Refinisher Vol65 Issue 4 2023

VOLUME 65 • ISSUE 4 NOVEMBER 2023

U A W

and

! p i h s r e n t r a p g n i n n i w a – G P P

ALSO INSIDE: • ENVIROBASE ® HIGH PERFORMANCE – STILL THE BEST! • MOONVAN TAKES PPG LINQ TO THE PEOPLE • SATA SPECIAL EDITION OFFERS THE ‘UNIVERSE’

• CREATING A SHOW STAR FROM A HUMBLE COMMODORE

Connect.

Automate.

Digitise.

The end-to-end digital ecosystem bringing advanced, game-changing technologies to your collision centre

Explore the PPG LINQ™ Digital Ecosystem.

Visit PPGLINQ.com

Introducing the 3D digital sprayout

Compact, fast, easy-to-use spectrophotometer

This advanced, 3D digital colour visualisation tool smoothly interfaces with the next-generation PPG DigiMatch™ camera-equipped spectrophotometer to totally transform the user experience of selecting the best colour match formulation from PPG’s extensive library.

PPG’s high tech DigiMatch spectrophotometer features a digital colour camera to significantly boost performance. The camera’s six imaging angles combine with six reflective angles to provide additional texture information to help quickly and precisely retrieve the correct formula match.

CONTENTS 4 ISSUE

November 2023 VOLUME 65

MAGAZINE

Editor-In-Chief Andrew Blake

Editor John M Stanley Creative Director Dean Parrott Published for and on behalf of PPG Industries Pty Limited by

Kisschasey Creative Pty Ltd Telephone (03) 9421 3311

Australia Head Office Locked Bag 888, Clayton South, Victoria 3169.

McNaughton Road, Clayton, Victoria, Australia, 3168 Telephone: 13 24 24 www.ppgrefinish.com.au New Zealand Head Office 5 Vestey Drive, Mt Wellington, Auckland, New Zealand.

Toll Free Telephone: 0800 320 320 Victoria 104-106 Woodlands Drive, Braeside, 3195 Telephone (03) 8586 0000 New South Wales 10 Peter Brock Drive, Eastern Creek, 2766 Telephone (02) 9854 6600 Queensland 18 Breene Place, Morningside, 4170 Telephone (07) 3823 8000 South Australia 97-105 Bedford Street, Gillman, 5013 Telephone (08) 8346 6870 Tasmania 136 Invermay Rd, Invermay, 7248 Telephone 1300 305 699 Western Australia Unit 2/6 Colin Jamieson Drive, Welshpool, 6106 Telephone (08) 9256 3920

PPG Logo, Delfleet, Deltron, Envirobase, Global Refinish System, Harlequin, PaintManager, Prizmatique, Radiance, RapidMatch, Startline and ‑ are registered trademarks and We protect and beautify the world, Crystallance and RapidMatch are trademarks of PPG Industries Ohio, Inc. SATA and SATAjet are registered trademarks of SATA GmbH & Co. KG. Third-party trademarks referenced in this magazine are the property of their respective owners.

SC A N TO R E A D T HE REFINISHER ONLINE

features regulars

Editorial Co-ordinator Chelsea Hilsberg

4 News oh wow!

6 H2 The region’s most popular waterborne basecoat system

in performance 10 Partners A close relationship based on a shared vision and values

10

we stand 16 United A new, purpose-built facility has given Walkinshaw Andretti United an impressive base but the real story is its people. Led by Team Principal, Bruce Stewart, there is a culture of trust and teamwork which has this renowned team on the cusp of a new era in Supercars.

dollars and sense of 20 The investing in staff

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Upskilling your team is a no-brainer

24 You need a Traffic

Management Plan How to create this crucial document

limits 32 No Tough, durable, customer-focused

32

trailer solutions

24

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REFINISHER NEWS

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Sloanebuilt Trailers recognised with prestigious award C

Thanks to a close partnership with PPG spanning over two decades, Sloanebuilt Trailers utilises a variety of PPG products – most of which are manufactured locally – to help give their products excellent durability and R appearance.

ongratulation to NSW based trailer and tipper bodies manufacturer, Sloanebuilt Trailers, for being awarded the title of Australian Owned™ Business of the Year 2023. The distinguished accolade recognises businesses who are advocates of the Australian Owned™ initiative and have a strong operational focus on Australian-produced and manufactured supplies and support services.

140 A

years of innovation

determination to continually search for innovative solutions was already in place when Pittsburgh Plate Glass Company threw open its doors in 1883. Now known as PPG, the company has been on a transformational journey over the subsequent 140 years. After laying a solid foundation of

innovation by producing America's first marketable plate glass, PPG has built on that rich history to become a leading paint, coatings and specialty materials manufacturer. These days, PPG’s footprint spans the planet, with over 52,000 employees in more than 70 countries, and a focus on local manufacture via a network of around 120 production facilities, including

local sites in Clayton (Victoria), Villawood (NSW) and Auckland (New Zealand). To mark its 140th Anniversary, PPG opened a special customer and employee experience centre at its global headquarters in Pittsburgh, USA, which showcases the innovative paints, coatings and specialty materials and technologies that exemplify the company’s purpose – WE PROTECT AND BEAUTIFY R THE WORLD®.

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DRIVE THROUGH F

or most collision repairers, the festive season holidays mark a welcome end to the working year. It’s traditionally the time for a major workshop clean, a lick of paint where needed and a general tidy up in preparation for the new working year. However, it can also be the perfect time to stop and consider how different areas of the business are performing and implement some new strategies for continuous improvement. This is where I believe PPG excels. While it’s primarily about developing market leading paint technologies, PPG chooses to surround them with everything else you need and more. The aim is simple – by offering tailored solutions to support their business, each of our customers become their own unique success story. It might sound cliched, but your success is our success.

WITH ANDREW BLAKE REFINISH MARKETING DIRECTOR ANZ

As a result, I would encourage you to take advantage of PPG. Talk to your PPG Territory Manager or Training Manager about what the latest product technologies, processes, techniques and tools can do for your efficiency and cycle-time. Check out the remarkable range of trailblazing PPG LINQ technologies, including the DigiMatch spectro, VisualizID 3D colour visualisation software and the MoonWalk automated dispensing machine. Last but not least, speak to your MVP Business Solutions Manager about all the business boosting strategies they have on offer. It could be the best New Year’s Resolution you have ever made for your business.

Finally, I would like to wish everyone – from our terrific customer base across the region, through to the incredible team at PPG – a merry Christmas, a safe and relaxing festive season and an awesome 2024! .

YouTube sensation H

ave you checked out the very cool ‘Muscle Car Respray’ series on YouTube? Brought to you by PPG and MIRKA, this 13-part series places you into the build process as master craftsman, Howard Astill, takes a 1971 Camaro body from bare metal, all the way through to a quality, ‘street car’ paint finish. Each episode follows a step-by-step format and is a unique opportunity to tap into Howard’s treasure-trove of experience and knowledge. “Products and processes are constantly changing so this is about providing people with the latest information, as well as tips, techniques and hacks that can make the job more efficient and produce a better end result. I am really pleased to do it in conjunction with PPG and MIRKA and have PPG technical experts on hand to help us understand why certain things are done at certain times.” You can find the Muscle Car Respray series on the Astill Design

YouTube channel (https://www.youtube.com/@AstillDesign), along with an array of other content from Howard, including a vast back catalogue of videos. Be warned, it can quickly become addictive! R

Meet the PPG team@Summernats W

ith its high-octane program, Summernats 36 (4th – 7th January 2024) is promising to be another epic automotive festival and the PPG team will be front and centre. Located at the traditional PPG Corner site, visitors can immerse themselves in the paint process thanks to a special display that follows the detailed restoration process steps, from bare metal, through to a show car finish. Of course, PPG colour is also a feature thanks to a colour wall showcasing PPG VIBRANCE COLLECTION® custom colours, along with a fan favourite selection of iconic muscle car

colours. As usual, there will be some awesome displays of PPG painted vehicles, including the 1971 Camaro that featured in the Astill Design YouTube series, and Howard Astill himself, will be on hand to talk about

the project. Throughout the four-day event, you can also chat one-on-one with a PPG expert who can offer advice on completing your own dream project with confidence. As if that is not enough, you can even take advantage of special pricing on MIRKA tools and abrasives R and SATA spray equipment.

