ipcm® n. 62 - March/April 2020 by ipcm® International Paint&Coating Magazine

The smart journal for surface treatments

ISSN 2280-6083

ipcm digital on

www.myipcm.com Special Issue

2020

11th Year - Bimonthly N° 62 - MARCH/APRIL

INTERNATIONAL PAINT&COATING MAGAZINE

Dealing with corrosion can be a costly business AkzoNobel’s range of powder primers combine a variety of corrosion-inhibiting technologies to extend the protection time of steel. Interpon Primers can also be combined with wide range of Interpon topcoats to give your product not only corrosion protection but an outstanding decorative ﬁnish. Discover our range of Primers • Interpon APP • Interpon BPP • Interpon PZ

For more information visit www.interpon.com

Karlsruhe, DE - 12/15 October

Always Curious ([SHULHQFH RXU ODWHVW LQQRYDWLRQV

&RORUVWUHDPÂ&#x160; ;LUDOOLFÂ&#x160; 1;7 New effect pigments, 'LJLWDO &RORU &DUG H (IIHNWH 0DJD]LQH 6elected color stylings and the latest evaluation of future color trends are waiting for <ou! ZZZ PHUFNJURXS FRP HQ H[SHUWLVH HIIHFW SLJPHQWV KWPO

)LQG RXW PRUH DERXW WKH QHZ 'ULYLQJ /LIHVW\OH WRRO 0HUFN 6S$ 3HUIRUPDQFH 0DWHULDOV _ 6XUIDFH 6ROXWLRQV 9LD 0RQWH 5RVD _ 0LODQR 0, _ ,WDOLD 30VDOHVVXSSRUW,7#PHUFNJURXS FRP WHO ZZZ HIIHFWV IRU FRDWLQJV FRP ZZZ PHUFN SHUIRUPDQFH PDWHULDOV FRP

Celebrating performance, flexibility, service and thousands of colours and effects

Join us at PaintExpo Karlsruhe-Germany Hall 1, Stand #1218

RIPOL delivers top performing powder coatings that provide unmatched durability, ï¬&#x201A;exibility and colour retention while being environmentally conscious

international@ripol.com T: +39 02 97 48 411 www.ripol.com

ARCHITECTURE SUPERDURABLE ACE

ANTICORROSION DECORATIVE SPECIALTIES

CONTENTS MARCH / APRIL 2020

RAW MATERIALS

FOCUS ON TECHNOLOGY

A Coating Plant 4.0 with an Automatic Positioning Device to Paint Braking Systems for Off-Highway Vehicles: Safim’s Choices © ipcm ®

Natures: Fully Biobased Polyesters for Coil Coating Applications

S P E CI AL Pa intE xp o

SP ECIAL Pai nt Ex po

FOCUS ON TECHNOLOGY

76 05 06 08 33 34

EDITOR’S LETTER

MARKET CLOSE UP

ANALYSIS

BRAND-NEW INNOVATIONS: PRESENT&FUTURE

BRAND-NEW

110

Product Industrialisation and Circular Economy in the Automotive Coating Field: A Possible Combination for IMR Industriale Sud, Thanks to an Innovative Automatic and Sustainable Paint Supply Technology

HIGHLIGHT OF THE MONTH Tras-mec Srl: A New Management Focussing on Innovation and Quality

FOCUS ON TECHNOLOGY MS Srl’s Revolution in the Furniture Industry: Dense Phase Powder Coating also Effective on MDF

SP ECIA L Pai n t Expo

Graco Will Exhibit Complete Industrial Paint Kitchen at PaintExpo

IPCM IN REVIEW

Blasting with Stainless Steel Abrasives. Lifecycle Assessment of Abrasives: From Cradle to Grave

38 44

FOCUS ON TECHNOLOGY

A Pioneering Nanotechnology Process Based on Phosphorus Compounds for Higher Corrosion Resistance. An Innovative Process Creates a New Payoff for VIV Group: Grow Up

BRAND-NEW

INNOVATIONS: PRESENT&FUTURE TIGITAL® 3D Materials: Revolutionising Additive Manufacturing

FOCUS ON TECHNOLOGY A Digitised Cataphoresis+Powder Coating Plant Like a Tailored Suit for OMR Spa, a Manufacturer of Excellence in the Industrial Vehicle Sector

106

SUCCESS STORIES A Hanging System to Improve the Efficiency of Coating Processes: Rostirolla Presents P25

HIGHLIGHT OF THE MONTH The Versatility of a Multifaceted Company: IBIX Srl’s First 20 Years of Business

SUCCESS STORIES Please Blast, Dip, Powder a 100 Times

HIGHLIGHT OF THE MONTH Artisanal Quality in Highly Industrialised Coating Systems: Why Eurotherm Chose to Go Against the Tide

