engineers and

engineers and scientists,” commented

benefits, such as the latest UV curing

AkzoNobel Research and Development

Jonathan Neale, Chief Operating Officer,

primer technology, low film weight, a

chemists and technicians will continue

McLaren Technology Group. “The technical

water-based colour coat and super-fast

to work closely together on further

developments AkzoNobel has delivered

clearcoat – all with significantly reduced

performance initiatives.

this year will be key to our competitive

emissions. The company’s Sikkens brand

position on track. Co-innovating on

– a frontrunner in providing premium

For further information:

projects over the winter has resulted in

automotive paint solutions – has helped

www.akzonobel.com

A1 1 4

The McLaren team relies on AkzoNobel’s

Welcome to the

Visioneering

Group

Dürr presents innovative systems and versatile solutions for exhaust air purification at ACHEMA 2018 in Frankfurt, Germany. Dürr Ecopure® Air Pollution Control Systems offer the most options for environmental compliance in a wide range of industries.

www.durr-cleantechnology.com

ÂŠFerrari

Opening photo: The new Ferrari Portofino. Its launch colour, Rosso Portofino, is obtained with the application of a pigmented glossy resin with organic pigments.

FOCUS ON TECHNOLOGY

S P E C I A L AU TOMOTIV E

Ferrari: The Italian Automaker Revolutionises the Car Painting Process with a Low Cure Clear Coat System Alessia Venturi ipcmÂŽ ortofino is a delightful village set

model (ref. Opening photo). With its 600

two rear seats that can be used for short

in the Italian Riviera that recalls

HP and accelerations from 0 to 200 km/h

distances.

elegance, sportiness, and discreet

in just 10.8 seconds, the Ferrari Portofino

Even the launch colour of the new Ferrari is

luxury. Ferrari dedicated its last marvel to

is the most powerful convertible to offer at

called Rosso Portofino. It is a deep red with

this town: Ferrari Portofino, the new Gran

the same time a retractable hardtop, a large

black shades, obtained with the application

Turismo V8, an exceptionally versatile open

trunk, and a spacious interior also featuring

of a two-component low cure pigmented

N. 51 - MAY/JUNE 2018 - international PAINT&COATING magazine

FOCUS ON TECHNOLOGY

making it energetically self-sufficient since

clear coat. The use of low cure clear coats is a historic turning point for the automotive sector and Ferrari, as a company of technological excellence in the world, is its absolute protagonist. The possibility of polymerising a coating system at temperatures suitable also for heat-sensitive substrates, such as carbon fibre, enables to follow at an industrial level the multi-material trend of the car sector, with excellent finishing results and the elimination of any colour matching issues in the assembly of components treated on different coating lines. Lower polymerisation temperatures also ensure a significant reduction in the energy consumption of the most energy-intensive phase of a car production process. This is a further point of pride for Ferrari,

2010 and allowing a reduction of over 30% of CO2 emissions. The switch to a low cure system involved a project that lasted eighteen months and was presented for the first time (still in its initial phase) at the Surcar conference in Cannes in June 2017. It required an important investment also in terms of plant engineering to adapt the application elements to the new two-component resin, developed by PPG and also available in matt and pigmented versions. Ferrari chose Verind as its technological partner, a company of the German group Dürr specialising in industrial and automotive application technologies. The investment involved the replacement of two spraying robots applying the clear coat on the exteriors of cars (Fig. 1), the

equipped with a trigeneration system

Portofino is a delightful village set in the Italian Riviera that recalls elegance, sportiness, and discreet luxury. Ferrari dedicated its last marvel to this town: Ferrari Portofino, the new Gran Turismo V8, an exceptionally versatile open model. With its 600 HP and accelerations from 0 to 200 km/h in just 10.8 seconds, the Ferrari Portofino is the most powerful convertible to offer at the same time a retractable hardtop, a large trunk, and a spacious interior also featuring two rear seats that can be used for short distances. Even the launch colour of the new Ferrari is called Rosso Portofino. It is a deep red with black shades, obtained with the application of a two-component low cure pigmented clear coat.”

Figure 1: The two new EcoRP L133 robots spraying the clear coat on the exterior of a car.

international PAINT&COATING magazine - MAY/JUNE 2018 - N. 51

SP ECIAL AUTOMOTIVE

The switch to a low cure system involved a project that lasted eighteen months and was presented for the first time (still in its initial phase) at the Surcar conference in Cannes in June 2017. It required an important investment also in terms of plant engineering to adapt the application elements to the new twocomponent resin, developed by PPG and also available in matt and pigmented versions. Ferrari chose Verind as its technological partner, a company of the German group Dürr specialising in industrial and automotive application technologies.” implementation of last generation high rotation 2K electrostatic bells, the integration of the manual spraying stations devoted to the car interiors with digital mixing machines and the Coriolis technology, and the addition of three new EcoSupply P systems, two to manage the matt and pigmented clear coats while one was added for the base coats.

A pioneer for over 70 years Established in 1947, Ferrari has always produced cars in its current headquarters of Maranello, keeping faith with its vocation over the years. The firm has grown progressively thanks to a large-scale plan and a far-sighted vision in terms of both design and quality. Ferrari exports about 95% of its production and it is present in more than 60 markets,

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after having officially landed on the Indian market in 2011 and on the Israeli one in 2012.

Carrozzeria Scaglietti The production site at which Ferrari’s car bodies and chassis are manufactured is the Carrozzeria Scaglietti in Modena. Some of the greatest Ferrari GT and sports cars ever built, including the 500 Mondial, the 750 Monza and the 250 GT berlinettas, have taken shape at the historic coachworks founded by Sergio Scaglietti in 1951. The Carrozzeria was taken over by Ferrari in 1977, and has two production lines for 8 - and 12 - cylinder cars. It is here that GT bodyshell production, door and boot fitting, and surface controls all take place. Since 1999 and the introduction of Ferrari’s first all-aluminium car, the 360

N. 51 - MAY/JUNE 2018 - international PAINT&COATING magazine

Figure 2: A Ferrari body at the entrance of the cataphoresis line.

Modena, the Scaglietti plant has been transformed into a genuine centre of excellence in aluminium fabrication in which the complementary skills of Ferrari, its strategic partners and R&D centres have led to the design and adoption of highly innovative solutions. Ferrari’s chassis and Bodies-In-White are entirely designed and engineered at Carrozzeria Scaglietti and it is here where Ferrari also builds prototype parts and full development prototypes before production begins. Working with suppliers, Ferrari’s engineers have developed 25 different high-strength aluminium alloys, some of advanced aerospace origin, for use in spaceframe chassis and Body-In-White construction. Today’s Ferraris use a mix of extrusions,

castings, hollow castings, sheet metal panels, and superplastic forming with a number of different joining technologies, including welding, cold metal transfer welding, riveting and bonding. Development concentrates on light weight and structural rigidity. A good example is the new Ferrari Portofino which features an entirely new chassis and bodyshell. Compared to the outgoing California T, the Portofino’s chassis and bodyshell weighs 32 kg less but with an increase in torsional rigidity of 35%. This is thanks to a reduction in the total length of welding seams of 30% and an extended use of castings (including hollow castings) to integrate component functions and increase stiffness in important areas.

FOCUS ON TECHNOLOGY

Ferrari stands out from any other sports

also feature carbon bonnets and rear

car company for the use of aluminium

wings,” explains Luigi Franzese (Fig. 4),

as the only Body-In-White construction

the Production Processes Direction’s

material since 1999 (Fig. 2). For its cars,

Technology Coating Area Manager.

twelve different aluminium alloys in the

“This characterises our production

form of extrusions, sheets, and castings

and differentiates us from other

are used. Carrozzeria Scaglietti, which

manufacturers, but also determines our

builds the chassis, has become a centre

innovation choices in terms of coating:

of excellence in the field of aluminium

Ferrari is the first industrial automotive

processing. There is a trend towards

group in the world to paint at low

increasingly extreme performance

temperatures. The project kicked off

levels and, for Ferrari, innovation entails

on April 16, after eighteen months of

continuous research on materials.

research and industrialisation phases.

The multi-material approach calls for

Now, we are using a coating system that

the use of innovative and lightweight

used to be the prerogative of small body

materials, such as carbon (Fig. 3) and

shops,” states Franzese. “This is a very

composites, for functional and decorative

important innovation because it greatly

elements.

improves performance and aesthetics

“Besides their aluminium body-in-white, all

even on the so-called “evolved” materials

Ferrari vehicles can have carbon bumpers

and with a much lower environmental

and sills; the new Ferrari 488 Pista will

impact per vehicle.”

Established in 1947, Ferrari has always produced cars in its current headquarters of Maranello, keeping faith with its vocation over the years. The firm has grown progressively thanks to a large-scale plan and a far-sighted vision in terms of both design and quality. Ferrari exports about 95% of its production and it is present in more than 60 markets, after having officially landed on the Indian market in 2011 and on the Israeli one in 2012.”

SP ECIAL AUTOMOTIVE

Figure 3: A detail of a carbon-look eﬀect carbon component on a Ferrari vehicle.

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Figure 4: Luigi Franzese next to a body with about 10,000 signatures of Ferrari employees and their families, collected during the last corporate Family Day.

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N. 51 - MAY/JUNE 2018 - international PAINT&COATING magazine

FOCUS ON TECHNOLOGY

“The ecological aspect of the coating process was another driver of

Besides the aluminium body-in-white, all Ferrari vehicles can have carbon bumpers and sills; the new Ferrari 488 Pista will also feature carbon bonnets and rear wings. This characterises the production and differentiates Ferrari from other manufacturers, but also determines the innovation choices in terms of coating: Ferrari is the first industrial automotive group in the world to paint at low temperatures. The project kicked off on April 16, after eighteen months of research and industrialisation phases.”

development. Ferrari is a company with a very strong green conscience: for example, we are the first self-sufficient European automotive company in terms of electricity, heating, and cooling,” says Franzese. “Our coating system already had a low VOC content thanks to the use of a powder primer and water-based base coats: now, the addition of a low cure clear carbon footprint of our production.”

coat enables us to further reduce the

The coating cycle: an industrial process with artisan quality Ferrari’s chassis take a long journey in the coating department, between meticulous quality controls and manual customisation operations. As in most of automotive plants, Ferrari’s paintshop (Fig. 5) is structured on various levels to separate “dirty” and “clean” processes. “We receive the assembled body from Carrozzeria Scaglietti,” says Luigi Franzese. “After a first check, it is loaded in the raw material warehouse, it is assigned a colour, and it finally reaches our paintshop. The department consists of Floor 0, housing the inspection and sealing phases, Floor 1, featuring the cataphoresis line, the spray paint booths, the oven, and the polishing and final control stations, and the Technical Floor, with utilities. “The cycle begins with the chemicalphysical pickling of the body. For cataphoresis, we have implemented a process tailored to our specific construction needs, i.e. with cars fully built in aluminium, and ours is one of the first plants installed by Dürr with a RoDip immersion and body rotation system. After curing, the body reaches a storage buffer and then the inspection area (Fig. 6). Here, any small cataphoresis impurities are eliminated and the body is equipped with the various accessories and protections needed for the subsequent processing stages. The following phase is

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Figure 5: The entrance of the Ferrari paintshop.

international PAINT&COATING magazine - MAY/JUNE 2018 - N. 51

SP ECIAL AUTOMOTIVE

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Figure 6: The cataphoresis inspection area.

clear coat application booth where

the manual sealing of the lower part of

body, followed by a blow off system

the vehicle; most of our processes are

and a dust removal station with emu

the same process is repeated (Fig. 9)

manual because we want to preserve

feathers,” says Franzese. “This double

and concluded with a 50 minutes long

the artisan quality of a product that has

cleaning process is necessary due to

polymerisation stage (Fig. 10) at 90°C.”

made us famous in the world. Then,

the complexity of our cars’ profiles: a

the body is sent to Floor 1 to enter the

simple manual operation would not

At this point, the coated bodies continue

powder primer application booth: the

be sufficient to ensure a high finishing

their journey through various phases of

application is manual on the interiors

quality.

inspection, control, polishing, and above

and robotic on the exteriors, with two

The base coat application booth

all finish customisation. “After the ICP

opposing robots. After curing at 180°C,

includes a first inspection workstation

(Initial Customer Perception) aesthetic

the car goes back to Floor 0, where the

followed by a manual application

check and polishing stations, the vehicles

operators check the primer layer and

operation on the interiors (Fig. 7)

can follow three different routes,” explains

the body is cleaned before reaching a

and a robotic one on the exteriors,

Franzese. “They can be approved and

storage buffer in front of the base coat

both with pneumatic guns (Fig.

stored, continue towards a further

application booth”.

8). After visual inspection, the

polishing station in case a more accurate

“This booth features a manual cleaning

body quickly passes in a flash off

intervention, not compatible with normal

workstation to treat some areas of the

area at 80 °C. Finally, it enters the

line speeds, is necessary, or undergo

N. 51 - MAY/JUNE 2018 - international PAINT&COATING magazine

FOCUS ON TECHNOLOGY

Now, Ferrari is using a coating system that used to be the prerogative of small body shops. This is a very important innovation because it greatly improves performance and aesthetics even on the so-called “evolved” materials and with a much lower environmental impact per vehicle. Ferrari’s coating system already had a low VOC content thanks to the use of a powder primer and water-based base coats: now, the addition of a low cure clear coat enables them to further reduce the carbon footprint of the production.” special treatments, e.g. application of three-layer colours, under-coats, two-colour finishes, and so on. In the standard route, on the other hand, the body reaches the masking stations before the application of aesthetic black layers and hot melt coatings. After curing, the protections are removed and the cars are controlled and approved. All of the vehicles produced undergo a 30-minute quality audit. Once any surface defects have been eliminated, the vehicles are checked again for 20 minutes and then proceed to the final approval stage.” For Ferrari, colour is very important. “Ferrari does not add a new colour by eliminating an old one,” Franzese goes on. “Collectors, loyal customers and, in general, anyone who wants to buy a Ferrari car must be able to choose from our entire historical colour range. That is why we now handle about 80 tints (Fig. 11), including 14 different red ones.” The brand new Rosso Portofino is among them. “Rosso Portofino is obtained thanks to the application of a glossy pigmented resin, which ensures the same depth and chromaticity of a three-layer system without any complex production phase required to apply a double base coat. Indeed, Ferrari only handles two very low absorption three-layer colours, applied on the customisation line.” Rosso Portofino is a peculiar finish obtained with a special metallic base coat and a pigmented clear coat containing patented PPG nanopigments called ANDARO®. The final effect that is perceived results from the particular combination of these two elements (metallic

SP ECIAL AUTOMOTIVE

base coat + pigmented clear coat with

Features of the new investment

ANDARO® pigments), developed through

The main driver of the switch to the

an accurate stylistic research study

2K clear coat was Ferrari’s need to

conducted by PPG specifically for Ferrari

work with increasingly particular and

to blend sportiness and elegance.

evolved construction materials. This

The metallic base coat was conceived

system enables to paint and polymerise

to give the colour a significant effect of

substrates of different nature together,

sparkling (aluminium reflecting light) and

since it is compatible with a wide variety

flop (difference in gloss perceived from

of materials, including heat-sensitive

different angles). The pigmented clear coat

ones. It therefore reduces operational

was formulated using ANDARO pigments,

complexity and simplifies the achievement

giving the colour greater saturation and

of chromatic harmony among the various

chromatic “cleanliness”, high transparency

parts of a car. In the near future, the

(lens effect), and a “fluid” depth that

evolution of the low-cure technology will

ensures a three-dimensional “lacquered”

allow to coat metal and plastic parts inline,

effect that could not be obtained with the

further favouring the use of lightweight

conventional technology.

components.

After the ICP (Initial Customer Perception) aesthetic check and polishing stations, the vehicles can follow three different routes: they can be approved and stored, continue towards a further polishing station in case a more accurate intervention, not compatible with normal line speeds, is necessary, or undergo special treatments, e.g. application of three-layer colours, under-coats, twocolour finishes, and so on.”

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Figure 7: A detail of the manual base coat application on the interior of a car.

N. 51 - MAY/JUNE 2018 - international PAINT&COATING magazine

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Figure 8: The automatic base coat application on the exterior of a car.

Figure 9: A detail of the manual application of the clear coat on car interiors.

the modification and approval of all base

clear coats was made possible by the PPG

tremendous support from PPG, which

coats – a process that in some cases was

laboratories, which created a new resin-

developed our new low cure clear coats in

really challenging.

hardener combination aimed at ensuring

their glossy, matt, and pigmented versions.

Ferrari currently uses new generation

higher quality aesthetics, improved chemical

In fact, we soon realised that this change

water-based base coats with a rapid

and mechanical resistance performance, and

was not possible with the one-component

polymerisation reaction, high moisture

surface properties offering better polishing

technology, so PPG immediately formulated

resistance and hydrophobicity, and better

and scratch resistance performance.

a two-component system. The change in the

film cross-linking to generate a stronger

Thanks to the development of this highly

chemical nature of the clear coat required

layer. The development of low cure temp 2K

sustainable technology in terms of energy

“In this innovation journey, we received

Rosso Portofino is a peculiar finish obtained with a special metallic base coat and a pigmented clear coat containing patented PPG nanopigments called ANDARO®. The final effect that is perceived results from the particular combination of these two elements (metallic base coat + pigmented clear coat with ANDARO® pigments), developed through an accurate stylistic research study conducted by PPG specifically for Ferrari to blend sportiness and elegance.”

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Figure 10: A coated body in the polymerisation oven.

N. 51 - MAY/JUNE 2018 - international PAINT&COATING magazine

FOCUS ON TECHNOLOGY

generation electric pump Dürr HPE400 (Fig. 12). We also equipped the already existing base coat management unit with an electric pump and expanded the EcoSupply P system with a third colour (Fig. 13), in order to give Ferrari greater flexibility in the management of special tints. At the same time, we integrated two EcoSupply P systems for the management of matt and coloured clear coats,” state Verind’s APT Auto Director Alessandro Molè and Technical and Operation Director Paolo Roncarati (Fig. 14). “As for the clear coat application booths, the main change was the replacement of the two existing robots with two new generation robots EcoRP L133,

11 1

equipped with EcoBell3 2K rotating bells (Fig. 15) featuring integrated mixers.

reduction, Ferrari can coat

The main driver of the switch to the 2K clear coat was Ferrari’s need to work with increasingly particular and evolved construction materials. This system enables to paint and cure substrates of different nature together, since it is compatible with a wide variety of materials, including heat-sensitive ones. It therefore reduces operational complexity and simplifies the achievement of chromatic harmony among the various parts of a car. In the near future, the evolution of the low cure technology will allow to coat metal and plastic parts inline, further favouring the use of lightweight components.”

Figure 11: The application of the clear coat on a blue car.

in-house materials such as carbon. “The real innovation was the implementation of such a cutting edge coating system, but the investment heavily involved its application aspects,” states Franzese. “Together with Verind, besides developing the coating management unit needed to handle two-component products, we chose to increase the number of the existing PIG systems. Moreover, we upgraded the clear coat application robotic devices, dating back to 2005, with new generation robots and electrostatic bells.” “Starting from the coating management unit, with the switch to the 2K system we added an extra unit for the management of catalysts equipped with a last

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Figure 12: The coating management unit with the new electric pumps Dürr HPE400.

international PAINT&COATING magazine - MAY/JUNE 2018 - N. 51

SP ECIAL AUTOMOTIVE

We then modified the manual clear coat spraying stations to adapt them to the new 2K system: four machines EcoDose 2K were installed (Fig. 16), two on each side: while one is operating, the other is in standby mode to enable a quick product change operation.” Technology has supported the revolutionary idea of coating metal and polymers together, transferring a typically artisan process to an industrial production plant. “The carbon parts of the car are assembled to the aluminium body after the base coat inspection,” says Franzese. “The improvement of the colour matching function and the operational simplification were incredible and solved a long-standing coating issue: combining materials with completely different heat resistances

13 1

while maintaining the same aesthetic and

Starting from the coating management unit, with the switch to the 2K system Ferrari added an extra unit for the management of catalysts equipped with a last generation electric pump Dürr HPE400. They also equipped the already existing base coat management unit with an electric pump and expanded the EcoSupply P system with a third colour, in order to give Ferrari greater flexibility in the management of special tints. At the same time, they integrated two EcoSupply P systems for the management of matt and coloured clear coats.”

functional performance level.”

Figure 13: The three systems PIG EcoSupply P for the management of the base coats.

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Figure 14: From left to right, Alessia Venturi (ipcm®) with Alessandro Molè and Paolo Roncarati from Verind.

N. 51 - MAY/JUNE 2018 - international PAINT&COATING magazine

FOCUS ON TECHNOLOGY

As for the clear coat application booths, the main change was the replacement of the two existing robots with two new generation robots EcoRP L133, equipped with EcoBell3 2K rotating bells featuring integrated mixers. Ferrari then modified the manual clear coat spraying stations to adapt them to the new 2K system: four machines EcoDose 2K were installed, two on each side: while one is operating, the other is in standby mode to enable a quick product change operation.”

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Figure 15: The two new robots EcoRP L133 equipped with EcoBell3 2K electrostatic bells for spraying the new low cure 2K clear coats.

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Figure 16: Two of the four EcoDose 2K mixers installed on the manual spraying stations applying the clear coat on the interiors of cars.

Ferrari currently offers three ranges of cars to the market: cars in production, track cars, and limited series. Additionally, the company offers three levels of customisation: Opt, i.e. millions of option combinations; Atelier, i.e. each customer can bring their own customised specifications; and Tailor-Made, i.e. the service that allows the customer to enter the factory and choose any detail with the help of a designer, starting from an approved chassis in production.”

N. 51 - MAY/JUNE 2018 - international PAINT&COATING magazine

Ferrari: where unique products are already a reality Ferrari currently offers three ranges of cars to the market: cars in production, track cars, and limited series. Additionally, the company offers three levels of customisation (Fig. 17): Opt, i.e. millions of option combinations; Atelier, i.e. each customer can bring their own customised specifications; and Tailor-Made, i.e. the service that allows the customer to enter the factory and choose any detail with the help of a designer, starting from an approved chassis in production. “Ferrari has a laboratory only devoted to testing the materials required for customised products,” says Franzese. “We 17 1

Figure 17: The diﬀerent interior finishes available are among the car customisation options oﬀered. In this picture, a component with a red carbon-look finish.

take pride in our One Off project, enabling customers to design their own unique and exclusive car based on an existing chassis. One Off is everyone’s dream: a product that is unique in the world but can be homologated worldwide.”

BRAND-NEW

S P E C I A L AU TOMOTIV E

Eisenmann Builds the World’s Most Flexible Paint Shop for Lamborghini

Figure 1: The paint shop now being built will support smart manufacturing of the Lamborghini Urus in line with the Industry 4.0 vision.

amborghini’s new paint shop enables

automotive painting lines, customization

The new plant will revolutionize the

each car to be quickly and easily

is generally extremely difficult and

car painting process, discontinuing the

given a customer-specific finish.

expensive.

conventional rigidly linear configuration

A revolutionary layout and intelligent

The paint shop now being built at the

in favour of a highly flexible “workshop”

production control via E-MES software are the

carmaker’s headquarters in Sant’Agata

with selected linear elements.

basis for highly flexible mass customization.

Bolognese, Italy, will support smart

This allows the efficient utilization of

In a world first, each Lamborghini car body

manufacturing of the Urus, the luxury

available resources, such as dryers

will be individually painted according to

marque’s new SUV, in line with the

or specific spray booths, even when

customer-specific instructions. In high-volume

Industry 4.0 vision (Fig. 1).

producing diverse paint finishes, or

N. 51 - MAY/JUNE 2018 - international PAINT&COATING magazine

BRAND-NEW

S P E C I A L AUTOMO TI VE

when simultaneously processing components of differing materials. The paint shop’s exceptional flexibility stems from its layout and design. Its “brain” is the E-MES production-control system from the Eisenmann Industrial Software Company (Enisco). This intelligent software, which supports online planning, materialflow control, and integrated, digital worker guidance, takes automotive painting to a new level. “By leveraging E-MES, we can paint a variety of body types and materials, and produce customer-specific finishes within a single shop,” explains Enisco’s Managing Director Werner Gruber. “For a long time, production systems have been engineered to support standardized, high-throughput processes. We are now able to implement mass customization,” he adds. The paint shop for the Lamborghini Urus will be completed by year-end 2018. In addition to the E-MES production control software, Eisenmann is supplying a sealing system complete with materialsupply equipment, topcoat spray booths fitted with E-Cubes for overspray removal, dryers, a high-bay warehouse, conveyors, and workstations. This will be the first time the Volkswagen Group will deploy an Eisenmann topcoat application system, which

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The Nordson spray systems utilize HDLV® (High Density Low Velocity) pumps to delivers unmatched performance through independent control of the powder and air volumes for soft, highly

direct electrostatic charging. This technology makes

repeatable powder application

will include paint supply equipment. The solution

it suitable for interior and exterior painting of both plastic and metal components. A single atomizer can be employed for a variety of painting processes – in

Signiﬁcant powder savings due to higher efﬁciency and tight process control

line with the highly flexible “workshop” production

No pump maintenance up to 4,000 hours

principle.

Intuitive advanced controls for operator convenience

“We believe Industry 4.0 is the ideal combination of flexible hardware, intelligent software, and digital services – maximizing customer benefits. We put this into practice at Lamborghini by achieving synergy across the entire Eisenmann organization,” explains Gruber.

Fast, reliable and automated colour change For a new fast colour change system or easy integration with your existing cyclone booth, get in contact with Nordson for more information.

Smart, connected manufacturing with mass customization is to become a reality at Lamborghini. The company is achieving industrial transformation through digitization. For further information: www.eisenmann.com

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BRAND-NEW

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BENSELER Uses Liquid Coatings for a Refined Look

produced by Lamborghini are composed

being visible in the final result. This means

individually must create an

of numerous parts, including about seven

that both the hue and the gloss level

aesthetically homogeneous set

accessories mounted directly around the

must be identical for all the components.

once assembled – a real challenge for

steering wheel. These parts are made in

BENSELER manages to ensure this through

coaters. The quality level, however, will be

plastic in order to reduce their weight.

a liquid coating process and special racks

high, if these are aware that the finished

The vehicle design requires the steering

on which the parts are hung. The thorough

components will be part of a premium

wheels of sports cars to be glossy black.

cleaning and primer application stages

product such as the steering wheels

This is possible thanks to the high

are followed by the actual coating phase

for the models of the Italian sports car

quality glossy black coating applied

and an 80 °C curing one. As a result, the

manufacturer Lamborghini (Fig. 1).

on components by BENSELER

components are clean, coated with the

That is why BENSELER’s surface finishing

Beschichtungen Bayern GmbH & Co. KG

same gloss degree and without any orange

experts keep their procedures firmly

(Bogen, Germany) on behalf of the plastics

peel effect, and totally compatible with

under control and use a liquid coating

manufacturer and second-tier supplier

each other, so that they can be assembled

process for their numerous steering wheel

Teetronic Weberit Werke Dräbing GmbH

directly.

components, with the aim of obtaining a

(Bretzenheim, Germany). The technical

black and uniform glossy finish. The ca. 30

challenge posed by this project is painting

For further information:

cm wide and 17 cm high steering wheels

the components separately without this

www.benseler.de

any small parts that are coated

Figure 1: The glossy plastic parts on the steering wheel of the Lamborghini Aventador S pose a real coating challenge.