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PPG PRODUCTS

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H2Ohwow!

As the region’s most popular refinish basecoat system, ENVIROBASE® High Performance continues to set the standard for fast, efficient and easy to use waterborne technology.

W

hen Envirobase High Performance launched locally in 2006, it kicked off with a huge advantage. The make-up of this third generation PPG waterborne technology featured unique and very clever latex resin particles which are suspended in a gel-like state. Not only is this technology still exclusive to PPG, it also delivers rewards that had been unthinkable up to that point in a waterborne basecoat, including speed of drying, productivity, colour strike, ease of use and ease of storage. Forget traditional mechanical mixing machines, Envirobase HP

just needs a temperature-controlled storage cabinet or, better still, a MOONWALK® automated dispensing system. PPG’s proprietary anti-settle technology keeps pigments in suspension and prevents them settling at the bottom.

When it comes to using each tinter, it takes a simple shake half a dozen times by hand and it’s ready to pour. It’s fair to say that Envirobase HP has had a dramatic impact on the Australian and New Zealand markets and a constant stream of new product additions, updates and refinements have helped it retain its position as the most popular refinish basecoat system in the region, bar none, says John Hristias, PPG Sales Director Australia.

s u d n i e h t g n i d Lea since

try

2006

Led the market to water In a market where there has been no government legislation requiring a change from traditional solvent-borne refinish systems, Envirobase HP has been responsible for leading the switch to waterborne. Interestingly, it was not necessarily because it’s a greener, more sustainable product – although it’s a feature that certainly helps! From the start, what really got both owners and painters excited is Envirobase HP’s unique, market leading abilities, in terms of colour offering, overall performance and user-friendliness. It made switching to waterborne a no-brainer and many collision repairers still fondly remember when they first installed Envirobase HP.

Painters love Envirobase HP It’s worth asking, ‘what makes Envirobase HP so popular?’ Why are painters drawn to it? The feedback we get is that working with Envirobase HP makes their life easier and it helps them produce great work.

It’s easy to learn, it’s easy to use, it’s very forgiving and it avoids all the annoying issues you are likely to find with other waterborne technologies.

If you only get to use a refinish system that has annoying issues, you could be forgiven for thinking that all waterborne systems suffer from the same issues. However, it comes back to the fact that waterborne technologies are not created equal and there are actually significant differences between them.

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!

In contrast to many systems out there, Envirobase HP has all the little features that people like, such as the ability to de-nib between stages and it can be tack-ragged so you can easily fix some of those potential faults that creep into the process. The blendability and mottle control of Envirobase HP also makes the lives of painters easier.

Tools for consistency The package of tools that come with Envirobase HP includes everything needed for smooth, consistent, high quality results every time. Rather than simply supplying the product and letting each painter work out their own application solutions, the local PPG technical has developed a full, easy to

follow process chart that includes the best spray gun setup, along with tips and hacks that let you quickly make the most of this extraordinary product so you can maximise paint shop productivity and profitability.

Top of its game It’s important to understand that the Envirobase HP system you can utilise today is actually an improved and refined version of the original. Although the basic technology remains the same, during its time on the market, over 20 additional tinters have been added in order the continually strengthen the Envirobase HP system and ensure it remains current. And it’s not just about outstanding colour – it’s now a complete paint system that puts productivity into overdrive thanks to a range of superb primers and clearcoats (including matt and semi-gloss clearcoats), as well as an Engine Bay Converter to conveniently recreate the finish in areas such as under-bonnets, boots, door jams, etc. Today, Envirobase HP is a system that allows a collision centre to paint 100 cars a week, if needed.

Alternatively, It’s just as happy and efficient doing a custom respray or being used for commercial transport work.

The best getting better One of the really cool things about Envirobase HP is that it meshes perfectly with ground breaking new technologies from PPG LINQ®. This includes the MoonWalk automated dispensing technology, along with the DigiMatch™ spectro and the VisualizID™ 3D colour visualisation software that lets you make fast and accurate colour matching choices without using a drop of tinter on spray-out cards. Although Envirobase HP is still at the top of its game, the best refinish basecoat system on the planet is set to get even better. Can’t say to much at the moment but stay tuned!

R

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PPG VIBRANCE COLLECTION

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Holden’s Commodore may have disappeared from new car showrooms but the long running Altona North nameplate is beginning to make a big Smash Repairs, in impact in the show-car halls.

Melbourne. According to

W

hen aiming for high-end show car accolades, builders often start with an iconic local model from the ‘70s or prior, such as an early Falcon, Monaro or Torana. However, the status quo is shifting. In the 2022 / 23 show season, the mint-fresh rebuild of Frank Darmanin’s VH Commodore SL/E not only romped away with an Elite Top Ten and Top Sedan at Summernats, it also wowed the judges to be named to the Meguiar’s Superstars Super Six. It would seem that this epic machine was single handedly making Commodores very cool.

For Frank, it’s the culmination of a 30-year love affair with this Commodore which happens to be the first car he owned.

This is actually the second major build on the car and both have been done with his good mate, Elvis Barbieri. If you recognise the name, you may be aware that Elvis has his own Ford Capri show car and runs several high-profile events through his ‘Showcars Melbourne’ organisation, as well as working alongside his two brothers at

Elvis, this second iteration of PROGM-8 is one of those instances where things got a little carried away.

“About 15 years ago, I did the original build on Frank’s VH Commodore and it cleaned up big time on the show scene.

I think Frank must get a bit bored because a few years ago he decided to make some changes, such as upgrading the engine to a 440ci LS V8 that makes 900hp and fitting huge 22-inch wheels. From that, the project grew and grew until it became a full custom build, including a new floor and chassis.

Having built lots of custom cars, hot rods and street machines over the years, I know this process is hard so we started by putting a management system in place.

The first step was to get the car drawn up by a graphic designer so that we had an overall vision for the build.”

“The VH Commodore is still a good-looking car so the biggest challenge was to keep it looking like an original car but also being fully modified

at the same time.

It’s about making the modifications subtle so they don’t hit you in the face. A custom chassis, a new raised floor and moving the firewall backwards gave us the ability to tub the rear and tuck the front wheels neatly inside. We also fabricated a custom K-frame at the front – like they use in Supercars – and created a custom wishbone suspension system. As well as a handcrafted, steel, custom reverse cowl bonnet, the car runs a full computer system which includes traction control and push button start. To help hide the rear tubs, we even had custom made rear seats which mould into the tub so when you open the back doors, it looks like a two-seater. When you see the car, it still looks like a VH Commodore but, the more you look, the more modifications you notice.”

As a qualified painter, Elvis has been using PPG products since day one, so it was a natural choice for this blockbuster build. “As a base, we settled on an early ’90s BMW blue colour which I altered by adding some PPG Vibrance tinters. Because the basecoat is transparent, I also played around with the look by using different ground coats. I did four samples with different shades of ground coat to see the effect and compare them in the sun because we were trying to get a good flip. Once we had chosen, we were able to add the custom formula in PAINTMANAGER® XI so it’s always there in the future. We colour coded the wheels in the same basecoat and then used a custom BMW grey colour for things

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like the diff, calipers, roll-cage, K-frame, etc. Because this is a fully engineered, road registered car, we laid down a black shade of PPG HiFill Primer Filler on all the underneath surfaces so that any stone chips won’t show. We finished it off with Vibrance Custom Clearcoat and used a satin finish on the grey parts and underneath.”

From the outset, Elvis, Frank and the rest of the build team set themselves a massive challenge in terms of the complexity and attention to detail that went into the car.

After countless hours spent over five years, they had high hopes when it hit the show car scene, says Elvis.

“I have built a lot of cars and the Commodore is one of the hardest to win awards at shows so for Frank to go for such big modification and reach this level of build is very rare. His goal was to win Grand Champion at Summernats and the car came runner up in 2023 which was a great result.