72 82

120

SUCCESS STORIES Transparent Information for A Simplified Management of The Coating Process 4.0

CONTENTS MARCH / APRIL 2020

S P E CI AL Pa intE xp o

SP ECIAL Pai nt Ex po

INNOVATIONS: PRESENT&FUTURE

140

SLA Industrie: A Last Generation Vertical System to Increase the Productivity of a Service Company in the Aluminium Profile Sector © ipcm ®

132

FOCUS ON TECHNOLOGY

UV Coatings and PVD Process, an Innovative Combination that Opens New Frontiers for Surface Finishing

S P E CI AL Pa intE xp o

INNOVATIONS: PRESENT&FUTURE

150 124

FOCUS ON TECHNOLOGY

Optimising Painting of Plastic Workpieces: Economically Fulfilling Stricter Requirements for Quality and Sustainability

INNOVATIONS: PRESENT&FUTURE

164

Increasing Productivity, Reducing Emissions

128

FOCUS ON TECHNOLOGY

INNOVATIONS: PRESENT&FUTURE PhoenixTM Company History

154

166

160

170

SUCCESS STORIES

HIGHLIGHT OF THE MONTH HUBO Automation: Innovation and Sustainability in Coating Automation

180

FOCUS ON TECHNOLOGY Daccordi Cicli: The Perfect Combination of Craftsmanship and Innovation

186

SUCCESS STORIES Optimal Blasting of Heavily Used Fasteners

FOCUS ON TECHNOLOGY Higher Productivity for a Contracting Coating Line Thanks to the Integration of a High Temperature Infrared Gas Oven

HIGHLIGHT OF THE MONTH

Paint Shop of the Future: Away from the Line, Towards the Box

FOCUS ON TECHNOLOGY From Railways to Architecture, up to the General Industry: A Nano-Technology Pre-treatment Process Becomes Strategic for Product Resistance and Appearance

A New Shot Blasting Machine Devoted to Stainless Steel Gives Viganò Accessori Srl Full Control over the Quality of its Products

190

HangOn Wins SEB Award for Best International Growth 2019

Hannex Increases Painting Efficiency and Quality with ProMix PD2K

136

174

188

BRAND-NEW

ART WITHIN SURFACES The Perception of Matter in the Goldsmith Work of Francesca Torri

194

HIGHLIGHT OF THE MONTH 2020 is the Year of Pink Oyster – a Happy, Soft and Optimistic Colour

196 198 201

ART WITHIN SURFACES BRAND-NEW STANDARD & LEGISLATION Brexit: What Effects Will It Have on our Relations with the USA?

202 TRADE FAIRS & CONFERENCES 206 ZOOM ON EVENTS

Your surface protection. 1/5

We care. Surface treatments and nanotechnologies

dn-chemicals.com

EDITOR’S LETTER

#EverythingWillBeFine Richiedi la versione in italiano a info@ipcm.it

As I write these lines, Europe is in a state of emergency due to the health crisis caused by the COVID-19 pandemic. ipcm®’s office is unusually calm and silent: our whole staff is working from home, continuing to show the utmost professionalism, dedication, passion, and social and human solidarity. Although distant and connected only through the bits of the network, our team remains united to face this unprecedented situation, which has changed our lives suddenly, but profoundly. Everyone, from people to governments, financial institutions, and central banks, was taken aback and groped in the dark before figuring out how to react. Many mistakes have been made, often in good faith, because the exceptional and fearful nature of the situation called for equally exceptional and fearful, but also unprecedented measures. We are in the middle of a “black swan event”, i.e. a situation that is as frightening as unlikely, for which no reaction model available as there are no past experiences to draw from. We are living history: we will teach the next generations through our behaviours, our mistakes, and our recovery. The industry is in the midst of a storm, not due to financial or economic reasons (these are side effects) but to an exogenous factor: COVID-19. It is not a structural crisis like the 2008 one, but a contingent crisis: due to the virus, the movement of people is forbidden, so that they cannot work or travel for work, and the movement of goods is limited. As a consequence, consumption is zeroed and production slows down. It is for a good cause, for the common good – but it is devastating for the real economy. It will take liquidity injections as well as fiscal and monetary policies to get out of it, but we will make it. The first countries to tackle this emergency with strong healthcare and regulatory measures (defined by someone “draconian”), now so scary especially for companies, will also be the first ones to recover. Meanwhile, ipcm® will continue to recount the strength of the European industry in the world through the tool we know best: information. We will unite people through our content, because we firmly believe that providing updated information and tools to take advantage of this period’s slower rhythms can be useful to seize all the opportunities that will surely arise at the end of the health emergency. These days, we are learning even more to work and live in a virtual world, where the importance of digital content is growing by the hour. Luckily, we were far-sighted. For a long time now, our website, www.myipcm.com, has made all our magazines’ issues and a daily-updated “NEWS” section available for free. Even if we were not able to send you your hard copies (but we are working hard to make it happen), you will be reached by our content. We are preparing an updated version of our “Trade Shows, Conferences and Events Calendar 2020”, which will be online in the next few days, to give you a complete overview of the events that will dot your and our autumn season.