N. 51 - MAY/JUNE 2018 - international PAINT&COATING magazine

BRAND-NEW

S P E C I A L AU TOMOTIV E

Dürr is Building for BMW Group a Smart and Resource-Efficient Paint Shop in Mexico

Figure 1: BMW was the first OEM to use EcoDryScrubber in its plant in Regensburg, Germany.

ürr is building a paint shop

Dürr is supplying the complete paint shop,

scope of services being provided by Dürr.

in Mexico for its customer

from pretreatment (PT) and electrocoating

The respective processes are designed

BMW Group that meets the

(EC) through to the spray booths with

around the consistent integration of smart

requirements for connected Industry

application technology to the ovens.

solutions.

4.0 production. This ultra-modern plant

The waste water treatment plant, the

In the first stage, the paint shop is being

featuring the first integrated smart factory

installations for the complete deionization

designed for a capacity of 30 vehicles

concept from Dürr in the world is being

system of the water (DI plant), and the

per hour, with the option to increase the

built at the San Luis Potosí site.

shop ventilation are also included in the

throughput to twice this capacity later.

international PAINT&COATING magazine - MAY/JUNE 2018 - N. 51

BRAND-NEW

S P E C I A L AU TOMOTIV E

Only the PT/EC area is designed for 60

therefore also the energy consumption for

of the robot data with the higher-level

vehicles per hour from the outset. BMW will

tank conditioning. The use of membrane

maintenance software and control system.

use its tried-and-tested, fully automatic IPP

technology in PT/EC as well as in the waste

The EcoScreen Maintenance Assistant

(Integrated Paint Process) in this plant, which

water treatment plant reduces the water

software from the digital@DÜRR range, which

eliminates the primer and therefore also a

consumption and the volume of waste water

is being used for the first time, determines

drying phase.

even more.

the plant condition based on the number

In terms of the paint shop layout, Dürr relies

A total of 30 EcoRP E/L133i robots from the

of switching cycles of the valves or the load

on a simple industrial building without any

third and therefore latest generation ensure

profiles of the servo motors in the robots.

intermediate levels in conjunction with

efficient paint application in San Luis Potosí.

This enables preventive maintenance

multi-functional body stores with high-bay

These can be operated on a rail running

planning and increases the plant availability.

storage technology at the BMW Group

either above or below in the top coat and

Service activities can therefore be based on

site. This concept offers the advantage of

clear coat lines. They are used as both

up-to-date plant data, and are no longer

sorting the vehicles with elective access,

trunk openers and for exterior and interior

oriented to predefined maintenance intervals.

which eliminates the need for an additional

painting. For the first time on the American

In the application technology, the interaction

painted body store of the conventional type.

continent, the new Dürr painting robot with

of the dosing pump, color changer, EcoBell3

The focus on sustainability starts right

cloud-enabled control is being used.

atomizer generation, and the award-

from the PT/EC area. The RoDip rotational

The newly developed EcoRCMP2 process

winning cleaning device EcoBell Cleaner

dip process is used in pretreatment and

and motion controller controls the third

D2 minimizes paint loss and detergent

electrocoating. Since the bodies are fully

robot generation from Dürr. An example

consumption when changing colors.

rotated in the tank, RoDip does not need

of the smart factory concept is the

The scope of delivery here also includes

entry and exit inclines. The smaller volume

integrated safety controller for monitoring

the paint and high-viscosity material

of this shorter tank reduces the quantity

the workspace and speed of the robots. A

supply as well as 25 sealing robots

of water and chemicals required, and

multitude of sensors ensure networking

from the EcoRS series.

2 1

Figure 2: EcoSmart VEC optimally adapts the energy use of the oven to its workload at any given time.

N. 51 - MAY/JUNE 2018 - international PAINT&COATING magazine

BRAND-NEW

S P E C I A L AU TOMOTIV E

These robots seal seams on the bodies

system software is being used for the first

exhaust air purification systems (Ecopure®

fully automatically, apply sound insulating

time. It improves the performance of the

TAR) of the ovens. The waste heat is made

mats and underbody protection, and draw

EcoDryScrubber by enabling the system

available again to the production plants as hot

delicate seam lines in the visible parts of the

to be self-regulating. As a direct result,

water using a waste heat boiler. To reduce the

door area.

optimum use is made of the limestone

solvent emissions, as a further environmental

For paint overspray separation in the spray

powder for binding the overspray,

measure the exhaust air flow from the clear

booth, BMW Group in San Luis Potosi once

thereby reducing consumption.

coat booths is purified using an Ecopure® KPR

again has chosen dry separation using

BMW is also using a product from the

adsorptive concentration system before it

the EcoDryScrubber. The Bavarian car

digital@DÜRR range for the ovens. The

leaves the plant.

manufacturer was the first OEM to use this

fully automatic EcoSmart VEC fresh

The plant will commence operation in San

technology in its plant in Regensburg in 2010,

and exhaust air control ensures air

Luis Potosi from August 2018. Well before

and it is now in use in more than 75 painting

management by energy on demand: the

production ever starts, Dürr is thinking about

lines worldwide (Fig. 1). The reason for its

oven’s energy use is optimally adapted

efficient maintenance and impressive ease of

popularity is the energy saving of up to 60%

to its workload at any given time (Fig. 2).

use: without poring over files, the electronic

in the spray booth. By completely eliminating

Instead of a constant volumetric flow rate,

EcoDocu documentation system enables direct

water and chemicals, up to 90% recirculated

the fresh and exhaust air is controlled

access to all plant-related data via QR codes

air can be used in production. This reduces

as a function of the number of vehicles

and enables smooth ordering of spare parts.

the cost of conditioning fresh air and is the

currently in the oven and their position.

deciding factor in the outstanding energy

Another measure to save energy is the

For further information:

efficiency of the spray booth. The new V5.X

recovery of waste heat from the thermal

www.durr.com

Opening photo: In its new paint shop started in the spring of last year, Nuova GM mainly coats plastic bumpers of luxury sports cars.

FOCUS ON TECHNOLOGY

S P E C I A L AU TOMOTIV E

Highly Automated Coating at the Service of Italian-Made Automotive Luxury Francesco Stucchi ipcm®

milia Romagna is famous all over the

power, technology, and above all beauty in

becoming an important partner of

world for being the “Motor Valley” of

this district every day. These boast a unique

manufacturers such as Maserati, Ferrari,

Italy, home to some of the world’s

design and highly technological materials,

Lamborghini, and Alfa Romeo. Established

most prestigious automotive and motorcycle

enhanced by high quality coating processes.

in 1984 in Camposanto (Modena, Italy), at

companies. Ferrari, Lamborghini, and Maserati

Carrozzeria Nuova GM has established

the core of the Italian motor district, it is

are just some of the well-established brands

itself on the automotive coating market

now one of the country’s leading industrial

that create four-wheel masterpieces combining

precisely thanks to its process quality,

body shops providing coating services to

N. 51 - MAY/JUNE 2018 - international PAINT&COATING magazine

FOCUS ON TECHNOLOGY

major automotive brands, but also to

for the aesthetic finishing of very

the motorcycle and general industry

peculiar bumpers with difficult-to-

sectors. Since the end of the 1990s, it

manage colours (Fig. 1). “Maserati

has been characterised by constant

has relied on our experience and

technological evolution and process

our well-established partnerships

automation, which now enable it to

with the world’s major coating

offer a complete and flexible service,

manufacturers, as well as on

always complying with the very high

our plant’s ability to handle high

quality standards required by its

quality standards and high volume

prestigious clientele.

processes at the same time,”

ipcm recorded the excellence of the

states Pinca.

processes performed by Nuova GM the Alfa Romeo 4C coating project1.

The system and the coating cycle

A new technological upgrade has

The inline dust-free pressurised

recently involved the finishing

coating plant features a two-rail

department devoted to bumpers and,

floor conveyor and four

more generally, individual workpieces

temperature-controlled booths.

in plastic and composite materials.

Upgraded after the move to the

Luca Pinca, the sales manager and

new building, these are “double”

the son of Mario, who founded the

booths, i.e. they consist of a first,

company together with Giuliano

completely automated part and a

already in 2014, in the framework of

Polacchini, explains how the project

second, manual part (Fig. 2); this is

was born: “In 2012 we were hit by an

used either as a touch-up station

earthquake and we had to relocate our plants in order to adapt all our buildings to the new earthquake

after robotic application or for the processing of small orders requiring

Figure 1: A detail of a Maserati bumper.

manual cleaning or coating

standards. This move was the starting

operations for which the robots

point for the replacement of damaged machines and the integration of new systems, which led to the start-up of a practically new plant in the spring of 2017.” “The standards imposed by our customers are very high. It is therefore essential for us to achieve the highest quality level with our plants and equipment,” says Pinca. “The investment for the start-up of new projects is always considerable and it requires significant time

cannot be programmed.

Carrozzeria Nuova GM has established itself on the automotive coating market precisely thanks to its process quality, becoming an important partner of manufacturers such as Maserati, Ferrari, Lamborghini, and Alfa Romeo. Established in 1984 in Camposanto (Modena, Italy), at the core of the Italian motor district, it is now one of the country’s leading industrial body shops providing coating services to major automotive brands, but also to the motorcycle and general industry sectors.”

The process stations, normally operating on two shifts per day, are as follows: - workpiece loading area, where the operator reads the barcode and creates a process queue; - cleaning area equipped with ionising bars that neutralise the electrostatic charge of the components’ surfaces; - automated flaming area for polypropylene workpieces;

and resources, but we considered

- primer application booth;

this as an opportunity to take a

- flash-off oven;

new challenge.” The new paint shop was

(ref. Opening photo), motorcycle

specifically designed for the finishing of

components (e.g. tanks), and other

plastic bumpers of high-end sports cars

accessories (tabs, headlight frames, pullers,

“Carrozzeria Nuova GM: 30 years of experience in the coating of car bodies in the service of the new Alfa 4C” ipcm®_International Paint&Coating Magazine Vol. V, No. 27, May-June, pages 40-49

and style components). Here, Nuova GM

- two booths for the application of the coloured base coat; - flash-off oven (also at high temperatures for water-based coatings, Fig. 3);

also handles a large-size order of Maserati,

- booth for the application of the clear coat;

a long-standing customer since the 1990s,

- curing oven.

international PAINT&COATING magazine - MAY/JUNE 2018 - N. 51

SP ECIAL AUTOMOTIVE

2 1

ipcm® recorded the excellence of the processes performed by Nuova GM already in 2014, in the framework of the Alfa Romeo 4C coating project. A new technological upgrade has recently involved the finishing department devoted to bumpers and, more generally, individual workpieces in plastic and composite materials.”

Figure 2: One of the manual booths used for touch-ups or for operations that cannot be performed by robots.

3 1

Figure 3: Workpieces inside the flash-oﬀ oven.

N. 51 - MAY/JUNE 2018 - international PAINT&COATING magazine

FOCUS ON TECHNOLOGY

In 2012 Nuova GM was hit by an earthquake and they had to relocate the plants in order to adapt all the buildings to the new earthquake standards. This move was the starting point for the replacement of damaged machines and the integration of new systems, which led to the start-up of a practically new plant in the spring of 2017.”

application of a primer, a coloured base

primer and two types of two-component

coat and a clear coat,” explains Pinca.

transparent coating; they are all solvent-

“However, for Maserati we also use

based. The catalyst is stored in nitrogen and

three-coat systems requiring two passages

the components are automatically mixed with

in our plant. This process includes the

Wagner Intellimix systems. “Albeit well-established

application of a base coat as well as an

on the industrial level, the water-based clear

undercoat with a special colour-reading

coat technology has not been implemented in

feature, since the second layer can affect

the automotive sector yet and therefore it is not

the final tint. Then, we perform a matting

included in customer specifications,” states Pinca.

operation and, finally, the application of

The base coats used, on the other hand, are

the second base coat and the clear coat.

one-component products; there are separate

The base coat plays therefore a crucial

circuits for the water-based and solvent-based

role. Maserati has different three-coat

ones (Fig. 4). “The paints used are supplied

colours, such as pearl white, red, and a

mainly by PPG, BASF, and Lechler, global partners

special ink blue.”

of the major car manufacturers. © ipcm ®

Nuova GM uses two types of two-component

“The standard coating cycle includes the

4 1

Figure 4: The coating management unit.

SP ECIAL AUTOMOTIVE

The inline dust-free pressurised coating plant features a two-rail floor conveyor and four temperature-controlled booths. Upgraded after the move to the new building, these are “double” booths, i.e. they consist of a first, completely automated part and a second, manual part; this is used either as a touch-up station after robotic application or for the processing of small orders requiring manual cleaning or coating operations for which the robots cannot be programmed.” The end customers develop the colours chosen directly with the coating producers and then, after approval, they turn to us for the approval of our processes according to the OEM standards”.

Automation Automation is the pride of this system and it was entirely developed by CMA Robotics (Pradamano, Udine, Italy). “We had no doubts about relying on CMA again for the automation of our new paint shop,” says Pinca. “We had already entrusted them with the Alfa 4C coating project with excellent results, and we chose them again for the upgrading of this system’s robotics, which was a bit outdated as well as not very suitable for this type of process.” The coating line is equipped with four 6-axis hollow wrist robots for the flaming (Fig. 5), base coat application, and topcoat

5 1

Figure 5: The robot devoted to the flaming of polypropylene parts.

Nuova GM handles a large-size order of Maserati, a long-standing customer since the 1990s, for the aesthetic finishing of very peculiar bumpers with difficult-to-manage colours. Maserati has relied on their experience and their well-established partnerships with the world’s major coating manufacturers, as well as on the plant’s ability to handle high quality standards and high volume processes at the same time.”

N. 51 - MAY/JUNE 2018 - international PAINT&COATING magazine

6 1

Figure 6: A 6-axis hollow wrist robot applying the transparent topcoat.

FOCUS ON TECHNOLOGY

For Maserati, Nuova GM uses threecoat systems requiring two passages in the plant. This process includes the application of a base coat as well as an undercoat with a special colour-reading feature, since the second layer can affect the final tint. Then, they perform a matting operation and, finally, the application of the second base coat and the transparent topcoat. The base coat plays therefore a crucial role. Maserati has different three-coat colours, such as pearl white, red, and a special ink blue.”

application operations (Fig. 6) and of a smaller rail robot applying the primer (Fig. 7). After the barcode reading in the loading area, the program associated with each barcode starts automatically; besides the four robots’ operations, it also includes some settings for the manual coating and cleaning booths (Fig. 8). “Currently, all our robots are pointto-point programmed offline. They are in fact programmed in our offices with kinematics and thickness simulations followed by a pre-test no-coating phase on the plant and by preliminary tests on samples to analyse the results. The program is optimised based on the results obtained and production can finally start,” says Pinca. “Programming accounts for about 40% of the time needed to start a new project. Our robots cannot automatically generate programs because coating luxury bumpers is a complex task, due to the several concave and convex areas and peculiar shapes. However, we will certainly tackle also this challenge in future.” Nuova GM is also currently assessing a few 4.0-oriented software packages ensuring the traceability of all process phases (system status, consumption, costs, and production progress) and, above all, the traceability of products, i.e. the possibility of coding each component treated in each

Nuova GM uses two types of two-component primer and two types of two-component clear coat; they are all solvent-based. The catalyst is stored in nitrogen and the components are automatically mixed with Wagner Intellimix systems.”

SP ECIAL AUTOMOTIVE

Nuova GM is also currently assessing a few 4.0-oriented software packages ensuring the traceability of all process phases (system status, consumption, costs, and production progress) and, above all, the traceability of products, i.e. the possibility of coding each component treated in each line in order to always identify its type, its processing date, the coating process carried out, and the system used.” 7 1

that we will obtain a great ROI once again. Figure 7: The rail robot, smaller in size and devoted to the primer application.

Indeed, Ferrari, Maserati, and Ducati have already placed new orders that will contribute to further consolidate our

line in order to always identify its type, its

Automation is the pride of this system and it was entirely developed by CMA Robotics (Pradamano, Udine, Italy). The coating line is equipped with four 6-axis hollow wrist robots for the flaming, basecoat application, and topcoat application operations and of a smaller rail robot applying the primer.”

processing date, the coating process carried out, and the system used.

Technology at the service of craftsmanship For twenty years now, Nuova GM has focussed on the industrialisation and automation of its processes without ever neglecting the craftsmanship factor that distinguishes it and that is typical of Italianmade products of excellence. “As is often said in these cases, we made a virtue of necessity: we took advantage of the need to reorganise following the natural disaster that struck us to take a new challenge and exploit a new growth opportunity,” says Pinca. “Also thanks to the technical support of CMA in terms of automation, we are sure

N. 51 - MAY/JUNE 2018 - international PAINT&COATING magazine

8 1

Figure 8: The system management interface.

know-how and our position of prestige in the sector.” In its new paint shop started in the spring of last year, Nuova GM mainly coats plastic bumpers of luxury sports cars.

Â®

Opening photo: The Gestamp plant of Wroclaw, Poland, processes steel components for cars, including commercial vehicle chassis – a field in which the company specialises.

FOCUS ON TECHNOLOGY

S P E C I A L AU TOMOTIV E

Gestamp’s New Cataphoretic Coating Plant Enables 4.0-Oriented Communication Barbara Pennati ipcm®

oday more than ever, the automotive

chain of vehicles that are more than just a

capacity of the cataphoresis line it installed

industry is one of the most cross-

consumer good. A new engine for growth

in 2016.

cutting, lively, and competitive global

in the sector is electric mobility, the new

Gestamp, a Spanish industrial group with

sectors. Attention to detail and quality plays

sustainable and efficient transport solution

over 100 production sites in 21 countries

a crucial role in ensuring that the increasingly

of the future. And precisely the production

and more than 40,000 employees, has

demanding and ever-changing market

of components for the Volkswagen group’s

specialised in the design, development,

requirements are met. Many players take

new electric mobility platform will enable

and production of metal car components

part in the productive and technological

Gestamp Polska to optimise the production

since 1997. Its high technological profile

N. 51 - MAY/JUNE 2018 - international PAINT&COATING magazine

FOCUS ON TECHNOLOGY

has allowed the group to pursue a product diversification strategy in order to strengthen its relationship with customers on its territory, creating a portfolio that includes Body-In-White, chassis and mechanisms (Edscha) processing operations. ipcm had the opportunity to visit the ®

Gestamp branch of Wroclaw, Poland, performing cold moulding, welding, cataphoretic coating, and assembly activities on steel components. “Gestamp’s Polish plant covers a production area of about 20,000 m2. It works mainly with the Volkswagen Group, the PSA Group, and Renault,” says Gestamp process engineer Xabier Garmendia (Fig. 1). “Production is divided into three business units devoted to welding, and Body-

The cataphoresis plant: a highly automated layout The plant is equipped with eight bridge cranes and a Power&Free overhead conveyor, with two automatic loading and unloading stations and a manual one (Fig. 3). “One of the most critical aspects presented to Cabycal during the line design phase was the handling of our workpieces,” states Xabier Garmendia. “We needed to relieve our operators from the loading and unloading of the chassis, the heaviest components we produce, by automating them.” Cabycal solved the problem by integrating a Power&Free conveyor that splits in two handling lines: a manual one (Fig. 4) for the loading of the smallest and lightest parts on hanging frames and a fully automated one featuring

the moulding, MAG

Gestamp, a Spanish industrial group with over 100 production sites in 21 countries and more than 40,000 employees, has specialised in the design, development, and production of metal car components since 1997. Its high technological profile has allowed the group to pursue a product diversification strategy in order to strengthen its relationship with customers on its territory, creating a portfolio that includes Body-In-White, chassis and mechanisms (Edscha) processing operations.”

two robots

In-White processing

and elevators.

of components for

In the loading

cars and commercial

area, a robot

vehicles. Over the

picks up the

years, the Gestamp

chassis from

group has specialised

the welding

in the co-design,

line (Fig. 5) and

industrialisation

places them on

and production

hanging cages

of chassis: the

(Fig. 6).

chassis for the

An elevator

Volkswagen Crafter

(Fig. 7)

commercial vehicle,

takes these

manufactured in the

to a 6-cage

nearby Poznan plant,

overhead

accounts for about 80% of Gestamp Polska’s production volume (ref.

storage buffer.

From here, a

Figure 1: From left to right, Xabier Garmendia (Gestamp), Enric Boronat (Cabycal), Rafal Rosa (Gestamp), and Sergio Mateo (Cabycal).

second elevator positions the cages near

Opening photo).”

the transfer

To cope efficiently development of complete turnkey

unit (Fig. 8) that hooks them to the bridge

generated by this component, a

coating systems (Fig. 2). Besides

crane connected to the cataphoresis line.

cataphoresis plant was installed between

chassis, Cabycal’s cataphoresis line

In the unloading area, a third elevator

the end of 2015 and the beginning

also coats different versions of other

feeds a second robot, which picks up the

of 2016. It was designed and built by

components manufactured in the

coating chassis from the cages.

Cabycal, a company based in Valencia

moulding and MAG welding production

The finishing line consists of 14

(Spain) specialising in the design and

units.

pre-treatment tanks, 1 cataphoresis tank,

with the increasing production volume

international PAINT&COATING magazine - MAY/JUNE 2018 - N. 51

SP ECIAL AUTOMOTIVE

a pre-treatment that includes as follows: 3 degreasing stages (spraying and hot immersion – Fig. 9), 1 immersion cleaning stage at room temperature, 1 deoxidation phase, 1 hot alkaline neutralisation phase, 2 immersion cleaning stages, 1 activation phase by immersion, 1 phosphating phase by hot immersion, 2 cleaning stages, 1 passivation phase, and 1 immersion cleaning stage with demineralised water.” “After pretreatment, the components are immersed in the cataphoresis tank where electrodeposition takes place at a temperature of 34-35 °C (Fig. 10). Then, they are subjected to two washing stages

2 1

with ultrafiltered water and a

Figure 2: The cataphoresis plant supplied by Cabycal.

N. 51 - MAY/JUNE 2018 - international PAINT&COATING magazine

about 30 minutes,” says Rafal Rosa.

and 1 polymerisation oven. “The plant

A 4.0-oriented management interface

was designed to process steel parts at a

The whole plant is managed through an

maximum speed of 6 metres per minute,

HMI interface enabling to check all the

adjusted by two driving units,” explains

process stages, the pH levels, and the

Gestamp process engineer Rafal Rosa.

temperature and conductivity values of the

“Once loaded, the workpieces undergo

tanks. “The operators can supervise the

2 rinsing tanks with ultrafiltered water,

Gestamp’s Polish plant covers a production area of about 20,000 m2. It works mainly with the Volkswagen Group, the PSA Group, and Renault. Production is divided into three business units devoted to the moulding, MAG welding, and Body-In-White processing of components for cars and commercial vehicles. Over the years, the Gestamp group has specialised in the co-design, industrialisation and production of chassis: the chassis for the Volkswagen Crafter commercial vehicle, manufactured in the nearby Poznan plant, accounts for about 80% of Gestamp Polska’s production volume”

polymerisation one in the oven for

3 1

Figure 3: The plant layout.

FOCUS ON TECHNOLOGY

4 1

Figure 4: The manual handling line devoted to small and light workpieces.

status of the line from one PLC. The tanks are equipped with recirculation and filtering pumps and even the pipes feature indicators allowing to detect any pressure drops in their integrated components, such as pumps, heat exchangers, filters, etc.,” states Cabycal project engineer Sergio Mateo Teruel. “Chemicals are automatically managed by PLC-monitored volumetric dosing pumps, while an extraction system placed on the bridge crane manages the tank vapours.” “A demineralised water production system (Fig. 11) composed of three filters and pressure regulation devices is connected to some line stations, including the

electrodeposition one, to maintain the required quality

5 1

Figure 5: The robot that picks up the chassis from the line.

+49 89 13928723

SP ECIAL AUTOMOTIVE

Figure 6: The hanging cages of the automatic handling line.

6 1

The whole plant is managed through an HMI interface enabling to check all the process stages, the pH levels, and the temperature and conductivity values of the tanks.” The bridge cranes and the conveyor were

level of water and ensure consistent

designed in line with the 4.0 approach, too. “The speed of each bridge crane can

coating results. For this purpose, also

be adjusted in terms of both elevation

the temperature of the cataphoresis

and translation. They are programmed

tank is kept under continuous control;

through automatic synchronisation based

if it raises, the cooling unit activates

on the process parameters set in the HMI

automatically to bring it under the

interface (Fig. 12),” says Enric Boronat, a

parameters set in the HMI interface.

technical sales engineer of Cabycal.

Moreover, an oscillation system

“The HMI system also manages the

eliminates the bubbles that can be

Power&Free conveyor, which has a load

created inside the workpieces, thus

capacity of 600 kg per frame and consists

preserving the quality of finishes,” says

of 4 loading and unloading stations

Mateo. “Finally, turbines that generate

(automatic and manual), 2 transfer

air currents have been installed at the

stations, 2 elevators between the cooling

entrance and exit of the polymerisation

area and automatic unloading station,

oven to prevent heat from dispersing.

and 2 elevators between the automatic

The walls of the oven were made of

loading station and the transfer area

insulating panels and internally lined

before the coating process,” says Mateo.

with galvanised sheets for higher yield.”

“Optical sensors in the loading/unloading

7 1

and tank entrance/exit areas read the

To cope efficiently with the increasing production volume generated by this component, a cataphoresis plant was installed between the end of 2015 and the beginning of 2016. It was designed and built by Cabycal, a company based in Valencia (Spain) specialising in the design and development of complete turnkey coating systems.”

N. 51 - MAY/JUNE 2018 - international PAINT&COATING magazine

Figure 7: The elevator that takes the cages to the overhead storage buﬀer.

Figure 8: In the transfer station, the cages are hooked to the bridge crane that takes them to the cataphoresis line.