It was a lot of hard work, I can tell you, but the finished product is amazing – I love it!” R

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SHOP PROFILE

Partners in

10

perf

Being a trusted partner and having trusted partners and staff has created a win / win situation that is helping Jason and Jo Campbell to enjoy business once again.

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ike many small business owners, husband and wife team, Jason and Jo Campbell, have poured years of blood, sweat and tears into establishing their business, West Hamilton Auto Refinishers Panel & Paint (WHAR), in Hamilton, about 120km south of Auckland. A key driver for the business’ growth centres around the trust, honesty, transparency and quality of workmanship that others have recognised in Jason from his early days as a spray painter.

As a result, when the Ebbett Group – which represents 25 vehicle brands across 21

dealerships in New Zealand – decided on a major dealership build program in Hamilton, it was keen to have WHAR onboard as a partner, according to Jason Campbell.

“Five years ago, our main work provider, the Ebbett Group, asked if we would like to be part of their new dealership precinct here in Hamilton. At the time, we were just a wee

shop in Frankton (a suburb of Hamilton).

Back when I was an apprentice spray painter, Ebbett was just a small operation but I have kind of grown up around the people who are now running the company so there is a lot of trust and shared values in the relationship. They wanted us to come on the journey with them so we moved from a little 350m² workshop to a new 1000m² space.”

Although the Ebbett Group built the new facility as an integrated part of the dealership precinct, Jason was basically given free rein to design a new home for WHAR. Despite building at the height of the COVID pandemic, the results are very impressive and WHAR made the move in February 2021. As well as a handsome, classy street facade and office spaces, the facility houses spacious internal workspaces that have helped to improve job flow. A large compound at the rear has space to store up

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rformance

to 100 cars which is perfect for stockpiling vehicles when the Ebbett Group makes a bulk purchase and means it's easy for the WHAR team to work their way through them.

The partnership with the Ebbett Group has also helped WHAR secure a close connection with one of the world’s most iconic brand names, says Jason. “We can now confirm that we have been approved as part of the GM Certified Collison Repair Network – currently, one of only two repairers in New Zealand to do so. It’s an achievement that took a lot of internal work and passing a gruelling audit process but we are extremely proud of the result.”

A growing list of recommended repairer appointments, including BYD, helped to prompt a switch to PPG paints and technologies in early 2023, via local distributor, Automotive Colours – Hamilton, Jason explains.

“We had been with our previous paint supplier for 17 years so it was a difficult decision but now we have changed over, I am very impressed with PPG. Dave Mills (PPG Territory Manager) has played a major role in making our transition to PPG seamless. Our paint team received training, both onsite and external, and we look forward to utilising the PPG Training Centre in Auckland for more courses in the future. Since the changeover, we have found a number of key identifiers that help with day-to-day production. In particular, the team love the new DigiMatch™ spectro and VisualizID™ 3D colour visualisation software.

When doing a colour match, it blows me away that you can use VisualizID to bring up 10 different variants and compare them all

under different lighting and angles. It makes it easy to select the right one which can just be mixed and applied and most of the time no sprayout is needed. And PPG is more than just our paint partner. We also take advantage of PPG’s MVP Business Solutions program and have been very impressed with Nigel Hamilton’s (MVP Business Solutions Manager NZ) enthusiastic and passionate nature as he guides us along the path to achieving smoother numbers.

Although we are still ‘new kids on the block’ with PPG, we are looking forward to a future of working closely together.”

Over many years in business, Jason and Jo Campbell have become an interconnected force who have overseen operations while raising three children.

Although the pace of business is just as fast at the new premises, some fundamental changes to the management structure are benefiting everyone, says Jason.

“Jo and I operate really well together.

Although it can be challenging at times, we feel privileged to have a working relationship and home relationship that works well for us. In the early days, we would bring the kids into the office so they have grown up around the business. For years it was just Jo and I as the management team but recently we have appointed more staff to key areas which has allowed us to enjoy more time with our family and enjoy a better work / life balance. We now have a panel shop foreman and a paint shop foreman and they

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communicate really, really well. We also brought in Raewyn Carter. I have known her for a long time and when she finished her business, we snapped her up. As well as taking on aspects of our roles, Raewyn brings a softer personality to the business.

She is a friendly face who greets customers and talks about their needs and then takes photos and writes up the quote. I wish we had someone like Raewyn years ago!

Letting go of parts of the business to trusted employees has been the hardest

S H O P FA C T S West Hamilton Auto Refinishers Panel & Paint Owners: Jason and Jo Campbell Staff: 9 PPG Product: Envirobase High Performance Territory Manager: Dave Mills

thing I have ever done but it’s probably been the best thing for my mental health.

The business becomes fun again – I have even been out in the booth painting jobs and enjoying it!”

The workshop team at WHAR currently consists of two panel beaters and an apprentice, along with three painters (including Jason) and an apprentice. Jason says, the biggest current challenge is to find a few more painters who fit the business’ culture and can help to get the workshop running up to capacity. In its sparkling new facility, WHAR has the space needed to handle more insurance work, alongside its traditional workload of preparing vehicles for the Ebbett Group dealership’s new and used lots. Despite the pressure to meet deadlines, a close and open relationship helps the process run smoothly, according to Jason “We definitely have an extremely close relationship with the Ebbett Group. Basically, our two businesses coexist and having all the services we offer close by in the precinct is a big advantage for them. When you think about it, the second the dealership buys a vehicle to put on their lot, the clock starts ticking in terms of getting it prepared and ready for sale so we need to be as efficient as possible. We also give them an onsite resource where they can refer their customers if they have accident damage or a query on paint or bodywork. If someone needs a bit more help, we are so close I can just walk to the dealership to see them.

At the end of the day, it’s all about our shared values and vision. Although we are a different business, to a customer we are just part of the Ebbett Group and that is how we represent them to their customer base.

When I look around at the people and facilities we have in place today, it’s a very R pleasing situation to be in.”

Hold the Universe in your hand

SATA

13

More than just a premium spray gun, SATA’s latest special edition, the SATAjet X 5500 Universe, is your portal into an exclusive world of SATA.

P

recision German engineering and craftsmanship has long placed SATA spray guns in another universe compared to the competition but the company’s latest special edition model, the SATAjet X 5500 Universe, takes it one step further. Like its exceptionally popular predecessors, it features stylish, durable and high-quality graphics that wrap around the whole gun. However, in this case, it’s not just for decoration. Imbedded in the striking QR Code design, complete with sophisticated black accents, is a unique key which unlocks an online experience that is only available to owners of a SATAjet X 5500 Universe.

Accessing this specially designed world is as simple as scanning the exclusive ‘Universe’ QR code which forms part of the graphics. This opens the ‘Universe’ portal where you can gain access by entering the SAL (SATA Authentication Label) of your SATAjet X 5500 Universe.

Once you are part of the SATA Universe a whole world of SATA becomes available, including exclusive content, benefits and promotions, along with competitions, sneak previews of new SATA products, newsletters and much more. It’s your bonus reward for purchasing a very cool, limited edition gun!

Along with its unique connection to SATA’s online world, the SATAjet X 5500 Universe is a star in the

real-life paint shop environment. Indeed, this fully functional spray gun comes complete with all the features of this premium model, including the revolutionary X-Nozzle System that takes atomisation and ease of use to a whole new level and has a fan size that remains consistent across the nozzle range. Available only in the highly popular DIGITAL® format – with a digital air pressure gauge built right into the gun handle – there is a selection of nozzle sizes to choose from, along with the option of HVLP or RP technology. This makes the SATAjet X 5500 Universe perfect for everyday use in the spray booth or, alternatively, it can make an excellent addition to your gun collection display cabinet. Either way, it’s only available while stocks last.

Given the sell-out success of previous SATA special

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edition models, it’s recommended that you place an order ASAP at your SATA distributor to avoid disappointment.

A comprehensive range of high-tech SATA spray equipment is available from your R SATA distributor.

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PPG LINQ

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High tech

triple treat PPG tech fest arrives

By installing PPG’s MoonWalk®, DigiMatch™ and VisualizID™ technologies, Leighton Panel & Paint maintains its high-tech advantage for repairing to a quality standard, not price!