Alessia Venturi Editor-in-chief Direttore Responsabile

The issue you are about to read was conceived as a special edition for the world’s most important trade fair on coating technologies, PaintExpo 2020, which was postponed to October, 12 to 15. Indeed, it is one of the most beautiful, richest, and most stimulating numbers we have ever written. We have had to struggle to finish it and print it, but it can now offer you top-notch articles about great technological innovations, cutting-edge systems, and success stories, testifying that this industry was being highly dynamic and in full development. And it will be again, because the virus of mistrust and fear must not prevail!

international PAINT&COATING magazine - MARCH/APRIL 2020 - N. 62

IN REVIEW

January and February in Review Barbara Pennati ipcm®

Communication beyond the five senses. And beyond the fear

It isn’t easy to summarize in a few lines what has happened in the last two months: everyday life as we knew it within our editorial office, houses, companies, the whole Country and the international community has been radically modified by the reasons we all well know. In the world of work, the activities already partially carried out and, in whole, those planned for this period of the year had to be reviewed and reorganized, in the best cases, or interrupted, in the worst cases. But ipcm® doesn't stop: in the light of the postponement of the main fairs of the sector,

Communication beyond the five senses

One of the main trends of

distribution programs of the magazines issued by EOS

Each company knows the

technological development:

Mktg&Communication will not

importance of involving

augmented reality.

change with respect to the

and encouraging the active

In fact, the term ‘augmented

editorial program presented

participation of its audience

reality’ was coined only in the

at the end of last year: we will

and also knows how difficult it

90s, but the first examples

follow all trade fairs based

is to capture and maintain their

of the implementation of this

on their new schedules and

attention in an increasingly

technology date back to 1962.

continue in our information

information and stimuli-

Today, it certainly is one of

activities of the surface

saturated world.

the most interesting tools,

treatment industry.

In this context, in addition

with a great communicative

Because the virus of mistrust

to a strong, functional and

potential, capable of stimulating

must not prevail and because

communicative message,

and enriching human sensory

we must reaffirm the strength

technological development

perceptions.

of the European industry

comes to our aid, offering

At the end of the year we

in the world through the

cutting-edge solutions to reach

described our path towards

instrument we know best: the

people and make ourselves

becoming a smart magazine, a

communication.

heard.

concept that we are committed

including PaintExpo, the

N. 62 - MARCH/APRIL 2020 - international PAINT&COATING magazine

2020 is actually the result of

IN REVIEW

editorial and photographic material gathered. In January the first issue of the year of ipcm® was distributed: thanks to a new layout and new sections dedicated to “Raw materials”, “Specialized training” and “Art within surfaces”, our main magazine has become even richer in topics and updated with current news. The offer of the ipcm® training division is also expanding: in February we re-launched the to representing by offering

trade fair activity. See you then

webinar dedicated to the topic

global magazines, rich of

next October at PaintExpo, hall

of PFP (Passive Fireproofing)

original contents and with a

1, booth 1442.

materials and their applications to allow those countries which

multi-channel distribution, and by building a community that

Time for planning

were unable to attend the first

expands more and more every

In January, we also outlined

time, due to the time zone

day.

other important projects, first

differences, to follow it. Given

In 2020 we want to keep

and foremost the services

the success of the initiative,

giving meaning to this word

offered by eos which, true

we have decided to expand

and in January we outlined

to its name, will not only be

the proposal: soon we will

different ways to achieve our

a publishing house but also

present the calendar of the

goal. PaintExpo will give us

a business and marketing

next webinars with the new

the opportunity to translate

consulting, graphic design and

topics covered in both Italian

words into facts, through a

event organization agency.

and English.

project that involves augmented

We have also outlined the travel

Finally, the renovation process

reality and interactivity as

plans for the upcoming months:

continues, once again affecting

tools to encourage the active

this year, our magazines will visit

the graphic layout of our

participation of our visitors.

around 70 fairs.

magazines: both ICT – the

The goal is to demonstrate

A similar number of exclusive

ipcm supplement dedicated

the communication potential

case studies will be written,

to cleaning technologies

of these technologies and the

following our travels to observe

– and ipcm_Ibérica/ipcm_

many ways in which they can

from up close the finishing

LatinoAmérica – the two

also be exploited for editorial

world, which you will be able to

newspapers dedicated to the

and advertising purposes.