8 1

information related to the workpieces

FOCUS ON TECHNOLOGY

Gestamp needed to relieve the operators from the loading and unloading of the chassis, the heaviest components produced, by automating them. Cabycal solved the problem by integrating a two-rail conveyor that splits in two handling lines: a manual one for the loading of the smallest and lightest parts on hanging frames and a fully automated one featuring two robots and elevators.”

9 1

Figure 9: The hot immersion degreasing tank.

OptiStar 4.0 The benchmark for the efficient gun control

Outstanding performance and process control -

Process control with the Gema electrostatic app Easy access to all coating parameters Reproducible coating results Intuitive handling and ergonomic display

www.gemapowdercoating.com

SP ECIAL AUTOMOTIVE

10 1

11 1

Figure 10: The spray cleaning tank.

Figure 11: The demineralised water production unit.

loaded on each frame and communicate them to the control system;

energy efficiency and environmental sustainability, an important aspect

this manages their speed and processing time and optimises their

for Gestamp, which aims at increasing its production levels in future.

movements, ensuring the parts’ traceability at every process stage. Both

“Cabycal has designed four cataphoresis plants for the Gestamp group.

the coating line and the P&F

This system has enabled

conveyor are integrated into

us to optimally cope with the needs generated

one electrical panel with a remote assistance service provided by our electrical engineering team.”

Towards a renewed production eﬃciency “The cataphoresis pre-

by the increase in our

Cabycal has designed four cataphoresis plants for the Gestamp group. This system has enabled them to optimally cope with the needs generated by the increase in production volumes. Although the line is currently working on a continuous basis and they are coating more parts than initially planned (they treat about 11,000 frames per year), they have not reached the line’s maximum capacity, yet.”

production volumes. Although the line is currently working on a continuous basis and we are coating more parts than initially planned (we treat about 11,000 frames per year), we have

system is of the latest

not reached the line’s

treatment and application generation and it integrates

maximum capacity, yet,”

all the most innovative

states Xabier Garmendia.

concepts of the 4.0

“The volumes generated

industry,” states Enric

by the Volkswagen Crafter

Boronat. “The whole line can

are increasing again and

be managed through the

soon we will also start

HMI system, which allows for

a new production of

flexible programming and

about 50/60 thousand

ensures constant control of

workpieces a year, again

all plant components and

for the Volkswagen

compliance with all process

group. For the future, we

parameters. This makes it

therefore plan to exploit

easier to manage energy

the line’s maximum

consumption and intervene

production capacity

when needed.” The advanced features of the line also ensure

12 1

Figure 12: The cataphoresis line is equipped with 8 bridge cranes.

N. 51 - MAY/JUNE 2018 - international PAINT&COATING magazine

and possibly expand it, if needed,” says Garmendia.

One partner for your automated paint applications Preprogrammed centralized controls Easy integration Modular build User friendly interface (HMI)

DISCOVER OUR SOLUTIONS

graco.com/ďŹ nishing

ÂŠ Eisenmann SE

Opening photo: The Smart Service Solutions constitute part of the overall strategy for implementing Industry 4.0. The aim is optimized linking of flexible hardware with intelligent software and digital services.

INNOVATIONS: PRESENT&FUTURE

S P E C I A L AU TOMOTIV E

Smart Service Solutions for Factory 4.0. Data-Based Services Secure Rapid and Effective Customer Service Doris Schulz Schulz.Presse.Text, Korntal, Germany

doris.schulz@pressetextschulz.de

N. 51 - MAY/JUNE 2018 - international PAINT&COATING magazine

INNOVATIONS: PRESENT&FUTURE

ncreasing levels of digitalization are changing

to achieve this aim, Eisenmann has joined forces with

workflows in industrial manufacturing and

18 other partner companies as innovation leaders in

logistics. This transition can only be smooth

the ‘MindSphere Word’ association. The aim of this

in conjunction with correspondingly modified,

cooperative effort is to build up and extend the cloud-

intelligent service solutions.

based, open ‘MindSphere’ operating system developed

The fourth industrial revolution is on its way, and

by Siemens as the main, global IoT platform, and to

no company can avoid its implications. Its ‘goal’ is

develop new digital markets.

the Smart Factory, aka Factory 4.0: A production human intervention, responding flexibly to

Smart Service Solutions for optimized production workflows

changing requirements. This is achieved on the

The digital services provided cover the entire

basis of intelligently networked data about the

value chain. These data-based services simplify

state of machines and plant components as

the commissioning, operation and maintenance

environment that organizes itself largely without

well as processes

of coating plants

and products. This

and other industrial

brings about a fundamental shift not only in industrial manufacturing and logistics – the smart factory approach also affects associated business areas such as customer service. In consequence, Eisenmann has developed a futureoriented, modular

production facilities.

The fourth industrial revolution is on its way, and no company can avoid its implications. Its ‘goal’ is the Smart Factory, aka Factory 4.0: A production environment that organizes itself largely without human intervention, responding flexibly to changing requirements. This is achieved on the basis of intelligently networked data about the state of machines and plant components as well as processes and products.”

service concept: Smart

The individually configurable Smart Service Solutions modules ensure, amongst other things, fast response times in cases of malfunction, preventive maintenance, uncomplicated and reliable spare parts ordering as well as simplified qualification

Service Solutions. “The Smart Service Solutions

procedures for operating personnel – leading to

constitute part of the overall corporate strategy for

optimized production workflows and high degrees of

implementing Industry 4.0. The aim is to achieve an

plant availability.

optimal combination of flexible hardware, intelligent maximum customer benefit (ref. Opening photo),”

Cloud, App and QR codes ensure fast access

explains Holger Ernst, Senior Vice President Service

The Smart Service Solutions are based on the Service

at Eisenmann. The E-MES modular production

Cloud which complies with the latest IT security

control system provided by the Eisenmann

standards for maximum data security. The Service

subsidiary Enisco allows for factory hardware

Cloud can be integrated into existing cloud solutions.

networking in two dimensions of integration:

Its central administration and service platform consists

horizontally across the whole production process

of all customer-specific information, machines,

and vertically across all process levels. To this

functions, data and documents. The interface to the

end, the browser-based Manufacturing Execution

cloud is provided by the Service App for mobile end

System (MES) has the capacity to register, analyse

devices (Fig. 1). This app features various standard

and visualize large amounts of data. In future,

and tailored functions that allow for fast, direct access

Eisenmann customers are to be able to network

to documents and services. In addition, the app

their own production control systems throughout

makes for easy communication with the Eisenmann

the world with the aid of the E-MES applications

service team and allows users to keep their plant

and an ‘Internet of Things’ (IoT) platform. In order

under supervision from anywhere in the world at any

software and digital services that adds up to

KMU LOFT – because resources are limited

Impresa leader nel trattamento dei reﬂui industriali e artigianali attraverso la tecnologia dell’evaporazione. Offriamo • tecnologie di evaporazione a basso consumo energetico e ridotta manu-tenzione; • esperienza e know how ventennale nella realizzazione di più di pro-getti; • soluzioni economicamente all’avan-guardia nella riduzione degli scarichi e nel recupero delle risorse

www.kmu-loft.it

SP ECIAL AUTOMOTIVE

Figure 1: As the central administration and service platform, the Cloud contains all customer-specific information, machine data, functions, data and documents that can be accessed via the Service App for mobile end devices.

previously. For components that are replaced

time. Another essential component of the Service Concept 4.0 is the identification of all functionally relevant components by means of QR codes. Eisenmann is already implementing this in all new plants as standard. The standard services include, for instance, that online documentation is available in the cloud and information about a plant and its components can be accessed at any time. This has the significant advantage that the data are always up to date, in contrast

by a new variant are automatically substituted and logged via the previous QR code. The QR code and the app’s scanning function ensure that each component can be uniquely identified. Information about its function, a 3D drawing or – depending on the component – a procedure, a circuit diagram or a representation of the respective pump group can be called up, for instance. In future, the QR code will also include a feature enabling fast and secure ordering of a replacement component.

to the printed documentation available

Eisenmann has developed a future-oriented, modular service concept: Smart Service Solutions. The Smart Service Solutions constitute part of the overall corporate strategy for implementing Industry 4.0. The aim is to achieve an optimal combination of flexible hardware, intelligent software and digital services that adds up to maximum customer benefit.”

2 1

Figure 2: The Service Cloud and the Service App also support automatic information exchange. If a plant component malfunctions, a warning message is sent to the Service Cloud automatically. From there it is forwarded to the registered end devices.

N. 51 - MAY/JUNE 2018 - international PAINT&COATING magazine

INNOVATIONS: PRESENT&FUTURE

Information Exchange 4.0 shortens response times In addition, the app and the cloud can be used for automatic exchange of information between the plant, components, the user and/ or Eisenmann (Fig. 2). This function is helpful in cases where a component malfunctions, for instance. In such cases the plant generates a warning message that is sent automatically to the Service Cloud and from there to all the registered recipients – i.e. to the mobile devices and/or desktop PCs of the respective members of staff. This means on the one hand that

- Support via Virtual Private Network

The browser-based Manufacturing Execution System (MES) has the capacity to register, analyse and visualize large amounts of data. In future, Eisenmann customers are to be able to network their own production control systems throughout the world with the aid of the E-MES applications and an ‘Internet of Things’ (IoT) platform.”

(VPN) With this solution, a so-called VPN tunnel sets up a connection between the plant and the Eisenmann service team. This allows the service technician to identify the malfunction on the monitor, pass on the required repair measures to the operating personnel and start up the plant again after the malfunction has been remedied. - Support via Service App and Cloud This variant gives the operating personnel more autonomy when it comes to

malfunctions can be dealt with more quickly

rectifying faults and servicing the plant with

and plant availability improved. On the other hand, less supervision needs to be carried out

half way round the world. With the Smart

the aid of the online documentation. The

locally, with correspondingly lower costs.

Service Solutions, this kind of plant operator’s

message generated when a malfunction

nightmare is also a thing of the past. The

occurs already informs the customer staff

Service Concept 4.0’s Remote Service provides

member about the plant component

Remote Services – various options for fast assistance

for three different options to get a plant

in question. The defective component

Because of a malfunction, a service technician

operational again remotely or to carry out

can then be identified via the QR code.

has to be called – and that may mean a trip

maintenance work.

Together with this data, information

Our solutions

for the automotive industry!

Automatic powder coating • Perfect surface results • High transfer eﬃciency • Maximum precision

www.wagner-group.com

Coating, bonding and sealing. Eﬃciency and highest quality.

SP ECIAL AUTOMOTIVE

the replacement

Predictive maintenance and process optimization

part is displayed.

A large body of plant,

Once the part has

process and product

been procured,

data is already

the information

being gathered as of

contained in the

now. The use of an

documentation such

MES such as E-MES

as drawings and

makes it possible to

circuit diagrams is

evaluate such data

there to help with

and draw relevant

its installation. If the

conclusions about

component cannot

the plant operability

be replaced without

and/or the condition

the help of a service

of individual plant

technician, the app

components. E-MES

can also be used to

ensures an especially

about the article number and the storage location for

make contact.

high degree of functionality with

3 1

- Remote Support with Smart Glasses

respect to gathering Figure 3: Thanks to the bidirectional real-time connection via the Smart Glasses, the information and instructions needed to rectify a fault can be transmitted directly to the glasses.

and evaluating the data. If a component

This is certainly

should return

the most elegant

values outside the

and effective way of providing service

be used to create and transmit screenshots

defined tolerance range, this is reported via

support via the cloud and the app. The

and photos. This state-of-the-art form of

the ‘Condition Monitoring’ function of the app.

Smart Glasses, individually licensed for

service support not only significantly reduces

Amongst other things, this allows for timely

the respective plant operator, provide

plant downtimes, but also the amount of

ordering of replacement parts, so unplanned

a bidirectional, real-time connection

time and effort needed for training the plant

downtimes can be avoided. In addition,

between customer personnel and the

operator’s personnel.

inspection intervals for various parts and

Eisenmann service team (Fig. 3).

assemblies can be laid down, and

The information and instructions

these can also be displayed via

needed to rectify a fault or

the app. For some components

carry out plant maintenance are transmitted directly to the glasses – for instance, in the form of a virtual instruction book for replacing a component. The service technician can supervise the work closely and intervene immediately if something is not going according to plan. As it is also possible to set up voice contact via the Smart Glasses, customer queries can be answered at once and instructions can be explained in more detail. The glasses can also

E-MES ensures an especially high degree of functionality with respect to gathering and evaluating the data. If a component should return values outside the defined tolerance range, this is reported via the ‘Condition Monitoring’ function of the app. Amongst other things, this allows for timely ordering of replacement parts, so unplanned downtimes can be avoided. In addition, inspection intervals for various parts and assemblies can be laid down, and these can also be displayed via the app. For some components it is also possible to program fully automated outward transfer.”

N. 51 - MAY/JUNE 2018 - international PAINT&COATING magazine

it is also possible to program fully automated outward transfer. This has been implemented for the new, skidless VarioLoc conveyor system, for instance. The permanent condition monitoring and evaluation of the data not only ensures smooth production workflows – the data also provides a basis for laying down customer-specific maintenance intervals, making for better plant availability and productivity.

Opening photo: Selection of various colours using the passive temperature management technology. The specific formulation reflects near infrared light and in doing so, reduces the temperature on the surface and inside of the car when it is hot and sunny.

HIGHLIGHT OF THE MONTH

S P E C I A L AU TOMOTIV E

N. 51 - MAY/JUNE 2018 - international PAINT&COATING magazine

HIGHLIGHT OF THE MONTH

016 was a year of

for a successful future. In line with our

for thin-film encapsulation of OLED panels

transformations for BASF: the

strategy, we heavily invested in new R&D

or colorful and flexible coatings for the

biggest chemical company

and production facilities – especially in

successful Adidas Boost sneakers. NBD is a

in the world, as well as one of

Asia Pacific (Fig. 2).

new and very interesting part of our Coatings

the oldest ones with 150 years of

This expansion will further enhance our

division and explores solutions beyond paint.

history, transferred its business with

local production and better serve the

industrial coatings to AkzoNobel. The

growing automotive market in the region.

Ipcm: Which kind of synergies will you

same year, it also acquired Chemetall,

In 2016, we transferred our business

have with Chemetall after its acquisition

one of the leading manufacturers of

with industrial coatings to AkzoNobel and

and integration with its surface

surface treatment chemicals, with a

acquired Chemetall – a global leader in

treatments business?

strong presence in the automotive

DB: Our new business unit Surface

sector. Almost two years later, ipcm®

Treatment, operating under the Chemetall brand, has strategically

interviewed Dirk Bremm (Fig. 1), the President of BASF’s Coatings division, to analyse the new structure of the company and its most recent R&D activities in light of the current mega trends in the auto sector. Dirk Bremm was born in 1973. He studied Business Management in Germany, Ireland and Mexico. Bremm earned his Master’s Degree in

2016 was a year of transformations for BASF: the biggest chemical company in the world, as well as one of the oldest ones with 150 years of history, transferred its business with industrial coatings to AkzoNobel. The same year, it also acquired Chemetall, one of the leading manufacturers of surface treatment chemicals, with a strong presence in the automotive sector.”

complemented our portfolio. There are a variety of synergies that we expect, especially in terms of innovation. By combining BASF’s know-how with Chemetall’s industry-leading expertise in surface treatment technologies, we can serve our customers even better across the globe. Thereby, our combined solutions are not just interesting within the Automotive

Business Administration at the Leipzig

industry, but have also already been

Graduate School of Management in Leipzig, Germany. He joined BASF

Surface Treatment. This way, we have

proven within the aerospace industry to

in 2000 in Ludwigshafen, Germany.

further developed our portfolio and

reduce selected process times significantly.

After holding different positions in

became an even more complete solution

We help to make our customers more

various segments of BASF Group,

provider for coatings.

successful.

Bremm became President of BASF’s

In addition to the traditional coatings

Coatings division in April 2017.

business areas, our New Business

Ipcm: In the last few weeks, we have

Development (NBD) unit develops new

learnt and published a lot about BASF’s

Ipcm: Can you trace the evolution

products and solutions for other ranges

biomass balance approach. Can you

of the Company in the last 5 years?

of application. This includes, for example

please explain this sustainability

DB: Within the last years, we set our

barrier films for encapsulation of flexible

approach and how it translates into

2025 strategy and laid the groundwork

photovoltaic modules, barrier materials

products and innovations?

PAINT SHOP 4.0 DIGITAL ∙ SMART ∙ EFFICIENT

www.eisenmann.com

SP ECIAL AUTOMOTIVE

our refinish products – which are the world’s first refinish products manufactured according to the certified biomass balance approach, therefore contributing to reduce CO2 emissions.

We are currently working on further products where we can use BASF’s biomass balance approach to provide our customers with more sustainable solutions. Ipcm: Energy efficiency is a mega trend and e-mobility is part of it: being one of the leading supplier of automotive coatings, what is BASF doing in this respect? DB: E-mobility, as well as autonomous driving, will bring additional requirements for

automotive coatings in the future which means

Figure 1: Dirk Bremm, President of BASF’s Coatings division.

that the functionality increases. One example of this is energy management. We developed a functional coating with a passive temperature management

resources to be used at the start of chemical

technology which boosts energy efficiency.

production. This allows us to process the

The specific paint system is based on a

products obtained via this process in the

basecoat that is permeable for high-energy

usual manner and use them to manufacture

near-infrared radiation (NIR) and a primer

The new business unit Surface Treatment, operating under the Chemetall brand, has strategically complemented BASF’s portfolio. There are a variety of synergies that they expect, especially in terms of innovation. By combining BASF’s know-how with Chemetall’s industry-leading expertise in surface treatment technologies, they can serve customers even better across the globe.”

balance approach already permits renewable

DB: The biomass balance approach is a method developed by BASF together with TÜV SÜD in which fossil resources in the current Production ‘Verbund’ are replaced by renewable resources such as bio-naphtha or biogas from organic waste or vegetable oils with sustainability certification. The biomass

N. 51 - MAY/JUNE 2018 - international PAINT&COATING magazine

2 1

Figure 2: Automotive coatings plant in Shanghai. In the last five years, BASF has heavily invested in new R&D and production facilities, especially in Asia Pacific.

HIGHLIGHT OF THE MONTH

that is NIR-reflecting. In this combination, the paint reduces the temperature on hot summer days on the vehicle surface by up to 20°C, which means the car interior heats up less (ref. Opening photo). The need to run the air conditioner to minimize the heat in the car is thus reduced. This both enhances comfort and at the same time, reduces fuel consumption or

PAINTING ROBOTS & SYSTEM INTEGRATOR We are able to provide the full range of articulated and cartesian robots for every painting need!

extends the range of electric vehicles. Another example of future requirements are paint systems on radar and lidar, as the importance of sensor technologies is increasing. BASF is working on this topic to ensure that sensor technologies, e.g. for distance and range detection, are

LeBot MV A5-A6: 5 and 6 axis articulated robot with self-learning, point to point and 3D offline programming, also available in chariot, carriage and carousel configuration with 3D Lesta shape acquisition system.

compatible with the whole spectrum of color palettes. Therefore, we closely collaborate with OEMs to develop solutions for future mobility. Ipcm: How does the energy efficiency trend affect color trends? DB: There are globally different approaches towards color and energy efficiency. In EMEA for example, the change from complex combustion engines to rather low-tech electro engines

LeBot C5: 5 axis cartesian robot with 3D Lesta shape acquisition system. acqui ystem.

is symbolized by greyed off greens or off-whites with effect. Instead of pastels and solid colors, light grey colors with sparkle and even matt surface are used to emphasize the new mobility. In Asia Pacific, e-mobility is connected with a clean approach. Therefore, bright colors such as sky-blues are used to represent purification and cleanliness as well as fresh air and a breeze. Apart from color trends, we also see a technical trend of increasing interest for functional coatings through which OEM brands are redefining themselves. As an example, BASF has

BASF developed a functional coating with a passive temperature management technology which boosts energy efficiency. The specific paint system is based on a basecoat that is permeable for high-energy near-infrared radiation (NIR) and a primer that is NIR-reflecting. In this combination, the paint reduces the temperature on hot summer days on the vehicle surface by up to 20°C, which means the car interior heats up less. The need to run the air conditioner to minimize the heat in the car is thus reduced. This both enhances comfort and at the same time, reduces fuel consumption or extends the range of electric vehicles.”

LeBot IA6: articulated 6-axis industrial robots with jointed-arm kinematics for all point-to-point and continuous-path tasks, controlled by our LeCRob K-Manager software. LeBot IA6 robots can work with 3D Lesta shape system. aacquisition ac qu tem.

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SP ECIAL AUTOMOTIVE

Ipcm: What do you see in the

see a stronger tendency to low bake

infrared-reflecting paint colors. In the future,

future of automotive coatings?

processes which is also driven by a

colors will support e-mobility, autonomous

DB: We see many opportunities in a

change in the car body substrates â&#x20AC;&#x201C;

driving and sustainability.

fast-changing and demanding industry.

especially for light weight solutions for

There are several driving forces in

electric cars.

Ipcm: Which are the companyâ&#x20AC;&#x2122;s newest

the industry such as electrification,

When it comes to markets, Asia

products and technologies for the

autonomous driving and car-sharing,

Pacific and especially China are

automotive industry?

which have a direct impact on coatings

markets with high growth and we are

DB: For our Refinish business, we have

for car batteries, car body surfaces and

growing above the market there. We

launched the UV Primer. It offers an ideal

interior design elements.

support this growth by having large

approach for making the work processes

We also see an increasing demand

investments and a complete set-up,

quicker, simpler and more economical.

for sustainable and environmentally

including manufacturing, R&D and

By using UV-A radiation, which is the least

friendly solutions. Hence, we do not

technical services. We also see ASEAN

harmful part of ultraviolet light, it permits

only focus on our products, but also on

as a growth region for the automotive

the primer filler to dry extremely quick,

the processes. In close collaboration

industry. Therefore, we have recently

without developing heat. It is not only an

with our customers, we optimize the

opened a plant in Bangpoo, Thailand,

efficient process, but this also prevents plastic

relationship between our products

to cater for the local demand

bumpers from deforming. It therefore makes

and their paint lines. The main aspect

(Fig. 3). In addition to these big players,

the product suitable especially for the repair

here is energy saving and with our

markets such as Mexico are also

of plastic parts, which are gaining importance

integrated process, we can eliminate

interesting where we also invested in

in the car body construction.

a complete process step. We also

our production.

ÂŠ BASF

already been recognized for its award-winning

3 1

Figure 3: The automotive coating plant of Bangpoo, Thailand.

N. 51 - MAY/JUNE 2018 - international PAINT&COATING magazine

BRAND-NEW

Adapta Antigraffiti

dapta’s anti-graffiti product range has been designed

the method B of the French standard NF F 31-112. The results

mainly to protect objects from acts of vandalism such

were as follows:

as graffiti made with spray paints and/or indelible

- Aggressiveness tests: excellent resistance to cleaning

markers. Indeed, it enables to clean with common solvents

products with positive results during the 30-minute, 2-hour,

and without damaging coatings.

and 24-hour expositions. - Effectiveness tests:

The products are available in any colour and finishing

CLEANING PRODUCTS

COATINGS

INDELIBLE MARKERS

PAINTS

chemical resistance to the most common solvents, such as

US266 in gel form

100%

97.2%

xylene, acetone, turpentine, and methyl ethyl ketone (MEK).

Bonderite 300

97.2%

100%

The latest version of these anti-graffiti products feature a

Bonderite 500

100%

24 hour resistance against the latter, which significantly

Bonderite 1302

97.2%

100%

94.4%

distinguishes it from its current competitors (Fig.1).

Socostrip T4210

100%

93.8%

94.4%

effect, including transparent and metallised. They feature good outdoor resistance and excellent

The UB Antigraffiti series has been approved by the

For further information:

(National Society of French Railways) in compliance with

www.adptacolor.com

Material Laboratory of the Railway Testing Agency of SNCF

Figure 1: Adapta’s anti-graﬃti product range features excellent chemical resistance to the most commonly used solvents, such as methyl ethyl ketone.

N. 51 - MAY/JUNE 2018 - international PAINT&COATING magazine

Oops...

FASTRIP, for the easy, effective and rapid paint stripping of metals.

ALIT Technologies, the chemical paint stripping specialist. Products, machines, processes and consultancy.

www.alit-tech.com San Bonifacio â&#x20AC;&#x201C; Verona - ITALY

BRAND-NEW

TOPFINISH Bell 1S Expands Range for Automated Liquid Paint Coatings

AGNER is expanding its range of

has been designed especially for use with

guarantee the shortest possible colour

high-speed rotation atomizers

reciprocators and linear axes. Thanks to

change times. The atomizer’s modular

with a special version for

its compact and lightweight construction, it

structure allows these paint valves to be

attachment to reciprocators and linear

can easily be attached to rigid movement

used both in the TOPFINISH RobobtBell and

axes. All models are available with valve

systems. The Bell 1S is therefore also

in the TOPFINISH Bell 1S.

discs featuring 2 or 4 paint valves for rapid

especially ideal for rim coating in the

colour changes and a 2K mixer.

automotive industry.

The new TOPFINISH Bell 1S from WAGNER coating can be used in a wide range of

Both versions of the

for automated liquid

Cost-eﬀective 2K version for reduced material consumption high-speed rotation atomizer are now

industry sectors to

optionally available

achieve high quality

with an integrated

coating results

2K mixer (Fig. 2). The

(Fig. 1). Just like the

processing of two-

proven TOPFINISH

component materials

RobotBell, the new

is made possible at

coating applicator with

low cost thanks to a

adjustable shroud

built-in static mixer

air streams allows

and the targeted

great variations in

cycling of two existing

the spraying pattern

valves. Here too, the

and can be used

atomizer head is

with various bell disc

positioned close to

combinations. Where

the mixing element

colour changes are needed, an additional flush valve close to the spraying head allows rapid, straightforward

— for fast flushing

and reduced material

Figure 1: The new TOPFINISH Bell 1S from WAGNER for automated liquid coating can be used in a wide range of industry sectors to achieve high quality coating results.

flushing and short

consumption during highly automated production.

workpieces are being coated with highly

Additional valve discs for rapid colour changes

Simple maintenance without special tools

automated systems.