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here are no mincing words when Mitchell Franks talks about the need to keep up with the latest collision repair industry technology. He is adamant that it’s a crucial part of long-term business viability.

“Continually keeping up with technology really is a no brainer. If you think of it in terms of the cars you are repairing, it reinforces the need to keep moving forward.

For example, some shops will use a 20 year old straightening bench to repair cars.

However, if you think of those 20 years in terms of cars, you are going back to a VZ Commodore or an N70 Hilux, both of which had pretty much zero tech or options. How do you fix today’s cars with yesterday’s technology? It can’t be done correctly! I believe it’s far more cost effective to invest $100,000 per year to stay up to date, than it is to be forced to spend a million dollars every 10 years.”

Mitchell has been at the helm of Leighton Panel & Paint, in the Perth suburb of Bicton, for around 11 years. He says, the customerfocused business doesn’t repair cars for insurers, it repairs them for its ‘clients’.

As a result, the quality of repair is the most important factor. He describes the business model as high-end boutique where the 10 staff do a lot of out-of-scope work which can range from old race cars, through to $50,000 repairs on a six-week-old car.

Having invested heavily to develop a groundbreaking series of new solutions designed to provide the collision industry with a pathway to a more efficient, high-tech future, PPG is now rolling them out under the PPG LINQ banner. The first to arrive was MoonWalk – the ultra-precise automated colour dispensing technology for ENVIROBASE® High Performance waterborne basecoat.

It has been followed by PPG’s exclusive DigiMatch spectrophotometer which gathers an extraordinary amount of information about a vehicle’s paintwork thanks to its six angles of reflectance measurement, along with an inbuilt digital colour camera that gathers data from six imaging angles.

This colour information is fed into the VisualizID software which creates a digitally rendered 3-D sprayout that allows technicians to make comparisons against the closest matching variants and specials, as if they were holding a conventional sprayout card against the vehicle.

Separately, these are incredible pieces of technology but, working together, it’s a triple treat that brings unprecedented levels of speed, accuracy and productivity to the colour matching and paint mixing tasks.

Triple treat for Leighton Panel & Paint When Simon Reynolds, PPG Territory Manager WA, gave Leighton Panel & Paint an early demonstration, he says Mitchell immediately picked up on the value they offered his business. “When there is a new piece of technology, Mitchell is always keen to know about it so he was one of the first that

we introduced the technology to. They give our refinish customers a fantastic new set of tools and Mitchell was very interested.

After doing some research, he wanted the technologies installed as soon as we could.”

Although he likes to take the technological lead, Mitchell says he still asks the hard questions to ensure it makes a good business case. “Everyone likes shiny new technology but you should always step outside your business and look in to see if it ticks all the boxes. For example, what difference does it create for this business, does it help attract new clients and does it help attract new staff? Massive changes are coming to the industry and we need this sort of technology to stay ahead.”

Installation Leighton Panel & Paint was the first customer installation of MoonWalk in WA which was followed by DigiMatch and VisualizID, once they were launched locally, according to Simon Reynolds.

“The installation and training went really smoothly. We worked with Leighton’s painter, Matt, and he took to it very quickly and was able to see the benefits in terms of reduced stress and time savings.” Mitchell was also pleased that these PPG

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technologies are so easy to take advantage of. ”The need for training was minimal – the team took to it overnight. Now, colour reproduction is almost a guarantee and we save a minimum of around 10 minutes per job which, in a shop our size, is great.”

Three into one goes perfectly Simon Reynolds says the PPG team has been kept busy conducting demonstrations on MoonWalk, DigiMatch and VisualizID and the response has been exciting. “It’s the ultimate scenario to have these three amazing technologies working together.

It’s really ‘wowing’ customers and we get fantastic feedback after our demonstrations.

The ability to virtually cut out spray-outs while making it fast and easy to choose the best colour match and then precisely mix it, is really winning people over.” R

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FEATURE STORY

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United

we stand

High level motor sport is like any other business – when you invest in people, give them the tools they need and trust them to get the job done, it becomes a winning formula!

B

eing part of a Supercars team is not for the fainthearted. This is a demanding sport where the people involved are required to consistently perform at their best, even when under extreme pressure.

However, by engaging and supporting those people, there are opportunities to create a team that is actually more powerful than the sum of its parts. It’s a philosophy Walkinshaw Andretti United (WAU) is using to great effect as it tracks a trajectory back to the top of the Supercars pack, says Team Principal, Bruce Stewart.

“Supercars can sometimes be portrayed as just being about one driver versus another, whereas we absolutely believe in the power of being a team. We have a real team ethos in our business which has

full buy-in from the drivers, mechanics, engineers and everyone from the newest intern to the oldest crusty diamond, like myself.

In that respect, it’s about operating like a big family where people come from different backgrounds, ethnicity, gender, whatever it might be – you accept them and embrace them as teammates.

It’s a really invigorating way to approach this sport and it’s part of the WAU DNA.” Rather than the image of a grumpy team leader, issuing orders left, right and centre, Bruce says his management style is more about being an enabler. “If we embrace our culture as a family, my job is to cultivate it. In that respect, I understand that we have a fantastic team of leaders in our business so I see my role as being able to empower them, give them opportunities in terms of financial, material and planning resources, and then get out of their way.”

Just like in the collision repair industry, skilled people are in high demand in motor racing. As a result, WAU has put measures in place to provide people with ongoing opportunities to learn the ropes and take incremental steps through the different classes.

“In 2023 we launched the WAU Foundation Academy which is about nurturing young talent.

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We believe it’s not just about drivers – it’s about engineers, mechanics, commercial people, etc. If we can create pathways into elite motorsport, we will attract good people and train them in the WAU way. For a start, we have a Toyota 86 program with a young driver, Matt Hillyer, along with race engineers who are being coached and cultivated by our technical director and his leading engineer to help them get the most out of a race car. We also have young mechanics from Kangan Institute TAFE who are being coached by a head mechanic so they learn the processes on a Toyota 86.”

“The second tier is Super2. We have two young drivers, Zach Bates and Ryan Wood, each of the two cars have mechanics and engineers around them who are on the next rung of the ladder. Then we have our Supercars team which has drivers,

Chaz Mostert and Nick Percat, and a group of accomplished engineers and mechanics around them. Across each of these tiers, opportunities are always coming up to take staff, train them and help them take the next step on their career pathway. If they end up leaving to go to work at another Supercars team or to Formula 1 or IndyCar, we have got to be comfortable with the fact that we are helping good people achieve what they might not necessarily be able to do otherwise and we are doing the industry a service.”

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FEATURE STORY

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United we stand

TEAM DREAM

Early in the 2023 season, WAU took a major step forward when it moved into one vast team facility in an industrial park in the Melbourne suburb of Clayton. Previously, different elements of the team had been scattered within a one-kilometre radius at the same industrial park. “Even a small distance between different parts of the team creates a separation that doesn’t help communication and is not great for the cross pollination of great ideas. Often, it’s those chats around the water cooler or in the lunchroom where new opportunities and new ways to improve the performance of our team are discovered so it’s super important.”

Along with a spacious area for car preparation, the new facility includes every element of team operations, including fabrication, machine shop, engine shop, paint shop, stores and everything in between. There is even a well-equipped gym where all team members can work on strength and agility which can make a significant difference in their day-to-day activities, particularly in the heat of an important pitstop. One simple but crucial bonus of the new facility is the ability to store the team’s transporter inside.

“We are a small business like any other so we need to understand where our costs are going. Why spend potentially tens of thousands of dollars repairing weather damage on our transporter when we could have it sit inside and put that money into the racing team. Equally, it’s much more comfortable to unload and load during a Melbourne winter and we can do it methodically and well planned so we put our best foot forward even before we get to the race track.”

With the paint shop now inside the main facility, WAU can concentrate on one of the long running

K

arl Richmond reckons he was hooked on motor sport from the moment he attended his first Formula 1 Grand Prix as a seven-year-old. After beginning his spray-painting career in 2000, he snapped up an opportunity to become WAU’s painter in 2017.