To achieve a high degree of automation

WAGNER uses the same basic

The new TOPFINISH Bell 1S product is

with a large throughput volume, very

components for both products, such

based on the technology of the TOPFINISH

short colour change times are needed.

as the turbine, bell discs and flexible,

RobotBell and is WAGNER’s response

WAGNER therefore uses integrated valve

exchangeable valve discs.

to the growing demand for automated

discs with two or four paint valves that

The replacement and wear parts are also

applications involving a range of movement

are positioned close to the atomizer

identical. The system’s easy maintenance

technologies. While the RobotBell is

head. The short pathways minimise waste

without specialist tools also saves times

mounted onto a robot arm, the Bell 1S

during flush and change operations and

and reduces operating costs.

colour change times — for fast cycling when

N. 51 - MAY/JUNE 2018 - international PAINT&COATING magazine

BRAND-NEW

2 1

Figure 2: Both TOPFINISH RobotBell and TOPFINISH Bell 1S are now optionally available with an integrated 2K mixer.

Excellent atomization for superlative surface quality The high-speed rotation atomizers achieve an application efficiency of over 90%. Their compressed air consumption is 20% less than with comparable products. An exhaust air concept that directs exhaust air backwards optimises the coating result further.

Bell discs for every material and workpiece For its TOPFINISH high-speed rotation atomizers, WAGNER offers bell discs in various sizes (30, 50, 70 mm) with different serration options (smooth, straight/cross serrated). “Small parts can be coated with a 30 mm bell disc, while the 50 mm model can be used as an all-rounder. And large, flat workpieces are coated in the shortest possible time with a 70 mm disc”, explains Peter Neu, Senior Product Manager at WAGNER Industrial Solutions. The bell discs are made from titanium or Consistal, a lightweight material based on aluminium which has excellent properties with abrasive materials. Both high-speed rotation atomizers can be used with solvent-based and water-based paints. If paint remains stuck to the bell disc during the spraying process, it can be easily removed within a second using two flushing devices inside and outside the bell head. For further information: www.wagner-group.com

BRAND-NEW

Alufinish Expand Their Range of Organic Dye Products

lufinish GmbH & Co. KG now

textile, paper and aluminium

Thanks to their favourable sales and

offer organic dyes for colouring

industries. To meet the

marketing structure together with an

anodised aluminium surfaces that

constantly increasing demands

extensive customer network, Alufinish

are made by the Thai producer Modern

of the market, the main focus

GmbH & Co. KG are taking over the

Dyestuff & Pigments Co. Ltd. (MDP).

of the company’s corporate

global distribution of Alumino® dyes for

Alumino organic dyes are supplied

philosophy is on the continuous

the aluminium pre-treatment sector with

in powder form and can be dissolved

advancement of their products.

immediate effect. The only exception is the

in water as usual prior to dyeing the

This ensures that international

Chinese market which will continue to be

porous surfaces by absorption. Besides

standards are also complied

directly served by MDP. In future, Alufinish

standard shades such as black, blue,

with and guarantees the high

will be able to offer an organic alternative

red, green, brown or yellow, the current

quality and lasting durability of

for dyeing anodised aluminium which will

range of colours is now to be expanded

their products. MDP operate two

benefit the European market in particular.

to incorporate special hues (Fig.1).

production locations in Thailand

Organic colourants are characterised

and China as well as their own

For further information:

by their good water solubility as well as

development centre.

www.alufinish.de

to temperature and pH fluctuations. In addition to the shades available for indoor applications, the range

their low sensitivity

includes dyes that are highly resistance to light, temperature and weathering and thus ideal for outdoor use. As one of the leading manufacturers of dyes and pigments, the MDP Group and their partners have been marketing colourants in more than 70 countries worldwide since 1990. Their customers include all the industrial sectors in which large quantities of dye are required, in particular the leather,

Figure 1: Besides standard shades such as black, blue, red, green, brown or yellow, the current range of colours is now to be expanded to incorporate special hues.

N. 51 - MAY/JUNE 2018 - international PAINT&COATING magazine

BRAND-NEW

Cool Touch Effect: Highly-Filled Polyamides with Special Properties

and combination of fillers as well as the

conductivity can be felt; they are cooler

know-how and new technical

interface adhesion are key parameters

and can thus further enhance the cooling

possibilities, ROMIRA is able to

to achieve the desired properties profile

effect of any electroplated layer that is

manufacture highly-filled polyamides with

of the matrix material. The correct filler

applied (Fig. 1). One good, vivid example

some specific properties: the products

selection and appropriate additives

of an application area is for the push-

are characterized by an excellent,

lead to special properties that are not

buttons in lifts or for light switches. When

homogeneous and fine dispersion of fillers.

innate to metals giving for example,

manufactured from highly-filled polyamides,

As a result, products with special

the possibility of thermally conductive

they offer not only a cool touch effect

properties such as higher notched and

plastics that conduct heat but are still

but also a superior quality look and feel

un-notched impact strengths, together

electrically insulating. Smooth surfaces

compared to conventional plastic buttons.

with better thermal conductivity and

are necessary, amongst other things,

exceptionally smooth surfaces can be

for parts that are to be subsequently

For futher information:

achieved. The type, structure, quantity

electroplated. The better thermal

www.romira.de

Mark Dymchenko © Fotolia

ith its process engineering

Figure 1: Highly-filled polyamides oﬀer a better thermal conductivity, which can be felt through an enhanced cooling eﬀect.

N. 51 - MAY/JUNE 2018 - international PAINT&COATING magazine

Automatic SEASIDE endorsement

*Fully integrated in SATâ&#x20AC;&#x2122;s vertical coating plants

sataluminium.com

Opening photo: Some of the entrance door panels manufactured by Obuk in Oelde, Germany.

FOCUS ON TECHNOLOGY

Full Automation ‘Batch 1’ – Powder Coating for Production of Entrance Door Panels Michael Lazin Nordson Deutschland GmbH, Germany

ics.eu@nordson.com

BUK is one of those hidden success

employees manufacture entrance door

From a purely technical point of view, the

stories of which there seem to be

panels in Oelde, Germany (ref. Opening

door to a building is something which has

so many in Westphalia. It may not

photo), and has only recently invested in

to has to fulfill multiple functions at one

be a brand everyone can instantly bring to

new powder coating plant using the latest

and the same time. It forms the boundary

mind, but this is a company of specialists

application engineering from Nordson.

separating the inside from the outside,

whose outstanding reputation in its own

Here is a report on the company’s

protecting the people who live behind

sector extends far beyond the frontiers

early experiences with the new powder

it from the effects of climate, noise and

of Germany. The company and its 160

application.

unwanted sights, as well as from crime.

N. 51 - MAY/JUNE 2018 - international PAINT&COATING magazine

FOCUS ON TECHNOLOGY

More than that, though, a door also

frames by carpenters on site. “Of course,

features of a door, but customers

expresses the aesthetic visions of the

though, the door leaf itself is a vital design

actually seek out their door in a well-

builder or owner and acts as a kind of

component in terms of the form and

lit door studio and expect its looks to

“visiting card” for homes or commercial

function of a door.”

be flawless, as they would for their

buildings. Thus the value of a door

car or the glossy surfaces of their

presenting an individual image has

kitchens.” Indeed, although more

become correspondingly important.

than 40,000 of them are made every

“In effect, every one of our entrance door panels is unique,” explained Henrik Wendt, operations manager at the Oelde factory, and that is no less than the literal truth. “Our door panels are genuinely manufactured to order and then supplied to installers both at

OBUK and its 160 employees manufacture entrance door panels in Oelde, Germany, and has only recently invested in new powder coating plant using the latest application engineering from Nordson.”

year, a very substantial amount of manual craftsmanship goes into any door, be it made of aluminium, plastic or glass, for example, when the glass has irregular light transmitting panels which are framed in delicate stainless steel. “This can only be achieved

home and abroad.” In fact, therefore,

economically if we make those

although OBUK uses the slogan “Doors

processes which do not require such Customers set enormously great store

craftsmanship as completely and

ready-to-fit doors, but just the leaves,

by this. “In fact,” Wendt reveals, “’only’

efficiently automated as possible,” as

the part of the door that actually

the normal standards for quality of

the operations manager knows all

swings, and which are fitted into door

facade really need to apply to the surface

too well.

for life”, they do not produce complete,

Figure 1: The coating plant is designed for a three-minute turnaround. Two minutes of that is given over to the powder coating, while the remaining minute is taken up by colour changes and preparation for the next traverse in the robot booth.

international PAINT&COATING magazine - MAY/JUNE 2018 - N. 51

SP ECIAL AUTOMOTIVE

2 1

Figure 2: “Spectrum COD” powder feed centre, which is equipped with 24 small powder hoppers and 8 large ones. The colour-on-demand system can provide 8 main colours, 20 auxiliary colours and 4 special colours.

Versatility of product, even down to a production batch of just one item, requires a high flexibility

because, as a successful business, we

quality reasons, we do not sub-contract

must respond to our own growth and

to other coating firms during peak times

also need to accommodate seasonal

but complete all our orders in-house.

peaks in production. Where we were

For this reason, with the high degree

Faced with the necessity of meeting ever

previously coating about 220 door panels

of individualization we offer, where our

more demanding customer requirements

customers can even configure their

ever more efficiently, OBUK decided last

requirements on the internet and we

year to replace their powder coating facility with a brand new modern system. “The old coating plant had been in use since 2005, although it was already using dense phase technology,” explained Daniel Hentschel, head of production engineering. “We had three automatic spray guns and one manual one from the first generation

Faced with the necessity of meeting ever more demanding customer requirements ever more efficiently, OBUK decided last year to replace their powder coating facility with a brand new modern system.”

build it as a one-off job, speed and flexibility are essential to our continued existence. The implementation of the plant was given to a well-known general contractor, and because of their many years of excellent experience with dense phase

and the whole system had run for 12 years

technology components supplied by

without fault. The new robot-assisted

Nordson, they even stipulated this in the

version, though, is just so much faster,” he

per week, now it is 600, sometimes

specifications. The layout and technical

grinned and then added a few more good

more!” Operations manager Wendt also

requirements for the new plant were

reasons for the conversion. “We urgently

added, “At OBUK we consciously focus

worked out in the course of an in-depth

needed some capacity enhancements

on flexibility of manufacturing and, for

analysis and planning phase.

N. 51 - MAY/JUNE 2018 - international PAINT&COATING magazine

FOCUS ON TECHNOLOGY

The layout and technical requirements for the new plant were worked out in the course of an in-depth analysis and planning phase. During this and all other phases of the project, support was provided for operations management at OBUK and for the EAR Rittersbach planning bureau. Integration was the key aspect. Each of the stations has its own control system. Adapting all of these to the overarching plant control system needed plenty of programming work at the interface points and cooperation between multiple experts.”

During this and all other phases of the project, support was provided for operations management at OBUK and for the EAR Rittersbach planning bureau. “Integration – that was the key aspect,” recalled Daniel Hentschel at the end of the conversion phase. “Each of the stations has its own control system. Adapting all of these to the overarching plant control system needed plenty of programming work at the interface points and cooperation between multiple experts. Basically, it did take time before everything was working flawlessly and even the very last intractable error was finally laid to rest.” That time was used well. Even while the system was being installed, the powder coating technicians, all trained by OBUK themselves, also received intensive training from Nordson.

Faster, better, more eﬃcient: these are the benefits from 12 years of technical advancement So, when regular operation started and the first components moved along the conveyor belt in the production hall, each accompanied by all its relevant data in bar code form, even experienced plant operators showed themselves not a little astonished at how much techniques have advanced, because much has happened in the field of powder coating over the last few years. Qualified engineer (Dipl.-Ing.) A. Ritterbach explained about the planning for the plant, “The coating plant is designed for a three-minute turnaround. Two minutes of that is given over to the powder coating, while the remaining minute is taken

SP ECIAL AUTOMOTIVE

up by colour changes and preparation

The quality of the coating was also

extremely uniform, even in recesses and

for the next traverse in the robot booth

noticeably improved beyond the already

areas of complex geometry. This level

(Fig. 1).” “This is really important for us,

high level of the previous plant. When the

of quality can practically be reproduced

because the concept of single-item job

6-axis industrial robot from ABB sprays its

almost as many times as needed. The strict

production is no pie-in-the-

internal quality controllers

sky dream of the future,

only refer a maximum of

but something we do on

3 to 4 percent of coated

an everyday basis,” added operations manager Wendt. Smart colour management is handled by a Nordson “Spectrum COD” powder feed centre, which is equipped with 24 small powder hoppers and 8

When the 6-axis industrial robot from ABB sprays its powder through the Encore robot spray gun at close quarters to the workpiece, then the coating, configured by OBUK to an optimal thickness of 70-90 μm, remains extremely uniform, even in recesses and areas of complex geometry. This level of quality can practically be reproduced almost as many times as needed.”

parts for reprocessing – a hitherto unattainably low level. “The secret of the especially high powder content in the ‘soft cloud’ is that it is expelled from the guns with relatively little air

large ones. The colour-on-

and actually rather slowly.

demand system can provide

This means the robot can powder through the Encore robot spray

get in closer, the material has more time to

and four customizable special colours

gun at close quarters to the workpiece,

spread over the surface and it has better

for the optimum possible flexibility

then the coating, configured by OBUK to

adhesion there,” explained Hentschel.

(Fig. 2).

an optimal thickness of 70-90 μm, remains

This optimizes the application of the

eight main colours, 20 auxiliary colours

3 1

Figure 3: Nordson HDLV pumps are virtually maintenance-free, which means they also enhance quality, flexibility and production benefits over the long term.

N. 51 - MAY/JUNE 2018 - international PAINT&COATING magazine

FOCUS ON TECHNOLOGY

powder, speeds up the coating procedure and

expectations and the answers will be many-

helps save a lot of powder from being wasted.

faceted, but invariably positive.

“Although powder application does still entail

Production engineering manager Daniel

losses, it was possible to lower the cost of

Hentschel emphasizes the ease of operation

powder coating per door panel by a considerable

for what is otherwise a really complex

amount because the transfer efficiency in the

installation. “When you have employees like

coating process has been markedly improved

ours who really know their powder coating,

and unproductive colour change periods have

then a conversion like this is not going to faze

also been eliminated,” Ritterbach summed up

anyone. On the contrary, the touch screen

with satisfaction, because that had been exactly

control for the system is highly intuitive and

what the prognosis had promised. Powder

doesn’t need a lot of training. The way the

consumption was analysed in great detail and

process is portrayed on the screen is almost

has been further improved. In particular, the

self-explanatory.” For operations manager

programming of robot movements still offers

Henrik Wendt the ease of production planning

major potential. “If you consider that even now

is of key importance. As an example, he

a first-pass transfer efficiency of 60% is already

mentioned the maintenance periods for the

being achieved, even though our doors have

HDLV pumps, which undergo heavy stresses

cut-outs, patterns of holes and similar in the way

(Fig. 3). “The pinch valves for the pumps are

of decoration, then our experience of many years

their only components which suffer from wear

shows that such results can only be achieved

and, even in spite of the stresses they have to

using dense-phase technology,” added Wendt.

endure, they are still good for 15,000 colour

For trained, professional staﬀ, a conversion like this is no problem

GANCI | HOOKS

TELAI | RACKS

changes. To be absolutely sure, we replace them after 12,500, but then we never have a single one wear out.

It is only economically possible to turn out 40,000

Even when faults do occur somewhere in the

door panels a year in the tiniest of batches

system, the signs are always there in advance.”

and with very high quality requirements with

More than 15,000 high-quality colour changes

the maximum amount of automation and if

have already been made since the plant was

precisely defined procedures can ensure that

commissioned at the end of January 2018.

production processes are reproducible to the

Even after a few weeks, trust in the state-of-

tightest of tolerance demands. It is essential for

the art Nordson powder coating system had

all components of the plant to offer excellent

grown to such an extent that the pre-existing

functional reliability, for them to be easily

coating system, initially retained as a fall-back

accessible and for maintenance intervals to be as

alternative, was deactivated entirely. Now

long as possible in order to keep downtimes to a

it has been dismantled and re-installed at

minimum and ensure that planning can handle

one of OBUK’s subsidiary plants, where it

the entire production process – especially when

will certainly remain in use for many years.

multiple coating is involved. Simple, undemanding

One feature of the old system has been

control, rapid set-up and cleaning and resource-

missed by OBUK employees on these cold

saving operation are the other things that round

February days, that being the enormous

off the list of requirements for ‘smart-factory’

amount of heat it used to generate. “On hot

production.

days in summer, it has been up to 40°C in

MASCHERATURE | MASKING

PER INFORMAZIONI E ORDINI VI INVITIAMO A CONTATTARE: PLEASE CONTACT:

the production hall, but in winter it was great The new powder coating system at OBUK has

– the new one is extremely energy efficient

only been in operation a few months so far, but

and it’ll never match that,” smiled Daniel

the procedures have already settled into place.

Hentschel.

Ask the operations and equipment managers whether investment of around 2 million euros in

See the movie about OBUK case study at

the latest, robot-assisted technology has fulfilled

youtu.be/VkGlZrpCix8

Cecilia Ghizzi Gola ghizzi-gola@emptmeyer.it Fon: +39 02 947 58 58 2

www.emptmeyer.it

Opening photo: Graco’s solution for paint booth automation involves creating a fully and easy integratable, completely automatic paint application system.

INNOVATIONS: PRESENT&FUTURE

Why Automate your Paint Booth? Bart Clerx Graco, Belgium

bart.clerx@graco.com

utomating a paint booth leads to

American automation market over the first

same period last year. The hottest industries

quality improvements, increased

nine months of 2017; a good indicator of the

were metals (54%), automotive components

productivity and streamlined

global state of the industry. According to the

(42%), and food & consumer goods (21%).

operations.

Association for Advancing Automation, robotics,

Record order levels were also recorded in

Automation is an express train that shows no

machine vision, and motion control segments

motion control & motors (up 10%) and in

sign of stopping, nor even reducing speed.

are at the highest levels of growth ever.

vision and imaging (up 14%). Globally, it is now

More and more production processes all over

In the area of robotics, orders valued at nearly

the eighth year in a row that industrial robot

the world are hopping on board.

$1.5 billion were sold in North America. This

sales have grown and prospects for 2018 and

Let’s look at the performance of the North

represents growth of 14% in units over the

beyond look promising.

N. 51 - MAY/JUNE 2018 - international PAINT&COATING magazine

INNOVATIONS: PRESENT&FUTURE

Automation is a key enabler for industry

separately controls applicator parameters,

The concept is that one system

development. It enables improvements

proportioner parameters, robot, reciprocator

controls all paint process variables

in the quality of work. It allows dirty,

and other devices, sensors etc. This also

of fluid handling equipment and

tedious or dangerous work to be

requires extensive PLC programming

applicators. Communication with

transferred from human to machine.

robot or reciprocator is

It leads to reductions in labor costs,

simplified and standardized,

improvements in productivity,

which reduces the level of

and provides a solution to flexible manufacturing and the strong customization of products that is driven by consumer demands.

What about its cost? Questions need to be asked about the investment cost for automation. Is it an

According to the Association for Advancing Automation, robotics, machine vision, and motion control segments are at the highest levels of growth ever. In the area of robotics, orders valued at nearly $1.5 billion were sold in North America. This represents growth of 14% in units over the same period last year.”

PLC programming needed. Central to this are the preprogrammed logic routines within the equipment: the Graco Control Architecture (GCA). Many integration options are possible with one

obstacle? For a paint booth operator,

familiar system. No

for example, what does it cost to move

matter which brand of reciprocator, robot or other

from a manual to an automated spray application?

knowledge. In addition, the programmer

PLC driven device, it can be easily

The most evolved examples of automated

needs to clearly understand the complete

integrated with the Graco Control

paint spray applications are to be found in

paint spray process. However, the overall

Architecture software. The external

the automotive industry. Here ATEX paint

cost for the automated paint spray process

PLC, regardless if it’s using Profinet,

robots integrate all paint process variables

in general industry is less than that of a fully

Profibus, Ethernet or Devicenet, will

into one. Robot controls, dosing and mixing

equipped automotive paint robot.

be uploaded with the standardized

equipment, colour change and spray

configuration file (GSD, GSDML etc.).

the Paint Robot’s PLC. It is fully integrated,

The Graco approach to paint booth automation

fully programmable into detailed levels,

A third approach is possible, which is the

data such as the communications

but it comes at a price. The investment

path that Graco pursues. It involves creating

options, I/O configuration and the

cost necessary for such a system can easily

a fully and easy integratable, completely

available diagnostics of the Graco

equipment are all centrally controlled by

With this configuration file, system integrators can determine basic

Control Architecture.

exceed 200,000 EUR.

Having this standardized

General industry has a growing need for fully automated paint applications. However, the return on investment when purchasing such automotive paint robots is not always optimal. Moreover, these automotive grade paint robots require a specific education level from its programmers, maintenance people and operators. Once programmed, the paint application will run smoothly, but the moment changes need to be

I/O configuration readily

Automation is a key enabler for industry development. It enables improvements in the quality of work. It allows dirty, tedious or dangerous work to be transferred from human to machine. It leads to reductions in labor costs, improvements in productivity, and provides a solution to flexible manufacturing and the strong customization of products that is driven by consumer demands.”

available, the job load of the PLC programmer is drastically simplified. Through a single Ethernet IP cable, a connection with the Graco GCA Gateway is established. The GCA contains the mapping which enables smooth communication between

programmed and implemented, then

the communication protocol

qualified, specialized personnel need to

used by the PLC and the

be on-hand.

automatic paint application system –

Modbus protocol used within the

Alternatively, in general industry many

including dosing, mixing, colour change and

Graco Control Architecture.

automated paint spray processes are

applicator – for an affordable price (ref.

One system controls all paint process

constructed around a central PLC, which

Opening photo).

variables:

international PAINT&COATING magazine - MAY/JUNE 2018 - N. 51

Figure 1: The Graco Control Architecture software allows to control the complete paint spray process through one PLC.

Mixing and dosing: - Flow rate control; - Recipe: colour change, mixing ratio; Dispensing: - Fan and atomizing air control, electrostatic kV and μA; - Gun trigger or trigger input signals; - Brush files. With this unique and innovative concept, users are able to automate the complete paint spray process. It’s controlled by one PLC, which is easy to program. Fluid supply, dosing, mixing, flow and pressure control, atomization and spray parameters, robot or reciprocator: all controlled with one PLC (Fig. 1).

100

N. 51 - MAY/JUNE 2018 - international PAINT&COATING magazine

Integrated system for numerous benefits This unique concept for integration offer numerous benefits. For a start, it is easy to use. All paint variables are in one place for streamlined integration. Mixing ratio, flow rate, fan air, atomizing air, electrostatics and gun trigger are all in one simple system. The communication structure is straightforward and consistent. All that is necessary is one Graco gateway and one Ethernet cable to connect the system to the PLC or robot controller. The mapping structure is standardized for repeatability and consistency, while robot pre-sets (brush files) are available for grouped control of spray variables. It also offers a

INNOVATIONS: PRESENT&FUTURE

Another approach is possible, which is the path that Graco pursues. It involves creating a fully and easy integratable, completely automatic paint application system – including dosing, mixing, colour change and applicator – for an affordable price. The concept is that one system controls all paint process variables of fluid handling equipment and applicators. Communication with robot or reciprocator is simplified and standardized, which reduces the level of PLC programming needed. Central to this are the pre-programmed logic routines within the equipment: the Graco Control Architecture (GCA).” user interface that is familiar to anyone working with a Graco interface. It’s a safe system on account of the built-in logic to disable electrostatics in certain situations, and the low-voltage cable gun which reduces risk to operators. And it’s smart. The internal logic for linking spray gun operation

HAI UN IMPIANTO DI MOVIMENTAZIONE A CATENA? TRAS-MEC è la prima azienda che mette in sicurezza il tuo impianto e ti garantisce da contratto una produzione senza fermi improvvisi Non dovrai più lavorare accontentandoti HM YRE WSPY^MSRI GLI RSR XM WSHHMWǻ Progettazione: Mandaci il tuo progetto e studieremo il tuo trasportatore così che risponda alle caratteristiche che rendono il tuo ciclo produttivo unico.

Non avrai più dubbi sulla produzione del tuo materiale Produzione: Costruiremo il tuo trasportatore secondo metodi standardizzati sviluppati nel tempo per farti avere un impianto performante.

Non dovrai più preoccuparti del montaggio del convogliatore Installazione: Con quest’opzione, avrai il tuo convogliatore chiavi in mano montato da un team di tecnici montatori esperti.

with fluid control reduces PLC programming (Fig. 2). Logic

Non avrai più blocchi di produzione

routines are available to enable/disable certain features when

Servizio di manutenzione: Con il nostro servizio di manutenzione avrai un’assistenza periodica e continuativa che ti eviterà fermi non programmati, perdite di produzione impreviste.

the PD2K is in specific states such as Mix, Mix Idle or Colour Change. Moreover, the gun selector automatically enables features based on gun type.

A favourable return on investment The equipment investment for such a system is around 90,000 EUR. Breakeven is estimated within one year. All factors influencing the return on investment need to be incorporated into the calculation: - Cost of labour; - Process improvement (increased amount of parts per year); - Reduction of process materials, solvent and consumables; - Improved quality, fewer rejected parts, scrap, warranty expense.

Reduced total cost per part There’s a further advantage beyond ROI, which is that the automated paint spray process will minimize the total cost per part. One well-known practice in the paint booth to reduce total cost per part is through remote colour change and mixing. Flushing

TRAS-MEC è la prima azienda che ha integrato tutti i processi in un unico sistema industriale, per farti lavorare nel modo più performante senza più fermi di produzione che non sono stati programmati. Se vuoi avere più informazioni sul tuo trasportatore scrivi a customercare@tras-mec.it Riceverai in regalo il report “I 5 errori da evitare per mettere in sicurezza il tuo impianto nto ed eliminare per sempre il rischio dei fermi improvvisi” vvisi”

REPORT IIN N RE REGALO! REGALO EGALO! LO

With the intelligent paint kitchen, users

waste can be reduced by up to 80% by mixing close to the applicator, and by increasing the flushing sequence and the colour change time. This is fairly obvious as only the zone between colour change bloc and the dosing pumps need to be flushed. However, automation in the paint shop results in even more cost reduction, as the energy consumption and VOC emissions can be reduced. A Graco Control Architecture Paint Kitchen ‘Supervisor’ controls the different paint kitchen system components, such as the electric paint circulation pump, back pressure regulator, electrical agitator, pressure transducers, tank level monitor

can remotely monitor and control key circulation parameters like pressures, flow rates, tank levels and agitator speeds. It is a less complex, less expensive alternative to advance remote monitoring and control for the entire paint shop – especially compared to traditional custom-built systems. All components are standard products, which makes them easy to be configured and install. Both the initial investment and installation costs are lower. Graco’s easy-to-integrate automation technology can significantly improve paint shop productivity, profitability and quality. It’s no wonder smart manufacturers are making the switch.

etc.

The communication structure is straightforward and consistent. All that is necessary is one Graco gateway and one Ethernet cable to connect the system to the PLC or robot controller. The mapping structure is standardized for repeatability and consistency, while robot pre-sets (brush files) are available for grouped control of spray variables. It also offers a user interface that is familiar to anyone working with a Graco interface.”

2 1

Figure 2: The internal logic for linking spray gun operation with fluid control reduces PLC programming.

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N. 51 - MAY/JUNE 2018 - international PAINT&COATING magazine

INTERNATIONAL PATENT

NITROROBOT Eurosider, a company with vast experience of using various fluid carriers for liquid painting, has developed a new system to produce a high density carrier in order to obtain better atomization which brings the advantages listed below. Nitrorobot can keep all day long the same settings and guarantee the best working conditions, independently from the conditions of the environment. The equipment, in Touch Screen version, is provided with the system of control of various settings, possible to monitor from any coating system control panel. Ideal application for Nitrorobot is on automatic coating systems with rotary bells, or it can be applied on conventional pneumatic guns, HVLP or electrostatic guns.

NITROTHERM The performance is reffered to fluid enriched in nitrogen with concentration of 93% Âą 1%, at environment temperature of 20 Â°C and atmospheric pressure of 1013 mbar. Inlet compressed air must be free from impurities (water, oil, solid particles). We advise to use filter elements supplied by Eurosider. All the data and images are merely approximate and can be changed; the performance vary in accordance with environment and working process pressure and temperature. Eurosider reserves a right to make modifications, even without advanced notice.

EUROSIDER Piazzale Thailandia 6 | 58100 GROSSETO | ITALY ph. +39 0564 425117 | fax +39 0564 418833 www.eurosider.com | info@eurosider.com

Opening photo: The FASTRIP system range includes in-line paint stripping systems, immersion paint removal tanks, and spray systems.

INNOVATIONS: PRESENT&FUTURE

Innovative Spray Stripping Systems: Alit’s New Products Presented at PaintExpo 2018 Ilaria Paolomelo ipcm®

aint stripping is a topic of great

company specialising in the production of

in the field of metal chemical stripping with

interest to any company operating

chemical paint removal systems for metals,

the aim of effectively restoring badly coated

in the coating sector. Chemical

presented an important innovation in this

components at a convenient cost and without

stripping processes, used to remove paint

sector at the PaintExpo 2018 exhibition.

wasting time. That is why Alit has developed

from components with surface defects and

The firm based in San Bonifacio (Verona,

FASTRIP, a range of innovative paint stripping

hanging accessories, usually require the

Italy) was established about three years

systems suitable for the different needs of each

workpieces to be completely immersed

ago to make up for the lack of adequate

company. The FASTRIP system range includes

in a stripping product. Alit Technologies, a

knowledge and provide concrete answers

in-line paint stripping systems, immersion paint

104

N. 51 - MAY/JUNE 2018 - international PAINT&COATING magazine

INNOVATIONS: PRESENT&FUTURE

removal tanks, and spray systems, with different sizes and equally different investment costs (ref. Opening photo).

The Fastrip T5 system This off-line stripping system for hooks, frames, and parts to be restored features a medium-sized tank with a capacity of about 600 litres of chemical product. The process enables to remove the paint on hooks and components without attacking the base metal. The system is available in three versions combining a chemical and a mechanical action: • T5-U with ultrasound technology; • T5-A with an air agitation system; • T5-M with a mixer. The machines are built in steel AISI 304 and they are equipped with a heating system and a thermoregulator that enables to adjust and reach temperatures up to 80 °C. A version that allows to reach temperatures of 150 °C is available for all models. Their innovative design and the presence of an exhaust valve and wheels allow them to be transported anywhere. In order to optimise the use of this system, Alit has developed three types of chemical process that are part of the Metalstrip Up&Down range, which enable the operators to use chemical products during the coating cycle without any problem.

The Fastrip S system In order to meet the needs of the numerous companies that clean and coat their machined components in-house, Alit has developed Fastrip S, a vertical spray stripping system that allows to create a paint removal station with a small footprint, adjacent to the industrial cleaning plants. Presented for the first time at Paint Expo 2018 in April, Fastrip S enables to chemically strip several metals, including iron, aluminium, and magnesium, without damaging their surfaces. It can be adapted to the needs of the each customer. Fastrip S consists of a paint stripping station and a rinsing tank. Since it operates at high temperatures (up to 150 °C), the system dramatically reduces the paint stripping times (e.g. about 40 minutes for alloy wheels), depending on the type of coating product to be removed. It also ensures that the operators do not come into contact with the products. At the end of a paint stripping cycle, the machine can be opened to perform a visual quality check; if necessary, the stripping cycle can be repeated. Alit, always attentive to environmental issues, recommends the use of paint strippers from its Metalstrip range, which quickly remove the coatings without damaging the base surface, are economical, and have a reduced environmental impact.

strichfiguren.de © Fotolia

STANDARD & LEGISLATION - UCIF Informs

Industry 4.0: the Challenges of 2018 Marcello Zinno UCIF – Italian Surface Treatment Equipment Manufacturers’ Association, Milan

info@ucif.net

ast year there, was a lot of talk about

This does not only mean that finishing

for the direct collection of financial

the Italian government’s plan for the

systems can acquire new abilities and

resources, with particular attention to

digitalisation of manufacturing and

become more innovative, but also that

firms intending to get in touch with more

mechanical companies. The Industry 4.0

this potential can produce advantages

financial operators in the context of

Plan focusses on both digitalisation and

for client/user companies – industrial

growth or internationalisation programs.

the improvement of firms’ technological

advantages (processing time reduction,

The first step of the agreement refers to

and applied research levels, and it soon

waste reduction, better monitoring of

the so-called ‘supply chain bonds’. This

boosted investment thanks to the tax

end-to-end production processes) but

instrument is aimed in particular at the

benefits provided by the Budget Law. The

also information benefits (control and

thousands of SMEs that play a decisive

ANIMA Federation immediately committed

management of data also in relation to the

role in the production chain of which

to inform its members on how to take

whole supply chain) that easily translate

they are part, but that fail to access the

advantage of these benefits. The main driver

into economic advantages. In order to fully

capital markets due to their size and

is clearly the 4.0-oriented nature of plants,

understand the innovative potentials and

economic results or use them without

and many members of ours, especially the

enabling technologies of our plants, UCIF

being given adequate creditworthiness.

finishing plant manufacturers represented

has organised a training day completely

That is why a series of data from each

by UCIF, have been producing such

dedicated to this topic, with reports by

supply chain, such as scope of activity,

machines for years now. Therefore, the new

start-up companies experts dealing with

companies involved, investment plans,

challenge for our companies is to deepen

Industry 4.0 issues and a few case studies

and economic and financial results

their knowledge of these technologies and

to be discussed together.

of individual companies, should be

understand how to further develop them

gathered and analysed in order to

with a 4.0-oriented approach. Predictive

However, our effort does not end there.

design a credit enhancement structure

maintenance, remote control, human-

The ANIMA Federation, to which UCIF

that can be financed on the market.

machine interface, and the Internet of

belongs, has signed an agreement with

Things are just some of the areas requiring

the Italian Banking Association (ABI) to

There are therefore no more excuses

special technologies able to advance our

facilitate the access of companies, even

or reasons to stay out of this important

sector.

the small and medium ones, to the market

business plan.

106

N. 51 - MAY/JUNE 2018 - international PAINT&COATING magazine

www.feitintas.com.br @/feitintas

Paints, Varnishes and

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TRADE FAIRS & CONFERENCES

JUNE 2018 SUR/FIN®

TECMA

Cleveland - OH, USA June 04-06, 2018 www.nasfsurfin.com

Madrid, Spain June 13-15, 2018 www.ifema.es/tecma_06/

SURFACE TECHNOLOGY GERMANY Stuttgart, Germany June 05-07, 2018 www.surface-technology-germany.de

ipcm

media partner

TRATTAMENTI TERMICI (HEAT TREATMENTS) Venice, Italy June 13-15, 2018 www.aimnet.it/ics2018.htm

AUTOMECHANIKA BIRMINGHAM

CHEMSPEC EUROPE

SUBCON

FASTENER FAIR MEXICO

Birmingham, UK June 05-07, 2018 www.automechanika-birmingham.com

Cologne, Germany June 20-21, 2018 www.chemspeceurope.com

Birmingham, UK June 05-07, 2018 www.subconshow.co.uk

Guadalajara, Mexico June 20-21, 2018 www.fastenerfair.com/mexico/english

GLOBAL AUTOMOTIVE COMPONENTS & SUPPLIERS

M-TECH

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SURFACE & COATINGS

ACHEMA

MANUFACTURING EXPO

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FABTECH CANADA

SURFACE DESIGN SHOW

ipcm

Stuttgart, Germany media partner June 05-07, 2018 www.globalautomotivecomponentsandsuppliersexpo.com/en/index.php ®

Poznań, Poland June 05-08, 2018 www.itm-polska.pl/en/

Tokyo, Japan June 20-22, 2018 www.mtech-tokyo.jp/en/

Bangkok, Thailand June 20-23, 2018 www.surfaceandcoatings.com

Frankfurt/Main, Germany June 11-15, 2018 www.achema.de/en/home.html

Bangkok, Thailand June 20-23, 2018 www.manufacturing-expo.com

Würzburg, Germany June 11-15, 2018 www.iccg12.de

Nürnberg, Germany June 26-28, 2018 www.sensor-test.de

Toronto, Canada June 12-14, 2018 http://fabtechcanada.com

London, UK February 05-07, 2019 www.surfacedesignshow.com

JULY 2018 MTA VIETNAM

CIAME

Ho Chi Minh City, Vietnam July 03-06, 2018 www.mtavietnam.com

Beijing, China July 19-21, 2018 ciame-show.com/english/index.aspx

ALUMINIUM CHINA

Shanghai, China July 11-13, 2018 www.aluminiumchina.com/en/

108

N. 51 - MAY/JUNE 2018 - international PAINT&COATING magazine

INACOATING INDONESIA

ipcm

media partner

Jakarta, Indonesia July 25-27, 2018 www.inacoating-exhibition.net

ipcm

media partner

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Finish First

ZOOM ON EVENTS

For the Seventh Time in a Row, PaintExpo Closes with Record-Breaking Results

t its 7th edition, PaintExpo carried on

satisfaction. They came from 29 countries, and

our trade fair schedule. Expansion to three

with the success story it started in

the proportion of companies from outside

exhibition halls is also highly positive in our

2006. With 537 exhibitors from 29

of Germany, namely 36.3%, was roughly 5%

opinion. The number of leads generated at

countries, the world’s leading trade fair for

greater than in 2016.

the event rose significantly once again this

industrial coating technology not only set a

The seventh PaintExpo also experienced

year as well”, explains Martin Weidisch, Senior

new record for exhibitor numbers. Visitor

a sharp rise in net exhibition floor space

Marketing Specialist at J. Wagner GmbH. This

numbers increased as well by roughly 12%

amounting to 16.6% for a total of 15,674 square

is underscored by visitor numbers which

Visitors journeyed to Karlsruhe from 88 countries

increased by 12%

for a total of 11,790.

to a total of 11,790. 35.4% of the visitors (plus 7.4%) travelled

(Fig. 1).

to Karlsruhe from outside of Germany.

“The quality of

After Germany,

the visitors is

the most well-

outstanding, which

represented visitor

means that we’ve

countries were

not only been able

Switzerland, Italy,

to establish very

France, Austria,

interesting contacts

Poland, the Czech

and get to know

Republic, the

important people,

Netherlands and

we also received

Turkey. Expert

several good

visitors came to

orders directly at

PaintExpo from a

the event. Beyond this, the trade fair is an excellent networking opportunity for

total of 88 countries

(74 in 2016)

Figure 1: The 7th edition of PaintExpo increased its number of visitors by roughly 12% for a total of 11,790.

us” reports John

around the globe. “The high level of internationalism and the distinctly

Richardson enthusiastically, Marketing

metres (168,700 square feet). As a result, the

positive atmosphere in the exhibition halls,

Communications und PR Manager of British

industry meet was evenly distributed over three

as well as the satisfied faces at the trade fair

Carlisle Fluid Technologies. Nearly all 537

well-occupied halls for the first time ever at the

booths are clear-cut indicators of the success

exhibitors (an increase of 7.2% as opposed

Karlsruhe Exhibition Centre. “PaintExpo has

of PaintExpo 2018 as the world’s leading trade

to 2016) who participated at this year’s

developed very well in recent years.

fair”, comments Jürgen Haußmann, Managing

world’s leading trade fair for industrial

It’s the industry sector’s leading trade fair

Director of FairFair GmbH and promoter of

coating technology from the 17th through

where people meet every second year, and

PaintExpo. This is confirmed by Frank Berg,

20 of April expressed similar levels of

PaintExpo is an essential constituent of

Managing Director of Caldan Service GmbH:

110

N. 51 - MAY/JUNE 2018 - international PAINT&COATING magazine

ZOOM ON EVENTS High Levels of Expertise and a Strong Propensity to Invest

we need to be. The visitors know exactly

become more international than at the last PaintExpo. The range of

In addition to the number of attending

discussions can take place based on

industry sectors from which the visitors

visitors and their high levels of

actual projects. Furthermore, we meet up

originated was also very broad-based.

internationalism, their expertise and

with visitors here from a great variety of

We participate at numerous trade fairs,

propensity to invest were also decisive

industry sectors. This is also one of the

in Asia and America too, but where the

for the success of the trade fair. This

reasons we like to exhibit here. Instead of

quality and passion of the exhibitors

is confirmed by Daniela Nett from the

running from one specialised trade fair to

and visitors are concerned, as well as

marketing department at Dürr Systems

the next, all of the sectors relevant for us

the quality of the products, PaintExpo is

GmbH: “Our second appearance at this

are represented here.” Dr. Peter Dolscheid,

the global leader. And that’s why there’s

trade fair has confirmed that PaintExpo

Managing Director of DOK Chemie, reports

no doubt that we’ll exhibit again in two

is one of the most important trade fairs

similar experience: “Nearly all of our

years.”

for us, and that this is precisely where

visitors came to us with concrete tasks.

what they want, so that highly concrete

“It was obvious that the visitors had

2 1

Figure 2: ipcm’s team at PaintExpo 2018. From the left: Matteo Sotti, Alessia Venturi, Paola Giraldo, Francesco Stucchi, Nicole Kraus.

international PAINT&COATING magazine - MAY/JUNE 2018 - N. 51

111

ZOOM ON EVENTS

This made it possible for us to arrange for

A.S.. Martina Orre, Marketing Manager

to a considerable extent. The trade fair is

the processing of numerous samples and

at Swedish company HangOn AB, also

highly significant for the development of our

to schedule visits at various companies,

confirms that PaintExpo is the platform

company because it provides us with an ideal

which is ideal for initiating new business

at which numerous companies present

platform for presenting our products. Aside

contacts. PaintExpo is the meeting place

new and further-developed solutions:

from this, we gain a great deal of input for the

for our customers and they expect us

“We’ve already exhibited several

further development of our products thanks

to be here. And thus we have a duty

times at PaintExpo. This year we have

to the broad spectrum of visitors who come

to exhibit and will be here again in two

nearly doubled our booth floor space

to our booth.”

years.” Tiemo Sehon, Managing Director of

because we are presenting our new

Sehon Innovative Lackieranlagen GmbH,

handbook, which has been published

was also pleased with orders taken at the

in 21 languages and includes 240

Worldwide Information and Procurement Platform

trade fair booth: “PaintExpo is the world’s

new products. We have invited our

One of the essential reasons for PaintExpo’s

leading trade fair in the field of industrial

distributors and customers from all over

strong appeal for users from all over the world

coating, and we’re certainly in good hands

the world to this presentation. We feel

is its unique concentration of companies

here. We are in the refinishing business

that it’s important to introduce our new

from the field of industrial coating technology. © ipcm ®

and we have been able to greet many

This results in comprehensive

guests from the

and targeted

sector here, and we

product and

have even closed

service offerings

orders directly at

ranging from pre-

the event. In light of

treatment, as well

our know-how and

as painting, systems

experience we see

and applications

our long-term future

technology, right

in industrial painting,

on up to final

and based on the

inspection and

leads we’ve fielded

packaging, the

here, we assume

likes of which is

that participation

unmatched by any

at PaintExpo will

other trade fair

provide us with new thrust in this direction”. “This is the fourth time

anywhere in the

3 1

world. This makes it possible for job-

Figure 3: ipcm’s booth at PE 2018.

shop coaters as

we’ve exhibited

well as companies

at PaintExpo, and things go better for

products and the handbook at PaintExpo,

with in-house painting operations from all

our company at the trade fair each

because it’s the most important trade

industry sectors to gather information and

and every time. We’ve been able to

fair for our customers, and thus for

procure solutions with minimal legwork.

establish significantly more contacts to

us as well.” Dr. Nils Reinke, Managing

The next PaintExpo, for which numerous

German companies this year, as well as

Director of Winterthur Instruments AG in

exhibitors have already confirmed their

to companies in France, Belgium, the

Switzerland, also reports on successful

participation, will take place at the Karlsruhe

Netherlands, from Northern Europe,

participation at the trade fair: “We

Exhibition Centre from the 21st through 24th

from the Balkan States, from the Middle

founded our company seven years ago

of April 2020.

East and from Asia”, reports Gökhan

and we’ve been exhibiting at PaintExpo

Bankoglu, Export Sales Officer at Turkish

ever since. We have been able to

For further information:

company Iba Kimya Sanayi ve Ticaret

continuously increase booth floor space

www.paintexpo.com

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ZOOM ON EVENTS

Let’s Talk About Innovation

very now and then people grumble

The emphasis is always on groundbreaking

application. Experts will be on hand to explain

about how innovation in the powder

technology but the true objective is to

the intricacies of compounding, electrostatic

world has been stymied or off-shored

contemplate how the industry will take these

deposition and testing instrumentation.

to some faraway place. Advocates in the

innovations to market. These aren’t just

Following the lab demos, attendees are invited

industry always worry about the future needs in

science projects conducted for the sake of

to peruse an eclectic array of tabletop exhibits

industrial finishing and if powder technologists

science.

while munching on delicacies and sipping on

are up to the task. Nowadays there is

Another aspect of the PC Summit is providing

cool refreshments. This is a rather intimate

considerably less doom and gloom hovering

abundant opportunity for networking, making

affair allowing visitors to spend quality time

over the future of powder coatings.

the resin chemist talk to the coating engineer

with industry experts outside the clamor of

Once a year BNP and the Powder Coating

and connecting the pretreatment expert with

a big coating exhibition. A newly revitalized

Research Group collaborate to produce the

the curing equipment technologist. It’s this

downtown Columbus offers a myriad of

Powder Coating Summit. This event brings

type of technical intercourse that brings reality

dining choices afterward. If attendees still

together the best and the brightest minds in

and opportunity to the conversation.

want to hang with powder coating geeks, Joe

the industry to dialogue on the latest trends in

The PC Summit spans two full days of

Powder will hang out with those interested at

presentations covering such diverse topics as: • Powder coil coating • New developments in dye sublimation

Dempsey’s Pub, a few doors down from the

technology. The 2018 PC Summit features

Westin Hotel. The second day is all about new technology. Speakers from around the world will be elucidating on how they are pushing the technology envelope in their respective

processes

fields. Ample time is available for questions

• The latest innovations in infrared

and answers and networking. Included in

technology to cure powders

this symposium will be a panel discussion

• Hyperdurable fluoropolymer based

examining the barriers to introducing new

powder coatings

technology. The panel is comprised of

• Conductivity schemes for non-traditional substrates • Novel techniques to troubleshoot coating defects • Bio-based powder coating technology

industry experts from a variety of technical

vantages that will be sure to provide

Figure 1: The Powder Coating Summit will be held on October 2-3, 2018 in Columbus, Ohio.

insight into navigating the path to the commercialization of innovative approaches in powder coating.

• Novel infrared curing processes swapping knowledge among all viewpoints

This year’s Summit is being held on October

of emerging powder coating technology.

2-3 in Columbus, Ohio (Fig. 1). Details can be

All of these are brought to attendees by the

Powder chemistry, application and curing

found on the Powder Summit website. This is a

foremost leaders in powder technology.

fundamentals fill the first morning at the

one-of-a-kind technology event and its strength

Speakers are obliged to bring something new

historic French Renaissance style Westin

is defined by the high quality of attendees and

to the party: old recirculated presentations

Columbus. The afternoon delivers live

the interchange they initiate with the Summit’s

heard a dozen times are not accepted. Another

demonstrations of powder processing,

technology experts. To be part of the evolution

goal for the program is to capture technology

application and coating evaluation at the

of new powder technology Powder Coating

from a broad spectrum of interrelated

Powder Coating Research laboratory.

Summit looks forward to meeting you in

components of the powder finishing process. It

This gives visitors a hands-on experience

Columbus in October.

strives to “connect the dots” from the powder

of powder coating technology from the

coating formula through to preteatment and

fundamental formulation and raw material

For further information:

application science and curing technology.

selection through extrusion, milling and

www.powdersummit.com

• Polyurethane technology for powder coating binders

international PAINT&COATING magazine - MAY/JUNE 2018 - N. 51

113

ZOOM ON EVENTS

Aluminium 2018 – New Topics to Meet the Future

lobal production of aluminium has

and what kinds of productivity benefits can

industry, the ALUMINIUM 2018 Conference

reached a record high level; the energy

already be achieved today by deploying high-

will focus on the material’s future prospects.

transition and the transport sector are

performance IT solutions in production.

Exhibitors at the ALUMINIUM Forum

driving demand for light metals. The precise

Another new exhibition area dubbed

will present their latest solutions and

trajectory might vary from country to country,

“Environmental Engineering” will cover water

technologies covering the areas of lightweight

but all around the world, the industry is making

treatment, air filtration systems and oil/oil

technologies, e-mobility and additive

new investments to gear up for an economy

mist vacuuming systems – and show how the

manufacturing, among others.

that continues to boom. This positive mood

aluminium industry is leading the way when

is felt as well at the ALUMINIUM World Trade

it comes to emerging topics such as energy

All roads lead to Düsseldorf

Fair – even with ten months still to go before it

and resource conservation in one’s own

More than 27,000 trade visitors from 100

opens its doors in Düsseldorf (Fig.1).

production chain.

countries are expected to attend ALUMINIUM

From 9 to 11 October 2018, the Exhibition

2018. Boasting a 60 per cent share of visitors

Spread across six exhibition halls, global

Technical education programme to deliver industry and science know-how

players, specialists and young innovative

Expert presenters from industry and science

share of foreign visitors from overseas was

companies will showcase the industry’s

at the ALUMINIUM 2018 Conference and

remarkably high at the last event – a gauge of

complete range – from aluminium production

the ALUMINIUM Forum will discuss the

ALUMINIUM’s worldwide relevance.

to machines and plants for processing to

trends and innovations of the aluminium

finished goods and recycling.

sector. Organised by the GDA, the umbrella

For further information:

The exhibition area will grow to 80,000 square

association of the German Aluminium

www.aluminium-messe.com

Centre on the Rhine will again become the global marketplace of the aluminium industry.

from abroad, ALUMINIUM is among the major trade fairs with the highest level of internationality worldwide. The 20 per cent

already booked. “A clear indication of the current momentum in the aluminium industry”, says Olaf Freier, ALUMINIUM’s event director.

metres, more than 80 per cent of which is

“We’re confident we’ll crack the 1,000-exhibitor mark at the upcoming event.”

New topics: Digitalisation and environmental protection Special exhibits like the Innovation Areas and themed guided tours are aimed at providing better orientation for visitors from user segments such as automotive engineering, mechanical engineering, aerospace and the construction sector. The well-known theme pavilions will serve as points of contact to lead visitors through the structured exhibition halls. In the new special exhibition area “Digital Manufacturing”, visitors will experience what Industry 4.0 means for the aluminium industry

114

N. 51 - MAY/JUNE 2018 - international PAINT&COATING magazine

Figure 1: ALUMINIUM World Trade Fair will be held from 9-11 October 2018 in Düsseldorf, Germany.

ALUMINIUM 2018 12th World Trade Fair & Conference

9 – 11 October 2018 Messe Düsseldorf, Germany www.aluminium-messe.com

Organised by

Partners

ZOOM ON EVENTS

he International

IMTS 2018 Increases Space for Hannover Messe USA: strengthened the International Orientation Manufacturing Technology Show will be held

September 10 – 15 at McCormick Place, Chicago, Illinois, USA (Fig. 1).

The show continues to widen its appeal to international and domestic visitors by dedicating 130,000 sq. ft. of exhibition space and display to HANNOVER MESSE USA. The organization of this space is entrusted to Hannover Fairs USA (HFUSA), the U.S. subsidiary of Deutsche Messe. IMTS 2018 is the premier and longest running manufacturing technology show in the Americas. “Co-locating HANNOVER MESSE USA further diversifies the technologies that visitors can experience at IMTS 2018,” says Peter R. Eelman, Vice President – Exhibitions & Business

Figure 1: The International Manufacturing Technology Show will be held September 10 – 15 at McCormick Place, Chicago, Illinois, USA.

Development at AMT – The Association For Manufacturing

Things (IIoT) solutions during IMTS

HANNOVER MESSE USA has had a

Technology, which produces IMTS.