"This is not an everyday job – you have to have the passion to do it. When the cars return from a meeting, I go through everything with the rest of the team so I know what I have to do and I am left to get on with it. It’s really about making sure the mechanics are never waiting for anything. The way the cars are built is actually from the back to the front so if it’s a round where they are going to need components from me to actually go onto the cars, rather than take them from spares, I will start with the rear bar, rear quarter panels and then work towards the front. The front bar is obviously the last thing that goes onto the cars. The overall process is basically the same as for smash repair – panels are repaired, if required, before being primed, painted, etc. If I was going to pick one real difference, it would be that even though we have deadlines to go racing, it’s not like a customer is coming to pick their car up so it absolutely has to be done.

There is also a lot less colour matching. It was quite a journey to get here but to land at a team that I truly loved and supported my entire life, is unbelievable."

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REFINISHER

19 cornerstones of the business – the immaculate presentation, appearance and recognisability of the team. It’s here that WAU leans heavily on its long-term partnership with PPG. “Having our own paint shop and being able to present the cars in the best possible light is always going to be a key part of our toolbox. The ability to work closely with the PPG team to ensure we stay at the cutting edge of car preparation to ensure they look like Walkinshaw Andretti United cars is super important and very much appreciated.”

According to team painter, Karl Richmond, colour and quality play a crucial role in the overall team branding and the PPG partnership makes the job smooth and easy. “Unlike a lot of other teams, who use more wrap, our Mustang Supercars are literally painted in PPG from the ground up, including the chassis, roll-cage, etc, and then stickers go on top. It saves a little weight but it’s also about controlling the quality. In my opinion our cars look the best on the grid. When you walk up to them, they look like a road car with the perfect finish. As well as PPG paint products, we also use SATA spray guns, as well as MIRKA abrasives, vacuum units, etc.

THREE INTO ONE

T

he creation of WAU brought together three giants of motor sport – Ryan Walkinshaw, Michael Andretti with his celebrated family heritage and Zak Brown with his global United Autosports operation. It’s a match made in competition heaven, says Bruce Stewart.

"You have three extraordinarily competitive racers from around the world who have one desire and that is to win races, win championships and take this team back to the top in Supercars. It’s really cool when you have a single-minded focus because it helps clear the clutter and make good decisions more often."

The support from PPG is fantastic, particularly when matching colours for team sponsor logos. I just give the PPG colour lab team a sample and they get it done for us.”

As all the pieces continue to be put in place, there is a tangible feeling across WAU that the organisation is firmly on the pathway to the success it has enjoyed in the past, Bruce explains. “I think we are a little bit special, in that we used to be the Holden Racing Team and we have fantastic leaders who were part of those successful days. We also have a lot of young team members coming through who can feel that we are on a journey. I love the thrill of competition and I enjoy the rough and tumble of this very turbulent industry.

I particularly enjoy the team culture where you can look at the people around you and know ‘we are in this together and we are working to one collective goal’. That is what gets me out of bed every day!” R

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TALKING TRAINING

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The dollars and sense of investing in staff Training investment

The difficulty in finding skilled staff is industry wide but an often-forgotten solution is to invest in upskilling your own staff to create a more productive and engaged workforce.

I

t’s no secret there has been a shortage of skilled staff in the industry for some time.

More than ever, it’s actually limiting the volume of work a collision centre can get out the door in a given time which is leading to waiting time blow outs for customers to get their vehicle repaired, as well as missed opportunities in terms of business revenue.

Change is unlikely to happen anytime soon but there is an alternative right under our noses, says John Hristias, PPG Sales Director Australia – invest in training to upskill existing staff. Best of all, the positive outcomes benefit your team, as well as the business.

As a business owner, it’s more important than ever to get the staff you have fully engaged and thinking about the implications of each step they are taking, as well as looking for the most productive and efficient solutions. Training to upskill will help to do that and it’s available in a variety of forms: • Products – This is about ensuring technicians are using the most appropriate products and utilising them in a way that gets the very best from them.

• Equipment – How a piece of equipment is used can have a dramatic effect on efficiency so this is about maximising the advantages with the best tips, tricks and techniques.

• Processes – A process driven workshop is a productive workshop.

Given that new, more efficient processes are constantly emerging, this is definitely an area where technicians can learn to work smarter, rather than harder.

Training resources On the panel side, I-CAR is a crucial training organisation where technicians can get the information they need in order to understand the most up-to-the-minute repair practices and equipment, particularly when it comes to efficiently tackling the latest vehicle build materials and complex structures. Many equipment manufacturers also offer specialised training to support their products. When it comes to the paint shop, we often hear complaints about it being a bottleneck in the repair process so it’s a clear target for upskill training and this is where PPG has taken the lead.

Right across the region, PPG training facilities and dedicated PPG training managers are available to deliver a wideranging portfolio of courses that cover pretty much every paint shop and detailing process you can think of. Best of all, it comes as part of the support package you get as a PPG customer.

Return on investment While it’s true that training does require an investment in time, where staff are away from everyday workshop tasks, the PPG regional training team have

TALKING TRAINING

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found that this commitment comes with a healthy reward that today’s collision centre owners should find difficult to ignore.

After learning the latest techniques and processes via just one PPG training course, it’s common to see a saving of at least one hour of labour time or cycle-time per day when they return to the workshop.

It doesn’t mean they come in as substandard tradespeople. It’s simply a matter of technicians learning all the productive habits throughout an entire process which then gives them the tools to be faster and more efficient. Importantly, those labour time savings really add up to show the real value training can have on a collision centre’s bottom line. That saving of one hour per day becomes five hours per week and then extends to 20 hours per month which, when multiplied by 11 months, adds up to 220 hours per year. Use an average paint shop cost of, say, $100 per hour and multiply it by 220 shows that a single training program can save a whopping $22,000 for each painter per year. These are realistic figures that the PPG training team have seen proven around the region time-after-time.

Engaged, efficient and effective Implementation is key! Before putting your training regime into action, spare the time to discuss it with your team and point out why you are making the changes and what the benefits are to the business, to them and to customers. It also gives them a chance to get any concerns off their chest. Because the collision centre owner cares enough about their staff to invest in them via an upskilling training program, it’s important that staff members also join in. For example, one of the areas where technicians can let themselves down is by not bothering to understand the technology they are being

asked to use. There is a responsibility for technicians to embrace change by asking what is different about this product, how does it fit into the overall process and how is it going to help us to get more done.

Start now When you add up the dollars and cents value, a training program for collision centre staff makes real sense. After all, in the current situation what is the alternative?

Training not only boosts the knowledge and confidence of staff, it also improves engagement and moral. In this day and age, I don’t think you can afford not to take R advantage!

Workshop hours/ day saved after attending course

Savings for one painter (multiplied by average $100/hour paint shop cost)

Two painters

Three painters

Four painters

1 hour/day

220/year = $22,000

440/year = $44,000

660/year = $66,000

880/year = $88,000

2 hours/day

440/year = $44,000

880/year = $88,000

1320/year = $132,000

1760/year = $176,000

3 hours/day

660/year = $66,000

1320/year = $132,000

1980/year = $198,000

2640/year = $264,000

4 hours/day

880/year = $88,000

1760/year = $176,000

2640/year = $264,000

3520/year = $352,000

This example shows the readily achievable savings that an average workshop can expect after undertaking quality training. Over a year the savings can really add up!

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PPG LINQ

22

Mobile coverage With its ability to drive to virtually any collision repairer in Australia, MoonVan is providing unique opportunities to witness the remarkable PPG LINQ™ technologies in action.

T

he moment word got around that MoonVan’s first port-of-call would be to South Australia, Joe Esposito (PPG Business Manager Refinish SA)

was inundated with calls from collision repairers angling to be one of the first have the technology packed vehicle onsite.

“Straightaway, collision centres were on the phone asking me when we could bring MoonVan to them. The excitement level amongst the PPG team, as well as South Australian repairers, was absolutely off the scale. When new technology surfaces, the issue for many repairers is that they feel like they can’t spare time out of their busy day to go somewhere else to check it out.

With MoonVan, we can drive

SA

to them, give them a live demo on a real job on their premises and, afterwards, pack it up and head to someone else.”