2018,” said Larry Turner, President &

presence in the U.S. market since

“HANNOVER MESSE USA has increased

CEO of HFUSA. In addition, the show

launching the industrial technology

its footprint by 44 percent and will

emphasizes technologies associated

shows at IMTS 2012. In 2018, it

feature approximately 500 exhibitors

with predictive maintenance, more

will become part of Integrated

in the East Building. IMTS already

efficient use of raw materials, faster

Automation, Motion & Drives

attracts visitors from more than 110

time to market and other trends in

USA (IAMD USA), North America’s

countries, and co-locating HANNOVER

industrial manufacturing.

leading trade show for Integrated

MESSE USA further strengthens our

“We also expect to extend the

Automation, Industrial IT, Power

international appeal.”

overall scope and global nature of

Transmission and Control, and the

“HANNOVER MESSE USA’s trade

the co-located shows this year by

fairs ComVac USA, Industrial Supply

shows will leverage the power of

highlighting more exhibitors from

USA and Surface Technology USA.

the HANNOVER MESSE brand by

around the world in our international

demonstrating the full range of

pavilions, including China, Germany,

For further information:

Industry 4.0 and Industrial Internet of

Italy, Korea and Taiwan,” adds Turner.

www.imts.com

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N. 51 - MAY/JUNE 2018 - international PAINT&COATING magazine

Supplemento a IPCM n° 51 - May/June 2018

INDUSTRIAL CLEANING TECHNOLOGIES

ICT digital on

www.myipcm.com

ICT - ANALYSIS

The Future for Solvent Vapour Degreasing Equipment. Innovation Driven by Legislation Syd Treacher EnviroTech Europe Ltd. – Esher, United Kingdom

streacher@hotmail.com

apour degreasing is the simplest

driven the development of new polymers

A little history of the chemistry helps to

but most effective degreasing and

with results as good as, if not better than,

explain the changes since the introduction

cleaning process for industrial

the solvent based originals.

of the vapour degreasing process. Suitable

use. It has, until recently, been subject

As with coatings, cleaning systems have

chemicals must be very good solvents

to little change since it was first invented

had to change. With increased regulation,

for oil, grease, and other industrial soils

in the early part of the last century. The

users of solvent have been targeted

non-flammable, safe for users and the

name for the process is a misnomer, as

and alternatives are encouraged by the

environment and very stable when heated

the cleaning is achieved by solvent vapour

relevant authorities and law makers

continuously for long periods.

condensing on the cooler target parts

often without serious consideration of

Halogenated hydrocarbons are the

the hot liquid solvent dissolving oil and

unintended consequences.

solvents of choice for “Condensation

removing dirt.

For example, water-based cleaning is

Cleaning”. The process is essentially

Vapour degreasing is a mature chemical

the obvious alternative but this has

simple. A tank with a sump to contain

technology on which legislation is now

many disadvantages compared to

the solvent, heaters at the base and

effecting changes so fundamental that

condensation cleaning as although

condensation coils around the top section

the more accurate name for the process

the machines are simple and relatively

to control the height of the vapour is all

“Condensation Cleaning” should be

cheap, the processes require multiple

that is required. When heated in the sump,

used to reflect the way in which it works.

tanks for immersion or spray processing

halogenated solvents produce a saturated

The open topped tanks so ubiquitous

or long programmed cycles in batch

vapour between 3 and 4 times heavier

in factories and workshops worldwide

machines for cleaning, rinsing and drying.

than air at a temperature greater than the

are no longer acceptable and the

Water based processes are slow, energy

ambient conditions. This allows the solvent

alternatives in equipment design and their

intensive and occupy more floor space

vapour to condense on the surface of

fundamental differences in technology,

than condensation cleaning equivalent

the parts to be cleaned. The condensate

which guarantee the continuing use of

where only one tank with small footprint

dissolves the contaminants such as oil,

vapour degreasing in the future, need to

is needed, delivering shorter process

greases and soils returning the used

be considered and understood.

times and most importantly using

solvent into the sump of the machine for

minimal energy.

recycling into vapour which continuously

In Europe, the United States and in other

The ideal cleaning process would be

condenses onto the parts until they have

advanced industrialised economies

“Condensation Cleaning” with water but

achieved the same temperature as the

increasingly stringent legislation to control

due to the physical characteristics of the

solvent vapour when, with no further

emissions of VOCs and especially solvents

water vapour/steam and the inability to

condensation, the process is complete.

has led to new formulations for paints

carry onto the surface of the targeted

Parts removed from the cleaning

and other coatings, where water replaces

parts surfactants to remove the oil,

machines are very clean, warm and dry.

most of the solvent. In the early days the

grease and soils and the difficulty of

The most common halogenated solvents,

quality of the coatings was not as good as

rinsing and especially drying this can only

in use for commercial purposes, are

solvent based coatings but innovation has

ever be a dream.

non-flammable so present no risk in this

118

N. 51 - MAY/JUNE 2018 - international PAINT&COATING magazine

ICT - ANALYSIS

process. Perchloroethylene, used mainly

in replacement for trtichloroethane.

development of machines able to safely use

for dry cleaning, methylene chloride

EnSolv has an identical profile, stable,

the more economical solvents.

used more widely in paint strippers

non-flammable, with the same physical

and trichloroethylene used for vapour

characteristics such as boiling point

As with all legislation for the use of chemicals

degreasing were the original materials

and specific gravity and it is an excellent

regulation and restrictions drive development

used based on chlorine chemistry.

cleaning solvent but without the potential

of associated processes and equipment. The

However continuing concern about the

for ozone depletion. EnSolv is a precision

most important developments in machines

environmental impact and danger to

vapour degreasing solvent and a safer

to use solvents for condensation cleaning

operators by exposure to chlorine-based

alternative to trichloroethylene.

use two different approaches and raise

solvents, especially trichloroethylene,

During this time new halogenated solvent

difficult questions as to which is the best most

has led to a continuing search for safer

blends using trans1.2 dichloroethylene,

economical and simplest in use.

1,1,1 trichloroethane (Genklene from ICI

The single tank

ÂŠ EnviroTech

alternatives.

hermetically sealed machines favoured

and Chlorothene from

by some equipment

Dow Chemicals) both

manufacturers uses

of which were based

a process tank to

on another chlorinated

contain the solvent

solvent were to

and a separate

become ubiquitous

storage tank/vapour

in the mid part of the

generator. Baskets,

last century as a much

containing soiled

safer, non- carcinogenic

parts, are loaded from

replacement for

the top or through

trichloroethylene.

access points on the

This was an excellent

side of the tank

solvent safe for

(Fig. 1). Lids or

users but which, with

doors close over

increased awareness

the opening and

of the environmental

the process tank is

impact of solvents,

hermetically sealed.

proved to be depleting

Baskets are immersed

the protective ozone layer around the Earth and was subsequently,

in solvent, where

agitation, ultrasonics

Figure 1: Solvac Automatic hermetically sealed vapour/liquid cleaning system conveyor fed.

banned. With the

or pumped liquid is circulated through the

development of the

parts.

REACH legislation in Europe, which now

a highly flammable solvent with similar

When the immersion process is completed

classifies trichloroethylene as a human

chemistry to trichloroethylene were also

solvent is removed to the storage tank

carcinogen, usage is allowed but with

developed for condensation cleaning. The

and vapour fed to the process tank from a

restrictions and stringent controls for use

trans 1.2 dichloroethylene is blended with

vapour generator for rinsing and drying. On

authorised in machines which control

a variety of different fluorocarbon solvents

completion of the cycle coil,s located within

factory emissions to very low figures close

which are not suitable as cleaning solvents,

the process tank collapse the vapour. The

to zero.

as they have very low solvency, but are

process tank is evacuated by vacuum and

Meanwhile cleaning solvents based on

used in these blends as fire retardants.

recycled through carbon absorption units to

1-bromopropane such as EnSolv were

An extremely expensive answer to a

remove traces of solvent from the air until the

developed in the United States as a drop

simple problem, already solved by the

concentration is below limits set by regulators

international PAINT&COATING magazine - MAY/JUNE 2018 - N. 51

119

ÂŠ EnviroTech

ICT - ANALYSIS

2 1

Figure 2: Solvac 1000 - Hermetically sealed multilevel vapour degreasing system for manual load batch processing.

when the lid opens automatically for the basket

hermetically sealed processes. The multilevel

cleaning in blind or through holes or oil ways in

of parts, clean and dry, to be safely removed

system uses a standard vapour degreasing

castings and fabrications.

and replaced with a further basket.

tank design with a sealed loading section

With the process completed the basket rises

Variations of process within the hermetically

above the process tank (Fig. 2).

to the freeboard area where the condensation

sealed tank are possible using sprays of cold

Components to be cleaned, in baskets or on

coils are located and parts allowed to drain and

or hot condensed solvent, immersion with

jigs, are fed to the automated hoist in the

dry. The tank seal opens to allow the basket

or without ultrasonics and revolving baskets

load section manually, by hoist or conveyor.

into the load section while the lid closes to seal

to deal with the problems experienced when

The loading door is sealed pneumatically to

the process tank. A fan is then activated which

processing machined and fabricated parts.

completely isolate the process. The process

produces a negative vacuum in the load area.

Continuous external distillation of the contents

tank sealing lid opens and the basket lowered

The loading door partially opens to allow a

of the vapour generator is also an option

into the process chamber. Depending on the

flow of air through the loading section which is

depending on contamination.

soils simple condensation cleaning can be

exhausted to atmosphere or can be recycled

used or with the lower section being filled with

through carbon absorption systems.

The alternative technology is much simpler

clean solvent for immersion cleaning with or

As baskets entering the loading space

and cheaper using well tried techniques

without ultrasonics or power sprays. Revolving

contain parts drained and dried only very

not requiring the long recovery times of the

baskets are a further option to improve

small amounts of solvent are carried in the

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N. 51 - MAY/JUNE 2018 - international PAINT&COATING magazine

ICT - ANALYSIS

exhausted air which is monitored to ensure compliance with appropriate legislation. When this is completed the door opens fully for removal of cleaned components. The loading section can be fitted with top or side sealed doors allowing baskets to flow through on conveyor systems or be loaded from hoists. No solvent enters the work area. Both processes will produce parts cleaned to the highest standards but the choice of which offers the best solution needs a little more consideration. The hermetically sealed vacuum process is complicated with the need to move liquids in the machine. It is relatively slow as the carbon adsorption process needs to remove high levels of solvent from the recirculated airstream from the process tank. This is inefficient as adsorption rates for carbon fall rapidly with increasing saturation. Final levels of solvent in the tank when the lid or loading door opens will be emitted into the workspace and the area in which the operator is working. Long process cycles reduce throughput. The simpler multilevel systems where movement of liquids is not required are more efficient and offer much faster process times. Cost of manufacture is also lower as no liquid movement or vacuum is involved. The extracted loading section ensures no leakage of solvent into the work area, which gives complete safety for operators and factory staff. The disadvantage of the multilevel machine is the height of the equipment compared to the hermetically sealed machine. This will often need the equipment be installed in a pit for easy access. Both designs of process machines fully comply with the emission regulations of the EU and U.S authorities. Which to choose will depend on many factors, which should be discussed with both the equipment and solvent suppliers who have the experience to advise on which offers the best process for the application. Equipment and solvent work together as a process and it is essential to ensure that the suppliers work closely together to offer a package with high levels of responsible care and product stewardship to ensure the best results and safest installation. The â&#x20AC;&#x153;Condensation cleaningâ&#x20AC;? process still gives the highest levels of economical cleaning with minimum energy usage, low footprint on the factory floor, safety for the operator, and high production rates with low solvent usage or environmental impact. With the new generation of sealed cleaning machines its future as the process of choice for industrial cleaning is assured. EnSolv cleaning solvents are supplied throughout Europe by Envirotech Surface Technologies

ICT - HIGHLIGHT OF THE MONTH

Economical Cleaning Solutions Are the Factor for Success Gerd Scholz PERO AG, Königsbrunn, Germany

pero.info@pero.ag

thorough part cleaning is

customers how to develop this best

mark, it can cost you the order, because

increasingly a must in industry.

solution was one of the focal points of the

production is too expensive due to too

However, the core competence of

User Days, to which Pero AG welcomed

much cleaning”. Those who are among the

most companies lies in parts production

145 representatives of manufacturing

winners and losers make their decision

- the complex interrelationships between

companies to its competence centre at the

long before a company puts a cleaning unit

production processes and parts

company headquarters in Königsbrunn

into operation. The decisive factor, Achatz

cleaning are difficult to oversee. This is

near Augsburg.

emphasised, is the extremely meticulous

manufacturer Pero AG offers its customers not

and comprehensive

why the cleaning unit

project planning of the cleaning process,

only modern technology

which also serves as a

but also comprehensive

basis for preparing a

advice on economically

quotation. As an aid to

viable cleaning processes.

customers, Pero has

Visitors to the Pero

prepared a guideline

User Days on 18 and 19

summarising the most

April 2018 were able to

important points in

experience the services

five subject areas,

on offer and at the same

this also contains a

time gather information

checklist.

on the latest innovations

inevitably pick-up dirt in

Production and cleaning must be perfectly coordinated

various ways. However,

Pero examines all

customers are placing

relevant aspects

(Fig. 1). During production parts and components

ever-increasing demands

jointly with the user.

on cleanliness. Although these can usually be fulfilled with different processes and units

Its expertise often Figure 1: In Pero AG’s competence centre, visitors to the User Days were able to follow demonstrations of the cleaning units with example components or have components from their own production cleaned as a test. Lectures by experts from the company and Pero partners rounded oﬀ the programme.

“there is always an

enables them to recognise an ancillary process that can be easily docked

economically optimal

to the production

solution for the specific application”,

“Invest as much as necessary - and as

process. But in fact there are many

emphasised sales engineer Steffen

little as possible” Achatz appealed to the

interdependencies between production

Achatz. Showing users and potential

visitors and warned: “If you overshoot the

and cleaning. In some cases, relatively

122

N. 51 - MAY/JUNE 2018 - international PAINT&COATING magazine

ICT - HIGHLIGHT OF THE MONTH

simple changes such as changing a cooling

with the customer’s original contaminated

lubricant can make the downstream

parts as part of project planning. This also

Economical advantage due to infrequent solvent changes

cleaning process more cost-effective. Of

makes the facility of central importance

Based on the knowledge he gathered

course, basic points such as the number

to CEO Horst Erbel (Fig. 2), a son of the

at the User Days, Thomas Nieland now

of parts to be cleaned, the type of soiling

company founder. He explains: “For us, the

also favours solvent-based cleaning.

and the desired cleaning result must also

customer is a partner for whom we wish

He and his colleague Uwe Fritz work

be clarified. Mr. Achatz also emphasized

to optimise the operation of its production

in technical development and sales

that this is also worth questioning: “Does

using our expertise. Different units and all

at Schmid Alutec GmbH & co. KG. © Pero AG

the cleaning objective set by the customer really make sense - or has a

The company, which specialises in machining a

designer simply adopted

wide variety of

the specifications from a

aluminium parts

similar part?”

for the automotive

It is also important to

industry, has been

have a precise overview

working since 2005

of the processes before

with a cleaning

and after part cleaning,

system that uses

which experts at Pero

aqueous solutions

often obtain during on-site

to remove

visits. For example, it is

particles from

important to ensure that

the components

the parts do not pick up

produced. The

new dirt on the process

process works

path after cleaning.

satisfactorily.

According to Achatz

However, Nieland

equally decisive is the

is increasingly

overall economic view,

questioning the

i.e. the total cost of

associated costs,

ownership. In terms of

and so he came

investment some solutions

to Königsbrunn

with aqueous liquids prove

to learn more

to be more expensive

about the available

than those cleaning with solvents. This is because in water-based units the cleaning fluid must be constantly checked,

alternatives. 2 1

“Solvents, modified

Figure 2: Board Chairman Horst Erbel: “In our competence centre we oﬀer our customers complete transparency with regard to units and processes. This ensures reliable production for the customer”.

adjusted and replaced at

alcohols or hydrocarbons – these substances sound dangerous

regular intervals. Pero’s

at first,” explains

solvent-based units, on the other hand,

common cleaning media for wet processes

Nieland. “But currently we are replacing

automatically recycle the solvents so that

can be compared. Tests with own originally

the content of the baths twice a week.

they sometimes last for up to three years.

contaminated parts demonstrate to the

And if - as I have learned today - I can

There are currently 19 cleaning units in

person responsible for cleaning, which

run solvent-based systems for one,

the Pero competence centre. One of the

combinations of cleaning unit and cleaning

two or three years with the same

tasks that the company’s engineers use

medium produce the desired cleaning

automatically recycled medium, this

these units for is to perform various tests

results.”

would represent a huge advantage”.

international PAINT&COATING magazine - MAY/JUNE 2018 - N. 51

123

ICT - INDUSTRY NEWS

Kemet Aqueous Processes Offer Efficient Cleaning

leaning and surface

Even sensitive metal parts can be

Applications include:

preparation are critical for

safely and efficiently cleaned in

- Remove polishing paste in ultrasonic cleaning

perfect quality of finished parts

a water-based cleaning system

and selecting the right process has

without damaging the substrate and

never been so important as customers

without using problematic solvents.

seek better quality and performance

This is done by using advanced

systems - Removing oil in spray or ultrasonic cleaning systems - Cleaning Carbide and HSS using spray or

protective additives (Fig. 1).

are involved and it is important to

Kemet offer a broad range of

- Protect sensitive substrates against corrosion

consider all the various options to get

ecological aqueous solutions

Environmental issues have also been an

the best cleaning process.

that meet extremely demanding

important driver in the development of these

The formulation of a detergent takes

cleaning requirements which, until

chemicals and the scientists involved in this

into account the substrate specifics as

recently, were carried out only with

extensive research and experiments are also

well as the impurities to be removed

solvents. All products lines comply

able to advise industrialists on the choice of

from the surface.

with ISO 9001, ISO 14001 and

method for managing their waste water.

The steps before and after the

OHSAS 18001 standards and many

cleaning process are also critical to

are suited to cleaning automotive

For further information:

defining the process.

components.

www.kemet.co.uk

ÂŠ Kemet

for their coatings. Several parameters

Figure 1: Automotive parts before and after cleaning with Kemet products.

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N. 51 - MAY/JUNE 2018 - international PAINT&COATING magazine

ultrasonic cleaning systems

ICT - CASE STUDY

Cleaning With Fixed Jets to Effectively Remove Swarf from Aluminium Components for Steering Systems Alessia Venturi ipcm®

hen we think of a car,

high performance and, above

clean parts, free from any oils, emulsions,

we usually focus on its

all, maximum safety. Therefore,

chips, and shavings generated by machining

exterior design and its

processes. Precisely the high cleanliness

automotive component sector

degree required for the components of

is, above all, a perfect assembly of

is one of the most demanding in

steering system led ZF TRW Automotive

numerous mechanical, hydraulic, and

terms of quality requirements,

Italia (Gardone Val Trompia, Brescia)

electronic components. All these parts

nor that the starting point for a

to install an innovative cleaning system

must perfectly fit together to ensure

correct assembly are perfectly

it should not surprise that the

beauty while forgetting that a vehicle

Figure 1: One of the mechanical machining centres of ZF TRW.

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ICT - CASE STUDY

ZF TRW Automotive ZF TRW Automotive was established in 2015 following the acquisition of the American multinational engineering company TRW by ZF Friedrichshafen AG, a German giant in the manufacturing of transport system components established in 1915 by airship inventor Ferdinand Von Zeppelin. ZF is now a multinational company with 137,000 employees and an 11-digit annual turnover. Its factory of Gardone Val Trompia is mainly devoted to the production of components for steering systems. Gil Goncalves, the plant manager, explains how its production has changed over

2 1

the years: “This factory has been existing since 1970: that year, TRW bought it from the Italian

Figure 2: Overview of the cleaning tunnel with overturned conveyor.

weapons manufacturer Beretta, which used it for deep drilling operations

gears and electric power steering

Cleaning issues

on rifle barrels. TRW was looking for a

(EPS) systems. The production flow

“We soon realised that the main problem

way to lighten its steering wheels by

starts with semi-finished blanks for

in cleaning this component was the

drilling their racks and this production

the steel components and castings for

presence of several holes and threads,”

site was therefore perfect.

the aluminium ones, both provided by

states Bonusi. “Machining swarf was

“We started with manual guides, and

external suppliers. These are subjected

deposited in such holes and it could not

we evolved with hydraulic guides and

to machining and to subsequent

be eliminated. This was not acceptable

the processing of steel and aluminium

treatments such as grinding and

to us, given the restrictive requirements

to produce pinions, seats, and all types

cleaning (Fig. 1).

concerning the level of permitted

of valves. Since 1995, we gradually

The sub-components produced are then

contamination that our quality standards

abandoned the hydraulic technology

sent to the foreign branches of ZF for

impose.” In order to solve this problem,

to make room for the electrical one.

final assembly.

ZF TRW attempted to adapt the plant

This had a major impact on the

“Recently, we have industrialised a new

already existing in its production line

company, which in the 2000s faced

aluminium component defined Main

to its new needs by trying different

a new challenge by starting to focus

Housing, i.e. EPS gear gearboxes – a

solutions (with fixed workpieces or

on components for electric steering

housing in which a plastic wheel and

with a rotating table), without obtaining

systems.”

a steel worm screw must be inserted,”

any satisfactory result. It was therefore

The electrical technology now accounts

explains AME Engineer & Program

necessary to substantially change

for 50% of the activity of the Gardone

Manager Paolo Bonusi. “However, the

the cleaning line. After assessing the

plant, whose core business is the

industrialization of this new component

solutions offered by different suppliers,

processing of steel and aluminium to

has presented us with a notable

the choice fell on Dollmar Meccanica

produce sub-components of steering

challenge in terms of cleaning.”

(Caleppio di Settala, Milan).

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127

ICT - CASE STUDY

3 1

Figure 3: The robotic station with the robot that loads and unloads workpieces.

“The cleaning issues presented to us

points to be cleaned through targeted

featuring a stepwise advancement

by ZF TRW were quite challenging,”

jets (Fig. 2).”

with a pitch of about 40 seconds. The

explains Gianfranco Fiori from Dollmar.

“We knew we had conceived a system

first two phases of the cycle are a

“First of all, the maximum contaminant

that could meet the needs of ZF TRW,

general washing stage and a dedicated

size required is a difficult-to-obtain

but for us the collaboration with Bonusi

cleaning one with jets arranged on

result on components with that shape.

and his engineers was crucial during the

mobile masks (Figs. 4-5), operated by

Secondly, the presence of so many blind

design phase,” states Fiori, “especially in

electro-pneumatic controls to position

spots and undercuts clearly called for a

terms of software and layout choices.”

themselves near the most critical

customised solution. Finally, there were

holes. They can also spray from below,

perfectly adapt to the space intended for

The system and its cycle: cleaning as a machine tool

the previous line. We therefore thought

Entered into operation in September

operation is a more aggressive double

of a fully automated overturned conveyor

2017, the plant is placed in a robotic

degreasing process, whereas the

tunnel, ready to use robotised loading

station in which a robot unloads the parts

second one is a rinse.

and unloading stations and with mobile

at the end of the machining line and loads

They both use a cleaning solution

spraying masks that could reach all the

them in the cleaning tunnel (Fig. 3),

(about 880 litres in the first stage

space constraints: the new system had to

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N. 51 - MAY/JUNE 2018 - international PAINT&COATING magazine

perfectly reaching even the most challenging points. The first cleaning

ICT - CASE STUDY

liquid remaining after the first operation, sending it back to the tank. “We only use detergents because they safeguard our components by creating a protective patina,” explains Bonusi. Subsequently, the workpieces are hot air dried and blown with compressed air at room temperature, pulsed through jets positioned on the masks with the same principle used for cleaning. This eliminates any water residue from blind

4 1

spots. “This is the only

Figure 4: The chambers in which take place the first two cleaning phases, degreasing and rinsing, both with detergents.

station where we have necessarily had to use compressed air at room temperature:

and 440 in the second one) with two separate

of thorough cleaning. The (adjustable)

in all the others, side channel turbo

feeding tanks and each with a pump and

temperature of the sprayed solution is

blowers have been installed that deliver

a separate spraying circuit. The detergent

about 50 °C, because higher temperatures

air at 70°C to save energy,” states Bonusi.

is dosed automatically to manage different

could cause colour variations in die-cast

“This is another aspect that we specifically

percentages in the two tanks. In the cleaning

aluminium. Between the cleaning and

developed with Dollmar. We are trying to

stations, it is possible to wash two parts

rinsing stages, there is a dripping phase, in

improve in terms of safety, health, and

at a time, subjected to about 80 seconds

which an air curtain eliminates the excess

energy consumption at all levels, and

with

DRY CLEANING

to perfect advanced clean production

PAINTING ! Cleaning with CO2 - snow jet www.acp-micron.com www.acp-micron.co.uk Phone: +49 7156 48014-0 international PAINT&COATING magazine - MAY/JUNE 2018 - N. 51

129

ICT - CASE STUDY

the starting point was precisely the

which are automatically opened and

avoiding the use of electrical resistors and

gradual elimination of compressed

closed again after the workpiece has

thus ensuring significant energy savings,”

air blowers.” The last station is a

reached its treatment position.”

explains Bonusi.

recirculating air cooling unit.

“Finally, we asked Dollmar to install

The pollutants present on the

enabled us to use our mains hot water

components to be cleaned are

because, especially in certain seasons,

An ad hoc system that has improved quality and productivity

mainly cooling lubricants employed

we need to dissipate a lot of heat. They

“We are very pleased with the result obtained

in the machining processes and

have not come into operation, yet,

with Dollmar. They created a completely

small quantities of neat oils used in

but they will be soon implemented,

customised machine for this new component,

heat exchangers that would have

which may seem a banal

can be “dragged” into the

workpiece but is actually

lubricants. The former emulsify

the machining centres, which

very challenging,” says

with the tank water, which is

Bonusi. “Our engineers

periodically replaced; the oil

have had the opportunity

separator eliminates the latter.

to cooperate with a

The swarf is collected by bag

knowledgeable and

filters located on the back of

friendly supplier both

each tank, which will be soon

in the design phase,

upgraded with the possibility

when they needed to

to automatically manage any

understand our needs,

clogging.

and in the rare occasions

“Another peculiarity of this

in which the system

tunnel is the automatic closing

needed to be fine-tuned,

system of the chambers,”

in which their timely

says Fiori. “Given the tunnel’s

interventions have

compact design, required to

allowed us not to lose

fit it in the spaces available in

productivity.

the robotic station, we had

“At the moment, the

to separate each treatment

plant is working at full

station with automatic doors.

capacity and feeding all

This prevents the spraying

six spindles. Although it

action of the first cleaning

features a very special

area to cause any swarf

technology and a rather

contamination in the second

complex management

one, as well as any dragging of

software system, after

cleaning solutions. We shared

about eight months of use

with ZF TRW the idea that a

we can say that the final

simple separation solution with

quality of our workpieces

the plastic strips typically used

is excellent and its

on this type of machines, which

reliability is very high. In

are moved directly by the

future, we will certainly

component as it passes, would

turn to Dollmar to apply

not have avoided any water

this cleaning technology

leakage and, therefore, any contamination with certainty. Hermetic doors were required,

130

5 1

Figure 5: A detail of the nozzles arranged on mobile masks.

N. 51 - MAY/JUNE 2018 - international PAINT&COATING magazine

also to the other types of components we produce.”

ICT - CASE STUDY

A Low Emission Cleaning Machine for a High Quality Production: SATA’s Commitment to the Environment and Production Flexibility © SATA

Barbara Pennati ipcm®

Opening photo: An air view of SATA’s headquarter in Valperga.

feature that many companies

stringent international regulations,

industrial, and ACE machinery sectors,

belonging to the automotive supply

especially relating to the environmental

such as FCA, Renault, CNH, and Caterpillar

chain have in common is the need

impact of vehicles. SATA Spa, an

(ref. Opening photo).

to diversify production and make it as

industrial group based in Valperga

Established around the 1920s and

flexible and versatile as possible.

(Turin, Italy), is one of the major players

still partly owned and managed by its

This enables them to meet the needs of the

of this sector: its customers include the

founding family, SATA took its first steps

market, but also cope with the increasingly

main manufacturers of the automotive,

in the production of parallel lathes but

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N. 51 - MAY/JUNE 2018 - international PAINT&COATING magazine

ICT - CASE STUDY

immediately started to diversify its

“We produce components in steel, aluminium,

existing one. “In the last two years, we

activity. It specialised in other machining

and cast iron and we stand out as a centre for

have seen an increase in customer

processes and, as early as the 1960s, it

the production of connecting rods. We have

requests for this component.

equipped itself with numerical control

adopted a rather innovative technology for

This prompted us to invest in a new

centres, rather innovative for the time,

them, which includes a cracking process, that

machining line that could support the

which gave the company the opportunity

is, breaking the big eye of the connecting rod

already existing one, which produces

to make a qualitative leap and stand

in two parts that are then reassembled; this

about 3,000 workpieces a day, and

out from local competitors. In the late

technique ensures a perfect correspondence

improve our production flexibility (Fig. 2),”

1990s, it began expanding its business

between the rod stem and the cover.”

explains Matteo Vacca. “However, it

by opening a second plant a Pozzilli

“Starting from the raw material, we

was essential for us to maintain the

(Isernia) and acquiring a third one in

manufacture connecting rods, engine

high quality level required by the

Valsugana (Trento), which enabled

flywheels, and EGR valve supports (Fig. 1).

market in terms of both machining and

the group to focus not only on the

We deal in-house with all production phases,

cleaning.” That is why SATA turned to

automotive field, but also on the ACE one

which we have completely automated,” states

STS (Ravenna, Italy), a firm specialising

and thus pursue its diversification goal.

Matteo Vacca. “All lines are in fact managed by

in the production of industrial cleaning

Almost simultaneously, SATA initiated

an operator through one panel that controls

systems that had already worked with

a process of internationalisation that

the robots and all the machines, from loading

the Valperga-based group for the

led it to be present in Argentina, Brazil,

and machining to cleaning, leak testing, and

installation of a water washing machine

and USA and create joint ventures

unloading.”

precisely on the first machining line

with industrial groups in China and

Due to an increase in the demand for

devoted to valve supports, as well as of

India, already operating in the local

valve supports, SATA decided to add a new

another cleaning plant for aluminium

industries of cars, compressors, and air

dedicated processing line to the already

inlet manifolds.

sector diversification, SATA also has two subsidiaries,

conditioners for vehicles. In terms of

Valbormida and Ergo Sata, specialising respectively in hot steel moulding and plastic die-casting. The headquarters located in Valperga extends over a productive area of 15,000 m2, it is equipped with 22 production lines, and it has about 200 employees. “The Valperga plant is perhaps one of the most balanced of the group in terms of production, since the components intended for the automotive, agricultural, industrial, and earth-moving sectors account for the same percentage of production,” says SATA’s Global Quality, Environment and Lean Manufacturing Manager Matteo Vacca.

Figure 1: EGR valve supports produced from SATA.

international PAINT&COATING magazine - MAY/JUNE 2018 - N. 51

133

ICT - CASE STUDY

exclusively with water-based products and performs the following stages: immersion cleaning, rinsing, drying, and vacuum drying (Fig. 5). “The machine has been designed to achieve not just the quality level required by SATA, but also a very low environmental impact: indeed, it uses only water-based, and therefore environmentally friendly, products, and it does not require any exhaust chimney. It is in fact equipped with HEPA filters that recirculate the emissions generated by the machine without dispersing them in the atmosphere, thus ensuring a certified air purity of 98.9%,” states Mauro Ballo, the technical manager of STS. “Chips

2 1

and swarf are also eliminated by air:

Figure 2: The second machining line devoted to EGR valve supports.

they are suctioned by vacuum pumps and sent to a storage silo through a piping system. With a view to energy

The new cleaning system: automated integration and sustainability

STS’ AQUAROLL® cleaning machine

saving and cost optimisation, cleaning

(Fig. 3), installed about two years ago on

water is also managed by a recirculation

the second valve support machining line,

system equipped with a separating

“EGR valves are a very important

can wash 2 baskets at a time and, therefore,

filter that allows it to be recondensed

component of undoubted relevance in

8 workpieces in total (Fig. 4). It works

in the cleaning tank. The washing

recirculation of engine exhaust gases thus preventing pollutant dispersion,”

the auto sector, since they ensure the

says Matteo Vacca. “These valves are installed on all diesel engines through a special support, included in SATA’s product range.” “We aimed at increasing our production volume of valve supports without compromising their quality level. We already had the know-how needed to ensure the success of this investment. This also helped us find the right technological partner for the cleaning phase, which is very important since it can make the difference in terms of final quality,” states Vacca. “Given the positive experience of five years ago, we collaborated with STS once again to develop the right machine and the most suitable cleaning programs to meet our needs”.

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Figure 3: STS’ AQUAROLL® water cleaning machine.

N. 51 - MAY/JUNE 2018 - international PAINT&COATING magazine

programs have been pre-set according to

ICT - CASE STUDY

the production needs of SATA and they are managed directly by the operator, who can also review and modify them as needed.” “On this second EGR valve support machining line, we produce about 900 parts a day (Fig. 6), which are then arranged by robots in baskets that are managed independently by the system itself. This plant, therefore, integrates perfectly with all our production lines’ automation,” explains SATA’s plant maintenance manager Rodolfo Chiantaretto. “The reduced need for human intervention due to the high degree of automation and the vacuum technology have enabled us to achieve a higher cleanliness degree, ensuring that our components are ready to reach the next

4 1

processing or control phase without the need for further manipulation.”

Figure 4: Valve supports ready to be cleaned.

COMPLEX CLEANING REQUIREMENTS – SAFECHEM offers customised cleaning solutions SAFECHEM offers complete solutions for high quality parts cleaning in line with ecological, social, and economic requirements. Comprehensive services and individual chemical-technical consulting help for an optimised cleaning process.

NECESSITÀ COMPLESSE DI LAVAGGIO – SAFECHEM offre soluzioni di lavaggio su misura SAFECHEM offre soluzioni complete per un lavaggio ad alte prestazioni di componenti industriali, che soddisfa i requisiti ambientali, sociali ed economici. Una vasta gamma di servizi e consulenza personalizzata tecnico-chimica per un processo di lavaggio ottimizzato.

SAFECHEM Europe GmbH Phone: +49 211 4389-300 service@safechem.com www.safechem.com

ICT - CASE STUDY

Production versatility 4.0

occurring again, but it is a situation in

“SATA has distinguished

progress and we are

itself since the beginning

waiting to see how it

as an advanced company,

will end. This implies a

attentive to technological

need for considerable

innovations. Over the

flexibility on our part:

years, this had enabled us

we must be able to

to steadily increase our

change our processes in

production volumes and

compliance with the new

better meet customer

regulations relatively

demands. Therefore,

quickly, in order not to

we needed a cleaning

compromise production.

machine able to treat our

STS’ machine will help

products in a functional

us because, not being

5 1

and effective way and to integrate perfectly with the

linked to any exhaust,

Figure 5: The cleaning process includes the following stages: immersion, rinsing, drying, and vacuum drying.

4.0-oriented approach that characterises the whole

waste management, or boiler feeding system, it is completely standalone and therefore

Rodolfo Chiantaretto.

easily rearrangeable

“The firm is also ISO 14001

production of SATA,” states

in any production

certified: we always strive

department and for

to reduce not only our

any type of product,

energy and disposal costs,

by simply modifying its

but also the impact of our

baskets and cleaning

activity on the environment.

programs,” explains

Thanks to STS’ system, we

Chiantaretto.

do not produce any harmful

“In future, we intend to

emission. We have also

increase the production

optimised the maintenance

capacity of this second

and replacement of the

line as well, speeding

cleaning tank water, which

up the workpieces

we perform every three

entering and exiting the

months despite the line

machine and, therefore,

works continuously on three shifts. This translates in a reduced environmental impact as well as in

further improving the

6 1

cleaning process. It is a feasible goal, which we

Figure 6: The unloading of finished parts.

have already discussed with STS and remains

economic and energetic savings, since we no exhaust chimney was

The last case that best exemplifies

among the priorities of SATA. We will

required and maintenance interventions

this trend was the ‘Dieselgate’ scandal

wait to see the developments in terms of

are needed only seldom.”

that concerned the emissions of

regulations and then we will get to work,

“Our target sectors are often subject

diesel engines, precisely managed

aware of the advantages and flexibility

to sudden changes, dictated by

by EGR valves. The European Union

ensured by our cleaning partner’ expertise

circumstances that force companies to

has already issued new regulations

and by our own high technological level,”

modify their production parameters.

to prevent such falsifications from

says Chiantaretto.

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N. 51 - MAY/JUNE 2018 - international PAINT&COATING magazine

efficacia, ecologia e sicurezza

effective, ecological and safe

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Lavaggio rotazionale ad immersione

Lavaggio rotazionale spray Asciugatura rotazionale ad aria calda

Immissione rotazionale di aria Immissione rotazionale di aria

Risciacquo rotazionale spray

EE 30 R

EE 40 S

Risciacquo rotazionale ad immersione

EE 60 R

soluzioni ecologiche per il lavaggio e trattamento delle superfici ecological solutions for washing and treatment of surfaces STS Srl - Via Galvani, 8 - 48123 Ravenna RA (Italia) Tel. +39 0544 456731 - Fax +39 0544 456733 w e b : w w w. s t s i t a l y. i t e m a i l : s t s @ s t s i t a l y. i t Customer Care STS: tel. +39 0544 456732 email: info.sts@stsitaly.it

ICT - CASE STUDY

Parts Cleaning Ensures Added Value Doris Schulz SCHULZ. PRESSE. TEXT., Korntal, Germany

ds@pressetextschulz.de

Opening photo: The turning shop manufactures around eight million steel, stainless steel and aluminum parts per month in three-shift operation, all of which are cleaned in the two washers.

urned parts for functionally-critical

Like many inhabitants of the Auvergne-Rhone-

Pierre, Jacques and Claude Perrotton run the

automotive systems place the highest

Alpes region in the French department of

business. With around 380 employees, the

demands on precision, quality and

Haute-Savoie, Albert and Félisaz Perrotton

turning shop produces some eight million

cleanliness. At a French turning shop, the latest

began producing turned parts in 1945 in

high-precision parts a month on 200 modern

in machinery for production and quality control

addition to their original activity of selling

CNC, turning, grinding and honing machines

not only ensures a defect rate of just one ppm

butter and cheese. They laid the cornerstone

(ref. Opening photo). The parts are made

with around eight million parts produced per

for today’s Perrotton S.A. based in Bonneville.

from steel, stainless steel and aluminum rods

month, but also tailored cleaning solutions.

Meanwhile their grandchildren Philippe,

with diameters ranging between eight and

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ICT - CASE STUDY

60 millimeters. Most of them are exported

us and has always had a very high priority

μm” must be met for some parts. In addition,

worldwide to Tier 1 suppliers in the sectors of

in our production process,” reports Pierre

reliable corrosion protection is required by

fuel injection systems, steering, transmissions,

Perrotton, Head of Industrialization. The

customers worldwide, especially when it

turbochargers and brakes. The company has

company was looking for a strong partner

comes to steel parts. “These days, the first

further customers in the aviation industry. With

for industrial cleaning technology and

question we are often asked is whether we can

the acquisition of the Minesco turning shop in

decided on Ecoclean GmbH (formerly Dürr

reliably achieve, check and document certain

2014, Perrotton added small and micro turned

Ecoclean GmbH). “In Ecoclean, we have

cleanliness specifications, as well as protect

parts made from 0.5 to six-millimeter-thick rods

found a partner who can offer us optimum

parts against corrosion. The actual production

to its product portfolio.

advice and good service for all our tasks,”

of the workpieces is only discussed after that,”

comments Production Manager Claude

adds Claude Perrotton.

Parts cleaning and preservation - a success factor

Perrotton.

“We were already confronted with cleanliness

rise in the automotive industry, so too do

Cleaning and corrosion protection in separate chambers

requirements back in the 1990s. Parts cleaning

demands concerning parts cleaning. Today,

When a trichloroethylene-based cleaning

is therefore an important quality factor for

specifications of “no particles larger than 200

As cleanliness requirements continue to

Figure 1: Parts are cleaned in one chamber and preserved in the other. By separating the two processes, the quality of both cleaning and preservation is increased.

international PAINT&COATING magazine - MAY/JUNE 2018 - N. 51

139

ÂŠ Ecoclean

ICT - CASE STUDY

containers are equipped with a mechanical coding system to enable automatic selection of the appropriate part-specific cleaning program. Besides all process parameters, the system also contains information about whether the parts require preservation. At Perrotton, programs for new parts are configured by a team of experienced people from various departments. Not only the cleaning parameters are determined, but also the best way to place the parts in the cleaning container. The first chamber contains two solvent tanks with

2 1

separate filtration circuits.

Figure 2: Appropriate cleaning programs are stored in the machine control system for the various parts. All process parameters are recorded and documented.

This is where pre-cleaning and the main cleaning process take place. To meet the high cleanliness requirements

both the high throughput and the demand for

ÂŠ Ecoclean

designed a solution that met

integrated preservation. The hydrocarbon-based washer has two working chambers for batch dimensions of 640 x 450 x 320 millimeters and a maximum batch weight of 250 kg. The parts, which are mainly placed in containers for cleaning, are supplied and discharged via roller conveyors with generouslydimensioned buffer sections. In the feed line, the cleaning

Figure 3: The two almost identical twin-chamber cleaning systems are an integral component of parts production and contribute to the high product quality.

140

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ICT - CASE STUDY

4 1

Figure 4: To meet even higher cleanliness requirements, such as no particles >200 μm for example, an additional fine-cleaning process is conducted in a Universal 81C.

for the parts, which are usually placed

of 400 μm with the system, but also

in containers for cleaning, this working

such a good preservation quality that

Eﬀective distillation with continuous oil discharge

chamber has equipment for vapor

we can ship parts to any location in the

Since the parts to be cleaned are heavily

degreasing, high-performance injection

world without any problems,” explains

contaminated with machining oil, each

flood washing and ultrasonic cleaning.

Claude Perrotton. As with all other

washer has a bypass distillation unit with

After vacuum drying, the batches are

production steps, the parameters and

continuous discharge in addition to the

automatically transported into the second

data are recorded during cleaning

standard distillation units. As a result,

chamber, where they are preserved

and preservation to ensure complete

around 1,000 liters of oil per washer

and again vacuum-dried (Fig. 1). The

traceability of parts as they are

are separated from the wash fluid and

proportion of preservative in the solvent is

produced (Fig. 2).

disposed of every week. Despite this

two percent. To keep this value constant,

These advantages were so convincing

high discharge rate, the twin-chamber

it is automatically topped up as required

that the company replaced a cleaning

cleaning systems work economically.

and the concentration checked every 24

system without integrated preservation

The solvent consumption is

hours in our laboratory. “Not only can we

with an almost identical twin-chamber

approximately 1,500 liters of

reliably achieve cleanliness specifications

system in mid-2017 (Fig. 3).

hydrocarbon per year for each washer.

international PAINT&COATING magazine - MAY/JUNE 2018 - N. 51

141

ICT - CASE STUDY

it makes an important contribution to

For about 25 percent of the parts produced,

Extensive cleanliness and quality control

higher cleanliness requirements must be

Approximately 90 percent of the cleaned

only one ppm with around eight million

met, for example a maximum particle size

parts undergo a cleanliness inspection

parts produced per month and thus an

of 200 μm. Here, after cleaning in one of

in accordance with VDA 19 or ISO

extremely low reject rate,” concludes

the twin-chamber systems, a further fine

16232. “We have integrated a cleanliness

Claude Perrotton.

cleaning step is carried out in a single-

laboratory into our production facility

chamber system of the type Universal 81C,

and trained employees for this task,”

which is specially designed for this task

reports Pierre Perrotton. The same

(Fig. 4). It is also hydrocarbon-based and is

percentage of parts is subjected to

fitted with two flood tanks and an ultrasonic

an automated 100 percent quality

cleaning system with a higher capacity.

control with optical measuring systems.

The cleaned parts are discharged through

Defective parts are reliably identified

an encapsulated tunnel into a clean room

and rejected. “Optimum cleaning also

(Fig. 5).

plays a decisive role here. In addition,

Separate fine cleaning

5 1

Figure 5: After fine cleaning, the parts are discharged through a tunnel into a clean room.

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N. 51 - MAY/JUNE 2018 - international PAINT&COATING magazine

the fact that we achieve an error rate of

ICT - TECHNOLOGY OVERVIEW

Sustainability at Service of the Customer: Biokavitus Solutions for Recovering and Reusing Emulsions and Water from Industrial Processes Rossano Conidoni Biokavitus S.r.l, Concesio, Italy

conidoni@biokavitus.com

lear scientific evidence demonstrates

metalworking industry, also the textile,

of industrial liquids and already adopted as

how humanity is living in a

the food industry for fruit and vegetables

an innovative technology by some of the main

non-sustainable way, making it

washing or waste water treatment in the

European industries in the automotive sector

increasingly important to establish a

dairy industry, for processing of precious

(Fig. 1). Phoenix uses the physical principle

reduction in the consumption of raw

metals (precious metal recovery and

of cavitation and Biokavitus technology to

materials and energy, as well as in the

treatment of water from working

regenerate liquids and emulsions commonly

production of waste.

process to reduce COD and BOD values

used in all industrial area. The equipment

Biokavitus, an enterprise within the

), just to name a few.

that works in by-pass can integrate any type of system, keeping the

established as an innovation

tooling machines cleaner and

ÂŠ Biokavitus

industrial group Metal Work SpA, project in 2010, has chosen to base its mission on ecological

more efficient. Liquids can be recovered many times, reducing

sustainability in industrial

the expense for their periodic

settings.

disposal.

The company promotes the

When used to regenerate

achievement of a constant

cooling lubricant emulsions,

optimization of operating costs

Phoenix allows eliminating the

through the enhancement of

odors that are formed by the

the available resources while

bacterial load; it also leads to the

adapting, at the same time,

floating of suspended particles,

technological and production

i.e. all the polluting corpuscles,

processes to ensure recovery

and their separation from the

and re-use of the same at a sustainable cost. Biokavitus equipment exploits the formation of micro and nano bubbles (of air and other gas)

liquid to be regenerated.

As an additional benefit, it

Figure 1: Phoenix by Biokavitus, designed for the treatment of industrial liquids, has been already adopted as an innovative technology by some of the main European industries in the automotive sector.

inside the fluid to be treated.

allows separation of extraneous oils from emulsion of origin and better cleaning of tooling machines, with a consequent

Biokavitus technology can be

reduction in the machine

applied in all industries where there is a need

A contained initial cost characterizes

working cycle time and better performance

to optimize the management of emulsions

Biokavitus systems, which also extends to

of the skimmers. This improves the entire

and water from industrial washing.

operating costs.

production cycle, guaranteeing economic

Some of the areas where the company

Biokavitus flagship product is the Phoenix

savings, improved machine performance and

operates include, in addition to the

equipment, designed for the treatment

environmental protection.

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ICT - TECHNOLOGY OVERVIEW

parts2clean Quality needs perfection

In addition to the treatment of cooling lubricants, Biokavitus technology allows achieving effective and accurate washing processes, even at low temperatures. The washing water is cleaner thanks to induced flotation of particles in suspension and of extraneous oil, making the exercise of washing clean and odorless. When used to regenerate water from industrial washing machines, the Phoenix equipment provides better cleaning action on difficultto-clean parts and better skimmer performance, as well as a reduction in the use of detergents, water consumption and energy

Leading International Trade Fair for Industrial Parts and Surface Cleaning 23 – 25 October 2018 Stuttgart ▪ Germany parts2clean.com

with Again s d Tour e d i u G

costs for the heating of the washing water. To make an example, one of Biokavitus customers, a world leader that produces millions of automotive valves per year, uses the Biokavitus equipment both in its plants in Italy and in production sites in Poland. During the washing operation, Biokavitus technology enables to operate without using detergents; dimensional control machines have not detected an increase in waste components due to improper washing. Today, the production process integrates the Biokavitus equipment, allowing achieving the following advantages: total elimination of chemicals, reduction of wastewater destined to chemical-physical treatment plant, elimination of unpleasant odors in hot periods due to the presence of oil and water and the formation of bacteria. The use of Biokavitus technology has also allowed to reduce the presence of operators for daily assistance to the machines (skimming operations), and of the twice-a-week control of concentration, as well as a reduced workload for purchasing and warehouse personnel. Another customer company, user of Biokavitus technology and automotive company of international importance, which designs and manufactures metal sheet pulleys by cold plastic deformation, for use in light and heavy automotive field. The customer uses the Phoenix equipment to control and stabilize cutting emulsions used in the process of plastic deformation of metal sheets. Combined to a Biokavitus oil skimmer the equipment allows eliminating trump oil from emulsion, restoring optimal working conditions for the presses, guaranteeing a healthier, and cleaner working environment. Removed trump oil is awarded to the consortium for exhausted oils without extra charges and with overall savings on the process. Phoenix also ensures effective cleaning of machining tools and a longer life cycle of the emulsion in use, controlling the proliferation of bacterial colonies. Biokavitus currently takes care of the entire process of industrial fluids in use, and is able to provide solutions that allow optimizing the cycle and the recovery of fluids, up to the pre-disposal treatment. Phoenix equipment integrates perfectly with further systems designed by Biokavitus, such as evolved self-cleaning filters and deoiling systems meant for the management of all industrial fluids, both oily and water-based. Hannover Fairs International GmbH Ʊ)`̪ тΉΏ ΅Έ ΍΅ ΌΉ ΉΈ ΏΈ ͊ Mg3nͰJ3M `¡̪ nf

ICT - TECHNOLOGY OVERVIEW

In-Line CO2 Snow-Jet Cleaning Process to Clean Lighting Components Before Coating. Reject Rate Significantly Lower Since Changing Over to Different Cleaning System Doris Schulz ds@pressetextschulz.de

n American manufacturer of highquality injection-molded parts found out that the efficiency of

different snow-jet cleaning systems can vary dramatically. Since the changeover

SCHULZ. PRESSE. TEXT., Korntal, Germany

covers and door components. “Every day, among other parts, we produce around 25,000 reflectors for headlamps from Bulk Molding Compounds (BMC), which are coated and metalized using PVD processes” reports CEO Rick Taylor.

to the quattroClean technology from acp, the company has been able to reduce the lighting components, which are cleaned

Cleaning decisive to product quality

before being coated, to almost zero.

Before being coated, the reflectors

Nanogate Jay Systems was founded as

undergo a cleaning step to remove dirt

the plastics division of the family-run

due to handling, fingerprints and de-

American company Jay Industries in

burring residues. To improve cleaning

1968. The company, which has had a

results and integrate this process step

majority interest in the Nanogate Group

into the production line, some time ago

contamination-related reject rate of vehicle

since 2017, specializes in manufacturing

the company invested in two CO2 cleaning

high-quality injection-molded parts from thermoset and thermoplastic materials,

systems from different manufacturers. 1

as well as in applying high-tech surface coatings. The company’s portfolio covers product design, materials development and manufacture, tool making, injection

However, the performance of both systems was poor. One proved to be

Figure 1: The patented two-component ring nozzle ensures good and even cleaning results. The array used by Nanogate Jay Systems is fitted with twelve nozzles.

molding, coating, metalizing, finishing and

inefficient because approx. 40 percent of the carbon dioxide was wasted rather than being used for the process. With the other system, cleaning results were poor,

assembly. Customers of Nanogate Jay

causing an extremely high contamination-

Systems include the automotive industry

of the headlamps for trucks and passenger

related reject rate of around 10 percent.

and manufacturers of household appliances,

vehicles from leading OEM’s. It also makes

The CEO therefore started looking around

as well as companies from other areas of

exterior panels, roof coverings and ABC

for a more efficient cleaning system. “On

industry. The main applications are parts

pillars, as well as interior fittings ranging from

a visit to one of our parent companies

for lights – the company produces most

center consoles to dashboards, loudspeaker

in Germany, I noticed the quattroClean

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ICT - TECHNOLOGY OVERVIEW

crystals. These are bundled by a

in touch with acp – advanced clean

The two-component ring nozzle is what makes the diﬀerence

production GmbH and explained his

The cleaning solution uses liquid carbon

and accelerated to supersonic speed.

requirements. After conducting cleaning

dioxide as a medium, which has an almost

The non-abrasive jet of snow and

tests in the company’s technical center

indefinite shelf-life. It is supplied via

compressed air has a temperature

on some components, Nanogate Jay

cylinders or tanks.

of minus 78.5°C. Since this can be

Systems ordered the first quattroClean

The core of the quattroClean system

directed highly accurately, practically

system. Besides the good cleaning

is a patented, wear-free circular two-

performance, the extremely competitive

component nozzle, through which the

all the CO2 is used for cleaning, and

price convinced us to buy”, adds Rick

non-combustible, non-corrosive and

results throughout the entire work

Taylor.

non-toxic CO2 is fed. On exiting the

area.

system from acp and was impressed”,

circular jacketed jet of compressed air

the process achieves uniform cleaning

remembers Rick Taylor. The CEO got

nozzle, it expands to form fine CO2

2 1

Figure 2: The quattroClean systems for cleaning the reflectors with a jet of CO2 snow are integrated into the paint and metalizing lines and controlled by the MES from Nanogate Jay Systems.

international PAINT&COATING magazine - MAY/JUNE 2018 - N. 51

147

ICT - TECHNOLOGY OVERVIEW

In-line, componentspecific cleaning process

by PVD to apply a reflecting layer of aluminum,

Nanogate Jay Systems now uses

jet and removed via an integrated extraction

three quattroClean systems,

unit, thus preventing parts from becoming

which are operated six, or

recontaminated.

sometimes even seven, days a

Since process parameters, such as volume

week in three shifts. Tailored

flows for compressed air and carbon dioxide,

by acp to the company’s exact

cleaning time and motion sequences, are

requirements, the systems take

adjusted exactly to suit the parts to be

the form of a robot with a nozzle

cleaned, optimum cleaning results are

array. The latter has twelve

assured (Fig. 4). In addition, only the amount

nozzles with a total jet width of

of carbon dioxide or compressed air required

120 mm (Fig. 1). Liquid carbon

for the process is used. “We are so pleased

dioxide and compressed air

with the quattroClean system and our

are fed to the array via a hose

working relationship with acp that we are

system.

already talking about integrating the system

The robots are integrated

into more of our paint lines”, concludes Rick

into the paint and metalizing

Taylor.

and then packed (Fig. 3). The dirt cleaned off is swept away by the aerodynamic force of the

lines. The cleaning systems are controlled

3 1

by a superior

Figure 3: The workpiece carriers containing the reflectors are processed fully automatically. They are cleaned, coated with basecoat, metalized by PVD to apply a reflecting layer of aluminum, and then packed.