A van full of tech Neatly built into the high roof MoonVan is a complete PPG MOONWALK™ automated dispensing unit which, at the press of a button, will measure out ENVIROBASE® High Performance waterborne basecoat tinters to an accuracy of 0.01 grams. Even when miniscule amounts of tinter are required, it dispenses with absolute precision day-in, day-out.

It’s joined by the incredible DIGIMATCH™ spectrophotometer which features an inbuilt digital camera to gather data from six imagining angles, along with its six angles of reflectance. This means DigiMatch captures an incredible amount of data about a vehicle’s colour – including crucial texture information about pigment particle size, etc – which is then fed into the VisualizID™

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PPG LINQ

23

The Body R e Salisbury P pair Shop, lain, Adelaid Owner – M ick Caruso e “I had

already seen MoonWalk at the MTA MoonVan on SA but havi site was a gr ng eat opportun The PPG gu ity for my st ys drove it in aff. to the works hop and pa the paint sh rked it in op where th e painter coul out. It let m d check it y guys cont inue with jo doing but to bs they wer e use the tech nology in M They took sp oonVan. ectro readin gs with Dig brilliant! – an iMatch – it’s d then wen t through the of choosing process the best co lour match around exce us ing VisualizID llent flow an . Our works d these tech hop is built measuring no logies just en up the pain hance it. W t room to se e are now e how it will fit in.”

3D colour visualisation software. Using some very clever PPG developed colour science algorithms, VisualizID generates a 3D digital sprayout card that can be conveniently compared to a digital sprayout of all the variants and specials associated with the target vehicle colour. This new age colour matching tool makes it super easy to compare colour search results next to each other without using a drop of tinter. The 3D colour sprayouts can be rotated to check the flash, flop and face, there is a ‘blend view’ or ‘edge view’ option, the light source and direction can be altered to help view different effects and you can even zoom right in to help pick out potentially subtle differences.

Joe believes PPG LINQ technologies represent a never-before-seen shift in day-to-day operations for painters.

“Painters are super interested in seeing this new technology in action. In fact, at some shops we visited, the painters literally ran to MoonVan! Even me – I have been a painter for over 40 years and this the first time I have ever seen anything like this.

Today, painters are under pressure to get the job done quickly and that can lead to human errors, especially when mixing colours. MoonWalk removes that human error element, dramatically improves colour accuracy, speeds up the process and minimises wastage.”

Onsite service With the three key PPG LINQ technologies packaged into the one vehicle, MoonVan makes it easy for collision repairers to get a clear insight into how the these innovations would slot into a typical paint shop environment. Feedback from early visits R has been outstanding.

ervices, Premier Panel S Adelaide Ferryden Park, helan Owner – Paul W

e but seen it on YouTub MoonWalk and t ou ab d rea just d is “I ha tching it work it and actually wa g hin uc to we it, p, g ho seein in our works onVan was setup Mo ter Af atch el. lev giM Di next with using the colours starting of le up co a th d wi mixe are it side-by-side re able to comp DigiMatch, spectro. We we have ordered a were using so I we tro ec sp LINQ the y and this PPG built a new facilit t jus ve ha e W ing too. where we are go lements exactly technology comp management, It’s about ‘lean’ for in the future. racy and productivity, accu ge and minimising wasta my hands time. I can’t get gh, to on it quick enou be honest!”

JV Crash Repai rs, Wingfield, Adela id Owner – John Ve e rdnik

nk To see PPG Li r fo es gi lo techno to your k ea sp lf, se your Manager.

PPG Territory

“We are a busy shop and having MoonVan onsite us to mix a coup allowed le of colours and really understan the principles of d what it can do.

This is impressiv technology and e new it’s great for time saving and for les wastage, as we s ll as being good for our marketin We now have a g.

MoonWalk on or der.”

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MVP BUSINESS SOLUTIONS

24

You need a Traffic Management

Plan

SPEED HUMP

Few collision centres actually have one but an effective Traffic Management Plan is all about providing a vital blueprint for safe people and vehicle movements on your site.

W

hether on foot or in a vehicle, when we travel the highways and byways we follow a set of clear and comprehensive visual markers that let us know the safest way to do so. Despite dealing with lower vehicle speeds, the same principles apply to manoeuvring around the outside spaces surrounding a collision centre. It’s about avoiding opportunities for pedestrians and vehicles to come together because it’s typically humans who come off second best. This is called a Traffic Management Plan (TMP) and requests from collision centres to help create this crucial document have made it one of the most

popular services provided by the regionwide MVP Business Solutions team, according to Greg Tunks, MVP Business Solutions Manager ANZ.

Creating a Traffic Management Plan When you think about it, walking in and around a collision centre can be a dangerous environment. For example, there are typically customers arriving who don’t know where to park or where reception is located. On top of that, they may be aged or have a group of kids with them. As well as dealing with general vehicle movements, they can be faced with parts deliver vehicles or tow trucks loading or unloading or even forklifts operating. With that in mind, where do you start with a TMP? For many collision centres it’s as simple as asking their MVP Business Solutions manager for help. During an onsite visit, the MVP Business Solutions expert will take a detailed overview of the facility and physically measure up everything that is required, including estimating bays, parking spaces, speed humps and other traffic calming devices, driveways, pedestrian walkways and crossing, etc. Afterwards,

they use their in-depth knowledge and a specialist software program (similar to that used for creating an emergency evacuation plan or a workshop layout and design) to create a scale, schematic diagram with all the details required. Typically, it’s printed out in A3 size and handed over to the collision centre to provide a blueprint to work from.

Communication To get maximum benefit from a TMP, it needs to be communicated to all staff at, say, a morning ‘toolbox talk’. You can share details of the TMP, point out that it's focused on the safety of themselves and visitors to the site and that everyone must adhere to it.

Cost For PPG customers, this is actually a free service from the MVP Business Solutions team which comes as part of using PPG products. As well as the actual TMP documents, the PPG team can also supply standardised templates for creating the various markings. Then, if you want to do it yourself, it is literally the cost of the paint and the time it takes to do it. Alternatively, there are organisations who will do it for you.

MVP BUSINESS SOLUTIONS

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TRAFFIC DIRECTION

TRAFFIC

ZONE

DELIVERY

ZONE

PEDESTRIAN CROSSING

TRAFFIC MANAGEMENT PLAN KEEP IT VISUAL

Key considerations • Keep it visual – Any markings or signs must give people a crystal clear visual understand of what is involved or required.

When someone turns up to the site for the very first time, no one should have to tell them where to park and where to walk safely into the business – it should be immediately obvious.

• Protecting pedestrians – One of the main aims of the TMP is to keep pedestrian traffic separated from vehicular movements. This includes a 5km/h speed limit, along with defined walkways and crossings at appropriate points in the carpark. If it’s a commercial vehicle repairer or the site is regularly visited by heavy vehicles, the layout will need extra care. In some cases, pedestrian walkways may need to be separated

from traffic flow using bollard, Armco-style fencing or some other device.

• Fire hydrants – If you have fire hydrants inside the premises, they should have an exclusion zone around them (no vehicles parked close by) so they can be easily accessed by fire brigade personnel.

• Parts and other deliveries – Deliveries to site are important but they should also be done safely. If possible, the designated delivery area should be away from pedestrian traffic and set out so that it’s as easy as possible for the driver to access.

• Forklifts, palette lifters, etc – These devices are generally seen on larger sites and they take special consideration

PROTECT PEDESTRIANS FIRE HYDRANT EXCLUSION ZONES DESIGNATED PARTS DELIVERY FORKLIFT PATHWAYS

because they are especially dangerous when operating. For example, there should be no one within three metres of a working forklift and there should be barriers between any forklift pathways and pedestrian pathways.

• Auditory signals – As well as visual makers, there are also signals we hear, such as the toot of a horn when crossing a doorway.

• Entering and leaving site – The TMP should also consider how vehicles enter from the street and return. For example, if a truck has to reverse out onto the street, that can be dangerous. If possible, a TMP may be able to offer a turnaround point onsite that lets them return to the street R without reversing.