Manufacturing Execution System (MES) developed by Nanogate Jay Systems (Fig. 2). “To integrate them, acp worked

The high level of cleaning efficiency is

closely with our programmers,

based on a combination of thermal,

and gave us tremendous support

mechanical, sublimation and solvent

when we put them into operation.

effects, which are activated when

It’s no problem at all that the

the jet impacts on the cleaning

company is in Germany and

surface. Thanks to these four cleaning

we’re in the States. They are

mechanisms, the quattroClean

always available if we need them.

system reliably removes filmic

However, since the cleaning

contamination, such as residues of

system has been in operation,

separating agents and fingerprints, as

no further support has been

well as particulate contaminants like

required”, explains Rick Taylor.

dust and de-burring residues. “We

To clean the various reflectors,

achieve much better cleaning results

about 30 part-specific programs

with this technology and have been

are filed. The MES selects the

able to reduce the contamination-

appropriate one in each case.

related reject rate to almost zero. It

The workpiece carriers containing

takes less than one year to achieve a

the reflectors are processed fully

return on investment”, remarks Rick

automatically. These are cleaned,

Taylor.

coated with basecoat, metalized

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N. 51 - MAY/JUNE 2018 - international PAINT&COATING magazine

4 1

Figure 4: By adjusting process parameters, such as volume flows for compressed air and carbon dioxide, cleaning time and motion sequences, exactly to suit the parts being cleaned, the contamination-related reject rate could be reduced to almost zero.

ICT - TECHNOLOGY OVERVIEW Automatic sealed ultrasonic cleaning machine 2S 90/24-P-F PCT AC Our machine requires only 5 kW (about 20% of the normal power requested by type Ib machines).

The future of green technology.

MEG S.r.l. Via Rometta, 13/G - S. Martino di Lupari (PD) - Italy Phone +39 049 9461165 - Fax +39 049 9461133 e-mail info@meg.it â&#x20AC;&#x201C; www.meg.it

PRECISION CLEANING

ICT - TECHNOLOGY OVERVIEW

How to Overcome Aluminum Parts Cleaning Challenges Joe McChesney KYZEN, Nashville, USA

joe_mcchesney@kyzen.com

hile necessary, metal parts

aluminum is the best cleaning option

production volumes of machined or cast

cleaning can be a complex

(Fig. 1). Typical soils that are removed

components. With the latest advances in

and time consuming part

from aluminum parts include:

flexible factory automation and advanced

of the manufacturing process when it

parts handling, these larger washers are

is not performed properly. When the

• Oils/Coolants

designed to seamlessly integrate with

results are less than desirable or when

• Aluminum Oxide

flexible manufacturing work cells. The

the parts do not meet the customer

• Aluminum Buffing/Lapping Compounds

washers are designed for continuous

specs, it can become an expensive

• Carbon

cleaning of parts contained on pallets and

problem.

• Aluminum Brightening

spray flushing of empty part pallets.

Along with regular metal cleaning issues,

Indexing parts washers are designed

aluminum parts cleaning has additional

When choosing a cleaning chemistry,

for the needs of part-specific cleaning

challenges to consider when choosing a

it must compliment the process, clean

applications. Conveyorized indexing

cleaning chemistry. From discoloration

effectively and not damage the part’s

washers are equipped with specialized

to parts damaged, this type of metal

surface (in some cases it must improve

part fixtures that carry parts in an exact

often reacts to certain chemistries

the surface). An effective process

orientation for precise part cleaning

that can be too aggressive to provide

embraces the right chemistry cleaning

and drying. Specialized part fixtures

the cleanliness required resulting in

with the equipment of choice considering

allow for consistent cleaning and drying

parts damaged and manufacturing

many factors such as pH level, post

of critical part features such as hidden

losses. Harsh chemistry can also be an

cleaning process to consider, corrosion

cavities, sensitive surfaces or blind holes.

environmental and personnel hazard

prevention needs, and more. The most

Chemistries used in this process also

and alternative solutions should be

popular types of cleaning equipment

should not foam or cause discoloration of

considered.

among manufacturers is:

the parts.

According to Engine Builder Magazine’s

• Spray-in-Air

most recent “Machine Shop Market

• Larger Drum, conveyorized or Indexing

Profile”, rebuilders spend more than 15

Parts Washers

Ultrasonic Cleaning requires special consideration to help remove tough

percent of their total production time

• Ultrasonic

soils. Components such as those

cleaning parts. So, how can the parts

• Spray Under Imersion

manufactured of highly polished

cleaning become a more efficient and

aluminum, can quickly be damaged

effective process thus avoiding costly

Aqueous spray in air cleaning processes

by ultrasonic cleaning action due to

problems?

are very effective for processing

cavitational erosion of the parts which

Today, more manufacturers are

aluminum parts. In most cases, a small,

is a condition where the ultrasonic

choosing aqueous parts cleaning

manually loaded work cell spray washer

scrubbing action actually erodes the

solutions to clean their Aluminum parts.

will suffice for screw machine parts. An

parts surfaces. This is an efficient

Aluminum is an especially sensitive

efficient chemistry that matches this

process for certain parts cleaning and

metal for both cleaning and protecting,

process will not foam during cleaning.

an experience technical team can help

so a cleaning product engineered for a

Larger drum, conveyorized or indexing

you evaluate the best option to fit your

broad range of applications specific to

parts washers are used for larger

needs.

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N. 51 - MAY/JUNE 2018 - international PAINT&COATING magazine

ICT - TECHNOLOGY OVERVIEW

Figure 1: Aluminum is an especially sensitive metal for both cleaning and protecting, so a cleaning product engineered for a broad range of applications specific to aluminum is the best cleaning option.

Platform oscillation is the most common

of dirt, thereby speeding the entire

higher impingement than straight platform

method of batch immersion parts washing.

action.

oscillation. As such, it is most effectively

It is the simplest way of covering irregular

“Spray” under immersion moves

used together with platform oscillation to

surfaces and reaching intricacies and the

solution over, under, around and

produce constantly changing flow patterns.

inside of hollow forms with a cleaning

through the parts. In this case, pump

This further accelerates the process by

solution. Oscillation of the work is an easy

agitation is used to turbulate the

reducing shielding.

way of accelerating the cleaning action.

solution. The turbulent flow is then

Regardless of your process choice, aqueous

With each oscillation the mechanical force

directed over the working zone using

chemistry is a safe choice for Aluminum

of the moving solution keeps washing newly

manifolds with jets or eductors.

Parts Cleaning. Consideration with the

formed emulsions and soaps away from

Specific problem areas can be

proper concentration, temperature and

surfaces while applying fresh chemical

addressed by the positioning of the

processing time are the key to a desirable

cleaning agents to the newly exposed layers

manifolds. This method produces

result.

international PAINT&COATING magazine - MAY/JUNE 2018 - N. 51

151

ICT - HIGHLIGHT OF THE MONTH

Francesco Stucchi, ipcm® from an interview with Sabino Di Pierro, Fismet Service

Opening photo: A Fismet Service cleaning line.

owadays, in order to design and

compared with other operations that

specialising for almost forty years in the

industrialise any product in any

are now highly automated and precise.

design and production of industrial and

material, we use technologies

Two examples are sheet laser cutting

ultrasonic cleaning systems. Fismet Service

with little margin of error. In the

and machining with CNC machines, i.e.

was established a few years ago thanks

machining field, interoperational cleaning

programmable electronic systems able to

to this vast experience. This contracting

is perhaps a process that has undergone

operate without human intervention.

cleaning and maintenance company can

fewer technological developments

Fismet is a well-established company

solve the most diverse washing problems,

152

N. 51 - MAY/JUNE 2018 - international PAINT&COATING magazine

ICT - HIGHLIGHT OF THE MONTH

allowing its customers to delegate any

every seven days: as a result, the first day

The solution to disposal problems

cleaning equipment management and

this solution will have completely different

Another major issue solved by Fismet Service

disposal issue and not to make any capital

characteristics and cleaning performance

is the disposal of spent washing solutions. “All

investment or face any staff cost (ref.

levels than the last one. Another aspect

cleaning systems basically transfer a certain

Opening photo).

affecting the process quality is the

amount of dirt from the treated parts to a

Fismet Service founder Sabino Di Pierro

arrangement of spray nozzles, designed

solution, be it a detergent or a solvent, thus

explains the reasons for the birth

without considering the different shapes of

creating a product to be purified or disposed

of the project (Fig. 1): “The cleaning

the parts to be cleaned during the service

of – a burdensome operation in terms of

techniques used by almost all component

life of the machine,” says Di Pierro. “In

costs and time,” explains Sabino Di Pierro.

manufacturers have involved, rather than

order to meet the countless requests for

“Our mission was finding a solution to reduce,

evolved: for legitimate environmental

high quality cleaning systems, we decided

if not eliminate, the disposal problem.”

reasons, solvents that were very effective in

to industrialise our washing experiments

terms of metal cleaning were

continuously regenerate

eliminated. The

the cleaning

developments

solution and

related to the

eliminate the

use of water-

need to dispose

based detergent

of it almost by

products

100% (Fig. 2).

have created

“Our machines

secondary

recover 96% of

management

cleaning baths

problems. Fismet

and 100% of

has therefore

rinsing baths

looked for new

and they no

solutions. One of

longer have any

these is carbon

free discharge

dioxide, but

of water or air.

the time is not

We manage

ripe yet for a

to treat the

wide use of this widespread in sectors such as the car one. We

cleaning

technology, now

solution by

Figure 1: From right to left, Sabino Di Pierro, laboratory specialist Sina Geran, testing director Girolamo Amodio, and production manager Enrico Mauriello.

focus on three

exclusively stripping the dirt removed from the parts

fundamental concepts to better understand

by expanding our testing laboratory and

while maintaining the solution’s properties

the needs of our customers and offer a

turning it into a workshop devoted to

unaltered. At the end of the process, only

reliable and cutting-edge service: progress,

contracting cleaning. We can treat any

the solid dirt expelled at the end of the cycle

product, and process.”

component with any quality specification,

remains to be disposed of. This system

carefully monitoring the solution service

dramatically reduces waste, improves cleaning

“Perfect cleanliness is crucial to the quality

life, the detergent amount, and the disposal

quality, and enables to save in terms of

level of a product, but one of the main

operations required. We have found that

energy and process management, including

problems is keeping it constant on each

even in this sector it is possible to achieve

bureaucracy.”

workpiece. With detergent-based cycles,

remarkable performance levels in terms of

Fismet Service’s customers range from the

the cleaning solution is usually replaced

both quality consistency and energy saving.”

precision mechanics to the medical sector,

international PAINT&COATING magazine - MAY/JUNE 2018 - N. 51

153

ICT - HIGHLIGHT OF THE MONTH

liquid one, where air is compressed at 60-70 atmospheres at 20-30 °C, and the supercritical one, where CO2 is compressed up to 400 atmospheres (Fig. 4). “The CO2

cleaning system works like absorbent paper. Assisted by the action of ultrasound and of complementary mechanical actions, carbon dioxide in liquid phase traps and holds the dirt particles. When pressure is removed from the system, the CO2 charged with contaminants flows and undergoes

a fractional distillation process where dirt is collected and separated, while carbon dioxide is recirculated. Consumption is therefore equal to zero, and the oil and grease removed from the workpieces can be reused for the operation they were originally intended for.” “This cleaning cycle can be used for all

2 1

porous metals,” says Di Pierro. “In the

Figure 2: Another cleaning system used by Fismet Service. All systems are equipped with ultrasound adjusted according to the type of part to be cleaned.

automotive sector, for example, fuel injectors have a porous structure and, if processing oil residues remain inside that porosity, they

by exploiting technologies that use CO2 as

will evaporate inside it during operation, thus

the detergent product.”

generating harmful gases. Other applications

materials are metals, plastics, glass, ceramics,

The machine devoted to cleaning these

and generally all products requiring a very

advanced materials employs carbon

of the CO2 cleaning process can be found in

high degree of cleanliness and having to meet

dioxide in various process phases: the

from the automotive to the cosmetics and pharmaceutical industries. The treated

residual contamination allowed is indicated (Fig. 3).

specifications where exactly the maximum

Deep cleaning of porous surfaces Fismet Service also treats delicate and sensitive substrates such as magnesium and titanium, featuring porous surfaces that determine their main characteristic, i.e. lightness, but greatly complicate the cleaning process. “Surface microporosity tends to trap dirt: it may be difficult to eliminate it only with high pressure jets and sprays, which are indispensable, on the other hand, to remove larger particles,” states Di Pierro. “In order to deeply clean a surface, techniques must be employed that can penetrate into metal and remove pollutants. We can achieve excellent results

154

N. 51 - MAY/JUNE 2018 - international PAINT&COATING magazine

3 1

Figure 3: An automotive component.

the aerospace and medical sectors, where a very high cleanliness level is required.”

Quality assurance

ICT - HIGHLIGHT OF THE MONTH

“In our lab, we carry out continuous checks on cleaning water to certify that quality is kept constant from the first to the last workpiece,” says Eng. Enrico Mauriello, Fismet Service’s production manager. “Moreover, we perform two types of checks on components (Fig. 5): direct and indirect. In the former, we examine the parts to look for any traces of organic and inorganic pollutants. We use ultraviolet ray systems, surface tension tests, or a metallographic microscope (Fig. 6) with which we can analyse the surfaces’ behaviour after cleaning. During the indirect checks, we subject a clean part to a further Figure 4: The CO2 cleaning plant.

4 1

FISMET SERVICE S.r.l.

ICT - HIGHLIGHT OF THE MONTH

“We have been able to meet the market’s needs thanks to our direct experience in the cleaning field,” states Di Pierro. “This new field of activity, added to the design of machines, has enabled us to brilliantly overcome the crisis in recent years and offer a service to companies facing cleaning issues and risking of losing further market shares due to the decrease in market demand, a staff reduction, or the increasing needs of their customers. These firms have entrusted us with the task of finding solutions for their problems

5 1

and we had to invest in human resources, equipment, service, and

Figure 5: Laboratory test tools.

quality. This path has not come to an end summary report of the cleaning process

yet, but we can say that Fismet

out if there are any residues, especially

performed on each workpiece, including a

Service is currently the only

inorganic ones, remaining on the

photo, the cycle description, the parameters

international company to offer a

surface.

set, such as temperature and concentration,

universal range of cleaning systems

The solution obtained is filtered; then,

and all the checks performed.”

and plant management skills.”

the filter is dried and finally checked under the microscope to identify the

cleaning cycle with the aim of finding

nature of the residual particles. The microscope is motorised, so that it automatically performs the particle counting task in order to certify the cleanliness level of parts. We work based on both our customers’ specifications and, if these are not provided, with our internal control procedures as per Fismet’s quality manual and according to international standards.” “For each cleaning cycle, we issue a certificate including the checks performed and the key parameters, e.g. turbidity, detergent concentration, pH, emission concentration, conductivity, and hardness,” states Girolamo Amodio, quality control manager. “Then, we produce a

156

N. 51 - MAY/JUNE 2018 - international PAINT&COATING magazine

6 1

Figure 6: The metallographic microscope for the control of residual dirt particles.

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ICT - INDUSTRY NEWS

ÂŠ H2O

H2O GmbH at the Surface Technology: Efficient Wastewater Treatment with VACUDEST

Figure 1: H2O booth at Surface Technology Germany.

he better the pre-treatment, the

treatment for used rinsing water. These

large part of the disposal costs is saved and

better the coating result. The leaders

systems offer the clear advantage of the

valuable fresh water resources are spared.

of zero liquid discharge at the Surface

option to re-use the cleaned water in the

The VACUDEST is currently available in

Technology (hall 1, booth D27 (51)) will explain

rinsing process.

six machine sizes and 17 performance

how vacuum distillation systems with patented

Unlike conventional evaporators, the

variables. The latest member of the

technologies from H2O GmbH help to improve

VACUDEST system treats used rinsing

VACUDEST family is VACUDEST XXL. With

the coating quality while also increasing cost-

water until it is crystal clear. Patented

30.000 mÂł/year it has the largest capacity

effectiveness. This international trade fair for

Clearcat technology leaves the treated

ever Since 30 years VACUDEST history and is

surface treatments & coatings takes place from

water virtually free from oils, and therefore

unique in the field of vapour compressors.

5 to 7 June 2018 in Stuttgart (Fig. 1).

ideally suitable for recycling in the rinsing

Evaporator technology is increasingly becoming

process.

For further information:

established as the preferred method of

As a result of the cycle management, a

www.h2o-de.com

158

N. 51 - MAY/JUNE 2018 - international PAINT&COATING magazine

IL LAVAGGIO DEL FUTURO… ADESSO

IL MASSIMO DELLA TECNOLOGIA ANCHE NEI MODELLI DI BASE The best technology also in the basic models

KP.EASY

L A V A T R I C I S O T T O V U O T O A L C O L I M O D I F I C AT I . I D R O C A R B U R I

www.ifpsrl.com

I F P E u r o p e S r l V i a l e d e l l ’ I n d u s t r i a , 11 - 3 5 013 C i t t a d e l l a ( P D ) I t a l i a Te l . + 3 9 0 4 9 . 5 9 9 6 8 8 3 Fa x + 3 9 0 4 9 . 5 9 9 6 8 8 4 i n f o @ i f p s r l . c o m

ICT - ZOOM ON EVENTS

Rich Array of Topics To Be Covered at the SurfaceTechnology Forum

Figure 1: SurfaceTechnology will be held in Stuttgart, Germany, from 5 to 7 June.

rom 5 to 7 June the

be addressed are surface cleaning, Industry

the removal of contaminants resulting from

SurfaceTechnology GERMANY

4.0, energy efficiency, QA and process

manufacturing processes, as well as cleaning

Forum in Stuttgart is presenting

optimization. All talks will be simultaneously

and decoating, pickling and etching, and

a series of 20-minute talks on every

translated and thus can be followed in

electrolytic degreasing and activation. A talk

conceivable aspect of surface technology

English and German.

on inline cleaning with CO2 snow blasting then introduces the theme of Industry 4.0

(Fig. 1). On all three days of this international trade fair for surface

The SurfaceTechnology Forum agenda

in surface technology. This will be followed

treatments and coatings, experts from

begins at lunchtime on Tuesday, following

by presentations on new regulations for

industry and the R&D community will

the presentation of the Stuttgart prize “DIE

electroplating plants, how surface treatment

be informing visitors about all the

OBERFLÄCHE” by the Fraunhofer Institute

processes are being future-proofed by means

hottest topics and trends. For attending

for Production Engineering and Automation

of automated analytics with maintenance-

professionals, this is a great opportunity to

(IPA). The Forum then gets underway with

free sensors, and potential benefits for SMEs

brush up their know-how on coatings and

coverage of various aspects of cleaning

as a result of the energy transition, i.e. the

surface treatments. Among the topics to

and pre-treatment. Featured topics include

structural move towards renewables.

160

N. 51 - MAY/JUNE 2018 - international PAINT&COATING magazine

ICT - ZOOM ON EVENTS

The Wednesday session of the Forum

alkaline zinc/nickel electrolytes. From midday,

At midday, the stage will belong to plant,

begins by looking at energy efficiency and

speakers will turn their attention to the use

equipment and processes â&#x20AC;&#x201C; for example,

the efficient use of materials. The speakers

of treated surfaces. Topics covered here

filtration devices for the adsorption filtration

will examine aspects such as saving energy

include the durability of nickel alloy coatings

of baths used in wet chemical cleaning, or

by fine-tuning and optimizing rectifiers,

when subject to corrosion and mechanical

modern rectifier control systems. Rounding

the use of process data and risk data in

wear, special plant technology for producing

off the dayâ&#x20AC;&#x2122;s agenda are talks on processes

the production process, as well as the

galvanic coatings of a specified thickness, the

for physical surface treatment, such as PVD,

recovery of usable metals from metal

improvement of the tribological behaviour

CVD and thermal spraying.

sludges. This will be followed by a series

of high-stress applications by technological

of talks exploring the implications of

coating systems, and coated PPS as a viable

The topics covered at the SurfaceTechnology

REACH, which is set to be a game-changer

alternative to lightweight alloys.

GERMANY Forum include electroplating,

for companies specializing in chromium-

irradiation, thermal spraying, industrial plasma

based coatings, whether as suppliers or

On the Thursday morning, the focus will be

and laser-based surface technologies, coating

users of the requisite process technology.

on QA and process optimization. Visitors

materials, surface treatment, environmental

A session devoted to new electroplating

can learn about the monitoring of process

and utility engineering, services, pre-

processes looks at dispersion layers

media and parts cleanliness, operating and

treatment, cleaning, and measuring, testing

in tribological applications, trivalent

production processes in the supply chain for

and analysis.

decorative chromium plating, high-

surface technology, digital transformation,

performance zinc/iron alloys, and new

and the use of X-ray diffractometry for real-

For further information:

technologies for the next generation of

world evaluation of coatings and thin films.

www.surface-technology-germany.de

In concomitanza con In parallel with

9 - 13/10/2018

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UCIMU-SISTEMI PER PRODURRE

ICT - ZOOM ON EVENTS

State-Of-The-Art Parts Cleaning Solutions Highlighted at Parts2clean 2018

n manufacturing processes such as

manufacturing results, and appropriate

challenges in the future, driven by global

adhesive bonding, welding, sealing

processes need to be put in place at

trends such as eMobility, autonomous

and coating, the cleanliness of the

vehicles, lightweight construction,

chain. The cleanliness specification

miniaturization and Industry 4.0.

the process and the correct functioning

will always be determined by the

of the finished product. The effective

requirements of the subsequent

“Many of the firms exhibiting at the

removal of contaminants, whether in the

processing stage. Furthermore, it is

upcoming parts2clean will be focusing

form of particulates or films, is therefore

already clear that industrial parts and

on these future challenges, as well as on

essential for consistent, high-quality

surface cleaning faces new and tougher

the demands of today’s manufacturing

every link in the production and supply

components directly affects the quality of

Figure 1: The 16th edition of parts2clean runs from 23 to 25 October 2018 at the Stuttgart Exhibition Center.

162

N. 51 - MAY/JUNE 2018 - international PAINT&COATING magazine

ICT - ZOOM ON EVENTS

and bath maintenance. Meanwhile, alternative cleaning processes such as CO2 snow blasting, laser cleaning and plasma cleaning will become increasingly relevant. These technologies permit selective dry cleaning of functional surfaces and designated areas of components prior to adhesive bonding, sealing, laser welding or assembly, as well as the cleaning of pre-assembled parts. Another advantage of these processes is that they lend themselves readily to being automated, such that they can be integrated into networked manufacturing environments. And with many more cleaning operations to be performed, a controlled manufacturing environment designed for cleanliness will play a key role in meeting the necessary requirements. For these and

2 1

all other challenges in industrial cleaning

Figure 2: parts2clean will be presenting solutions for all the challenges in industrial cleaning technology.

technology, the exhibitors at the upcoming parts2clean will be presenting solutions (Fig. 2).

Industry Forum and Guided Tours in English and German

and utilizing resources more efficiently”,

Meeting performance requirements reliably and eﬃciently

says Olaf Daebler, Global Director of

On the one hand, manufacturers now

parts2clean offers visitors from Germany

parts2clean at Deutsche Messe. The

have to meet more exacting standards of

and around the world a valuable source of

16th Leading International Trade Fair

particulate cleanliness, which have come

information about trends and innovations

for Industrial Parts and Surface Cleaning

about partly through the development

in cleaning technology”, notes Daebler.

runs from 23 to 25 October 2018 at the

of ever smaller and more complex

The simultaneously translated presentations

Stuttgart Exhibition Center (Fig. 1). “With

components, as well as components for

(German <-> English) will cover a wide range of

six months still to go before the start of the

high-performance applications. And on

topics and real-world applications in industrial

show, we are happy to report that nearly

the other hand, there is a growing focus

parts and surface cleaning.

all the market and technology leaders from

on the need to remove film-type residues,

The Guided Tours will be offered on all three

the various display categories featured

staining and discoloration, as well as – in

days of the show, in both English and German.

have already booked their space”, says

certain sectors of industry – biological and

Taking in selected exhibitor stands, the

Daebler. “This means that visitors from

ionic contaminants. As a result of these

tours give visitors the opportunity to gather

many different sectors, such as the car

new developments, wet chemical fine and

information on specific areas of interest in

and component supply industry, medical

ultra-fine cleaning processes will become

industrial parts and surface cleaning, for

technology, mechanical engineering, the

more mainstream. The use of such

every link in the process chain. Participating

aerospace industry, precision engineering

processes generates increased demand

exhibitors, for their part, have the opportunity

and micro-engineering, optics, electronics,

for sophisticated instrumentation

to pitch their products and innovations to a

semi-conductors and coating technology,

to monitor cleaning baths, check

highly receptive audience, thus resulting in

will be able to find all the suppliers,

for cleanliness post-treatment, and

additional leads and potential sales.

products and services they need to

continuously record and document

effectively and affordably solve their

process parameters. Also required are

For further information:

particular cleaning challenges.”

solutions for efficient water treatment

www.parts2clean.de

environment, such as increasing the energy efficiency of cleaning processes

“With the three-day Industry Forum,

international PAINT&COATING magazine - MAY/JUNE 2018 - N. 51

163

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SPECIAL AUTOMOTIVE INDUSTRIAL & CLEANING TECHNOLOGIES

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MONICA FUMAGALLI fumagalli@ipcm.it

NICOLE KRAUS

A NEW DIMENSION IN EFFECT POWDER COATINGS

MATTEO SOTTI

• Liquid paint-like 3D effects in one-coat • Brilliant and bright effects • Easy-to-apply: minimal equipment inﬂuence

sotti@ipcm.it

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Prof. Stefano Rossi:

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Marine and industrial anticorrosive coating cycles

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ipcm® n. 51 - May/June 2018

Articles inside

Ferrari: The Italian Automaker Revolutionises the Car Painting Process with a Low Cure Clear Coat System