PPG PEOPLE

Manny (Emanuelle) Grillo

P P G S TA F F P R O F I L E

National Colour Auditor/ Consultant

W

hen a new OEM colour variant arrives in your paint shop, yet there is a formulation ready to go on PaintManager® XI, you can say a word of thanks to the team at the PPG Clayton Colour Laboratory, including Emanuelle (Manny) Grillo. For over two decades, one of Manny’s main roles has been to audit incoming vehicle shipments in order to identify new variants. He reckons the need to continually learn has kept him interested and fresh during his long career, from his spray-painting apprenticeship – where he won the ‘Golden Gun award’ in his 3rd year at Kangan Institute TAFE – to roles as paint shop foreman and collision centre manager, through to joining PPG in the mid-90s.

“I started at PPG as a colour matcher and later moved to a territory manager role. However, because I had really enjoyed the work at the Colour Lab, I jumped at the chance to go back there as National Colour Auditor / Consultant.

Since vehicle manufacturing ended in Australia, my role has changed a bit so I am doing more urgent colour matching for customers, audits of new cars arriving in the country and helping with admin. Also, the Chinese vehicle manufacturers entering the market has kept us on our toes.”

2

200

“I enjoy the challenge of matching certain colours so I am still learning things today! When it comes to colour matching technology, it has been really interesting to use PPG’s new DigiMatch™ spectro and VisualizID™ 3D colour visualisation software. I am able to use it to clearly see variations in colour from vehicle to vehicle. Over my 28 years with PPG, what sticks with me is the strong relationships I have built up with colleagues and customers.”

MORE ABOUT EMANUELLE • Favourite hobbies/pastimes?

Watching and going to AFL football, the gym, gardening and home maintenance • Favourite food? Pasta, steak, seafood or pizza • Favourite drink? Beer/wine • Favourite music / band? 80’s music • Favourite car / motorcycle?

1957 Chev Sports Coupe • Favourite holiday destination?

Bali and Southern Europe.

ENGINEERED FOR EXCELLENCE

Thanks to an unrivalled combination of exceptional speed, superb colour accuracy, no-fuss ease of use and effortless blending and mottle control, this is simply the best refinish technology on the market. Backed by a range of primers and clearcoats featuring advanced low-VOC technology, it’s the eco-friendly choice which really delivers on outright speed. With everything a 13 24 24

modern, fast-paced collision centre needs to slash cycle-time while

@PPGANZRefinish

www.ppgrefinish.com.au

boosting productivity and profitability, Envirobase® High Performance is engineered for excellence!

REFINISHER

PPG IN ACTION

28

Chasing the

The Western Sydney Solar Team is taking on the world as it literally provides a vehicle for today’s sustainability innovators to thrive, while also inspiring the next generation!

E

ven without taking its in-built solar panels into consideration, the Western Sydney Solar Team’s high-tech car from 2019, dubbed Unlimited 3.0, could complete the 3022km journey from Darwin to Adelaide using less than $10.00 worth of electricity. As impressive as that is, the team’s latest 2023 version, Unlimited 5.0, is even more efficient! For the 25 Western Sydney University undergraduate students who make up the Western Sydney Solar Team, this latest generation car is the culmination of a lot of deep thinking, inspiration, hard work, collaborations, late

sun

nights, early mornings, trials, errors and triumphs. And when it’s all said and done, it’s not until Unlimited 5.0 fronts up to the starting grid for the 2023 Bridgestone World Solar Challenge (22nd to 29th October) that it will be possible to see how it compares against the cream of solar car technology from around the globe. However, no matter the outcome, it’s mankind that is the real winner.

Up for the challenge Humanity is currently facing perhaps the biggest challenges in its existence, in terms of combating climate change and preserving our way of life. As we wean ourselves off fossil fuels, we need to apply the best and brightest minds to the task of creating sustainable, renewable energy solutions that will power us into the future. Since 1987, the World Solar Challenge

has provided a framework to drive that innovation.

Run every two years, it’s all about designing a vehicle that can make the transcontinental journey from Darwin to Adelaide running on solar power alone.

After COVID forced the cancellation of the 2021 event, the focus has shift to 2023 and the Western Sydney Solar Team is planning to be front and centre.

Unlimited potential Building Unlimited 5.0 has been a constant battle to push boundaries and do more with less energy. While the foundations of previous generations provides guidelines, each new team cohort starts with a clean sheet, says Team Manager, Brad Nadalini.

“Although there are team philosophies, design principles and values that flow across the generations and influence design, we encourage team members not to take too much inspiration from past cars because we don’t want design bias.

We want to look elsewhere and consult a lot with industry to figure out how we can keep improving. For example, although solar cell technology has not gotten that much

PPG IN ACTION

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though it’s significantly harder to paint all the logos, it’s a good investment in time.”

Completing the striking red colour scheme took four days at PPG’s NSW Training Centre at Eastern Creek. This included everything from the smallest of emblems to the largest logos being applied using stencils and multiple colours. A gold metallic tinter was added to the first clearcoat layer, before it was chopped back and flowcoated.

Sustainability roadshow

more efficient, the electrical systems they are connected to have. It’s a similar story for the electric motors where it’s the motor controllers – the electric hardware and software that runs the motor – where the big innovations come in. Having said that, we have completely redesigned our motor housing to increase serviceability, efficiency and performance, while reducing cost and weight.”

Partner network As well as having mentors and advisors as part of the team, the students also have a network of partners behind them.

As challenges come up during the design / build process, team members are able to consult with industry experts and organisations to tap into their knowledge base and come up with viable solutions.

Thanks to a long-term partnership

with PPG, Unlimited 5.0 isn’t just about having a standout paint finish, Brad explains.

“Weight is really crucial so we have worked really hard with the PPG team to get it right in terms of paint types, thicknesses, etc. In 2019, PPG also helped come up with an innovation in our team livery. We worked out that it’s more aerodynamically efficient to spray on all the partner logos because even the thickness of a sticking applied over the clearcoat caused drag. Seventy percent of STOP PRESS the vehicle’s efficiency actually comes from aerodynamic performance so, even

Objectives for the 2023 World Solar Challenge are to build the most reliable car the team ever has, place within the top five and have a smooth, safe, stress-free race, says Brad. However, the Western Sydney Solar Team actually sees its overarching mission as delivering so much more.

“One of the most important aspects of our team is to use our community outreach program to inspire the next generation of sustainable thinkers. As part of that, we take the car to primary and secondary schools and events where we can engage with young people and cultivate a passion for sustainability and problem solving.

In 2022, alone, the team did over 70 events.

It’s about creating a better vision of tomorrow.“ R

During the World Solar Challenge event, Unlimited 5.0 gained 10 places to finish in an impressive 9th overall.

Team members were ecstatic!

If you think about PPG’s commitment to ‘protect and beautify the world’, it’s a perfect fit for the range of specialised packaging coatings that let us all enjoy the benefits of ‘cans’.

do attitude T

hey are so common that most of us don’t even notice them but the humble metal can is, in fact, something that should be celebrated for its contribution to modern living. If you stop and think about how often we take advantage of metal cans in our day-to-day lives, it can be mindboggling. It could contain pretty much any foodstuff you can think of – from fruits to vegetables, to ready to eat meats – or maybe your favourite beverage – including soft drink, juice, energy drinks or beer – or even personal care products, such as deodorant or hairspray. The use of cans is also responsible for reducing food waste by helping fresh foodstuffs stay fresh for long periods on the shelf with no refrigeration required. It’s a safe, durable container that can be conveniently shipped across the country or across the world. A lot this would not be possible without the development of specialised coatings for the inside and outside of metal cans and it’s here that PPG is a global leader.

Repeat cycle Every year, literally billions of metal cans are produced and that could be a big problem if it wasn’t for the fact that they are 100% recyclable. Every time a metal can is recycled it not only prevents it going to landfill, it also avoids the use of raw materials and energy to make a new one. In the US alone, over 42 billion cans are recycled each year. Steel food cans can be recycled over and over and over again with no downgrading of material which is why it’s reported that over 75% of all steel ever produced is still in use today. At the same time, it’s estimated that more than 70% of all the aluminium ever produced is still in use today.

e

Can do coatings When it comes to both packaging and sustainability, metal cans (aluminium, steel, tin) are an excellent solution. However, cans need to be very cheap to produce and that means making them in vast numbers, with high speed. As the demand for cans continues to boom, many manufacturers turn to PPG. The company’s Packaging Coatings business has created a range of effective coatings solutions for nearly all metal packaging end use in beverage, food, cosmetic and personal care industries.

Each packaging coating is formulated with a set of key attributes in order to function perfectly when applied either on the exterior or interior of metal cans. As it does for vehicle OEMs, PPG also provides onsite expertise to keep customer’s production lines running smoothly.

The amazing talents of can coatings • Many cans start out as sheets of thin rolled steel which are coated before the materiel is cut up and worked into a can shape. As a result, the coating needs to be tough but flexible enough to not fracture when being formed or if the can is dented.

• Other cans are formed and then coated. Typically, they are spun at high speed and the coatings is spray applied quickly and precisely.

• Coatings must be ‘thin film’ and feature excellent adhesion, along with excellent wetting so there are no pinholes.

• Curing is usually done in high temperature ovens with short dwell times.

• Dry film thicknesses are typically only around six to eight microns.

• Coatings are generally there to protect the material of the can from the effects of the contents. For example, soft drinks tend to be quite acidic and would eat through the can if it wasn’t coated. However, in some cases it’s the opposite, such as beer cans, where the internal coated prevents the aluminium taste being imparted to the beverage.

• Many foodstuffs are actually cooked after they have been sealed inside the can so the coating needs to cope with the high temperature process inside a pressure cooker.

• As well as being for decoration, exterior coatings need to have ‘lubricity’ to provide abrasion resistance during transportation and help avoid the issue of cans rubbing against each other and leaking.

Non-BPA solutions A key talking point around the packaging coatings sector has been the use of Bisphenol A (BPA) in packaging coatings.

Studies have raised possible concerns about the effect BPA may have on human health. As one of the world’s leading suppliers of packaging coatings, PPG has been working on non-BPA solutions for decades and today offers a complete range of protective internal and external non-BPA coatings, including PPG Innovel PRO, PPG HOBA, PPG Nutrishield and iSENSE solutions. In 2022, PPG gave can manufacturers an even greater choice when it launched PPG INNOVEL PRO technology. It builds on PPG Innovel’s nearly 10 years as the market’s most widely used non-BPA internal beverage spray coating. As of 2022, it’s estimated that PPG Innovel coatings have been used on more than 220 billion cans in more than 40 R countries!

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esign eedom to d fr e th s r e ive custom eeds, Set up to g eir exact n th it u s to ailer cess story c u s a a truck / tr is t n e ns. port Equipm ised solutio m Bulk Trans to s u c , ty igh quali based on h

Tuned to the customer

W

hen Bulk Transport Equipment (BTE) first threw open its door in 2007, it consisted of just handful of staff operating from a modest facility in Melbourne’s southeast. However, BTE offered something many trailer builders didn’t – it put the customer at the centre of the build and it was happy to create a fully customised product to suit. As its reputation grew, BTE expanded from a workforce of ten to the current workforce of over 100 in around ten years. During that time, it moved to larger manufacturing premises in the Melbourne suburb of Dandenong South, added another factory about 100 metres down the road for final fit outs and maintenance and further branched out with a production facility in Toowoomba, Queensland.

Fully incorporating the customer into the build process has been a major factor in BTE’s success, according to Factory Manager, Richard Byrne. “Some brands only offer a catalogue of standard products and if that doesn’t suit, then bad luck. However, with their background in trailer manufacturing, the owners of BTE recognised there was a healthy market for custom building of tippers and special purpose trailers for the bulk haulage sector.

It starts with the design process where each customer plays a significant role. We have five engineers in our team and one of them will sit down with the sales person and the customer to get an in-depth feel for what they need. We are very open to saying ‘yes’

to pretty much any modification within the rules and regulations, right down to little tweaks that suit the way they operate.

Right now, you could say we have around 100 possible models in the system but, really, it’s an infinite number because the next customer that comes through the door might want something completely different again. Sometimes those customer requests can also lead to innovations. For example, where most trailer makers use six-millimetrethick steel for the web which is the main chassis, we switched to a higher grade of steel which allowed us to fabricate it in four-millimetre-thick steel. It’s quite a weight saving and it has greater strength. We have also introduced some innovations in some of the steering systems which won us a few awards.”

BTE even encourages customers to drop in and see their trailer going through the build process – something that has received plenty of good feedback.

A sizable proportion of BTE’s builds are for the quarrying sector, followed by grain and

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agricultural haulage trailers and other specialised sectors.

Customers can choose from a wide variety of configurations, including truck and dog combinations, semi-tippers, B-doubles, PBS trailers and waste equipment. Although each build is different, something like a regular four axle dog trailer takes around 300 to 400 hours to go through the build process, the paint shop and final fit out.

Assembling a skilled team Like many businesses, BTE has suffered with a shortage of skilled tradespeople, particularly throughout the COVID years.

However, it’s now committed to employing people who fit the company’s culture and then investing in them to develop the skills they need, Richard explains.

“We were having real staff issues, mostly with people not turning up, so two years ago we started the process to bring in some tradespeople from the Philippines.

We now have 15 Filipinos onsite and another six on the way. We knew there would be a certain amount of training involved to bring them up to speed but they took to it really well and within a couple of weeks we were wondering why we didn’t do it sooner – they are really good!”

While welding and fabricating are key skills on the shopfloor, BTE is aiming to develop multi-skilled team members who ultimately become a more flexible workforce, says Richard. “We have certain tasks that we see as a starting point and once someone is proficient at it, they can move onto a more skilled task. We don’t want to pigeonhole people into just being a welder, a fabricator, etc – we are using a broad base of training to develop a workforce that has a broad range of skills. Although we might take a hit right now as we train people up, we hope that in a few months’ time, those people will be in a position to step up.”

“At the moment we run ‘cell building’.

We have bays where, for the majority of the time, whoever starts the job continues through until it’s finished. The most efficient way of doing it is to choose the right person to do each task. Because they are involved in various parts of the build process, we encourage team members to go for a walk to the fit-out facility just down the road to see the whole project come together with nice shiny wheels, paintwork, lights, etc.

It gives them a sense of pride.”

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Getting noticed Despite the fact these are heavy duty pieces of equipment, the quality BTE final finish is definitely important. All of the chassis and steel tubs are painted, whereas around 50% of aluminium tubs are left natural, around 25% are painted and about 25% have decals applied. When it came to selecting a paint partner, the choice was very straightforward, says Alan Griffiths, who is one of three BTE Company Directors. “We have been using PPG for about 15 years.

PPG had been the supplier to another trailer manufacturer where I was Factory Manager so I had developed a strong relationship with some of the PPG team and knew how good the DELFLEET® Evolution paint system is for commercial transport work. Not only that, the technical support we get from PPG also makes life easier for our painters.”

Although BTE’s paint shop facilities are functional rather than state-of-the-art, the skills of the paint shop team and the suite of PPG products they use, helps to turn out an excellent job which really gets noticed when each trailer hits the road, says Richard Byrne. “There are definitely some customers who are looking for that ‘number one’ paint job. Particularly in the competitive grain haulage sector where image is important

they are up to speed, it will help spread the load and increase the output.” and they want everyone to know who’s rig it is driving down the road. Our paint shop team is currently three strong but we are putting on four Filipino painters and, when

Keeping up with demand The popularity of BTE’s products in the marketplace is a very good situation to be in but it’s not without its challenges, Richard explains. “We are getting a lot of orders – some customers will order 10 B-doubles at a time – so at the moment we are quoting 14 to 16 months to deliver most products.

Probably the biggest challenge for us is to bring that lead time down. Once the efforts we are putting into increasing the skill base of our workforce start to pay off, we would hope to bring that lead time down to under 12 months. Although there are a few challenges ahead of us, the market is fairly buoyant. Overall, there are good things happening at BTE and I can see a really R good future here!”

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The PPG Logo and Bulls Eye Logo are registered trademarks, and MoonWalk is a trademark of PPG Industries Ohio, Inc. © 2019 PPG Industries, Inc. All rights reserved.

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