read about in the pages of our

Spanish- and Portuguese-

Once again, the ipcmLounge will

magazines. In this way, the first

speaking markets – were

welcome you, offering a meeting

two months of the year were

issued with a completely

and networking place where you

intense in terms of the number

renewed look and more and

can take a break from the hectic

of companies visited and the

more different contents.

international PAINT&COATING magazine - MARCH/APRIL 2020 - N. 62

ÂŠ Adobe Stock_mozZz

MARKET CLOSE UP

From more Functional and Smart Coatings to the Challenges of Regulatory Alignment with the US and Europe: a Closer Look to the Canadian Paint and Coatings Market From an interview with Gary LeRoux President & CEO Canadian Paint and Coatings Association

Even if we live in a globalized and

restrictions, how it relates with other

way of doing business, and bans

interconnected world, where

markets and the issues that might

and restrictions have affected the

information is within reach of almost

arise with regulatory alignment,

chemical industry, and consequently

anyone, sometimes it can be difficult

what investments and technological

the coatings sector as well. Not to

to truly grasp all the peculiarities

innovations are being pursued, and

mention the tug-of-war between

and singularities of a foreign market.

how social, economic and political

world powers and the general

Not only that, but several other

issues influence it.

uncertainties affecting our time,

factors play an important role in the

Lately we have witnessed an increase

which are also factors that play a

assessment and understanding of

in pursuing more sustainable

pivotal role in defining the status of a

a market: its regulations, bans and

solutions, which is changing our

market.

N. 62 - MARCH/APRIL 2020 - international PAINT&COATING magazine

MARKET CLOSE UP

This new section stems from our

and nanoparticles for improved

to the south, the United States. It is

will as an international magazine to

functionality. In fact, one of our

Canada’s largest trading partner by

provide our readers with a close-

members has become a leader in

far, with more than $2.7 billion/day

up of the different markets across

the nanoparticle space with the

in two-way trade between the two

the globe from the point of view of

production of graphite and graphene

countries. Since the first free trade

those who are an integral part of it,

with state of the art technology for

agreement between Canada and

to better navigate the current trends

improved performance and more

the United States, coatings products

and situations.

sustainable products.

shipped to Canada from the United States have increased from 35 per

In this first article, we present an interview to CPCA - Canadian Paint

The vast majority of architectural

cent to more than 50 per cent today.

and Coating Association’s President

products now manufactured in

This was also spurred on by massive

Gary LeRoux, who provides an

Canada are water-based. More than

consolidation over that same period.

interesting overview of the current

90 per cent of decorative paints are

However, the volume of coatings sold

state of the coating market in Canada,

water-based in Canada and 30 per

in Canada remains the same relative

how it relates to other countries,

cent in the automotive sector. Some

to economic circumstances. This

especially the US and Europe, and the

SME’s have become leaders in new

one issue requires that CPCA and

key role played by sector associations

approaches to recycling leftover

ACA remain vigilant with respect to

in this scenario in helping

paint or post-consumer paint under

regulatory alignment on a number of

manufacturers and end-users to

extended product stewardship

important regulatory issues including

orient themselves among regulations,

programs across Canada. In 2019

the assessment of chemicals in

bans and new trends.

more than 28 million kilograms of

commerce, VOC limits for product

paint was recovered in Canada,

formulations, raw materials and

What are the main features

enough to paint more than 500,000

biocide preservatives in coatings,

and characteristics of the

homes. A number of Canadian

hazard communications for worker

coating sector in your country?

companies are collaborating with

safety, and more. Given the foregoing,

What level of technological

universities and research institutes

it is critical that ACA and CPCA

advancement has it achieved?

to develop more functional and

collaborate very closely on key files

smart coatings. Several SMEs have

that impact our common members,

As in other countries, Canada is

substantial R&D facilities in various

and we do.

a mix of large multinational and

provinces across Canada, with one

national coatings companies. Within

recently opening a 30,000 square

What needs and demands does

this mix is a range of Canadian small

metre facility employing chemists

the coating sector currently

and-medium-sized enterprises

working on new product formulations

have?

(SME), which is defined as five

and new uses for leftover paint.

hundred employees or less. The

Finally one of our SME member

The demands of the coatings sector

larger companies have the capacity

companies pioneered the use of

are not unlike any other economic

for strong investment in R&D for

sustainable stains and sealants using

sector, it must have a level-playing

technological innovation as one

resins and gums from trees, dating

field to conduct business. The main

would expect, but increasingly in

back almost twenty years ago, while

challenge for a level-playing field

recent years SME’s have also become

still retaining strong performance.

is the regulations imposed on the

strong in both R&D and innovation

Stains now also include water-based

production and sale of products. In

with a focus on producing more

products to meet the growing

Canada, we have a disadvantage in

sustainable products. For example,

consumer demand.

that regard as Canada will often look to Europe for approaches to the

a number of SME’s have substantial labs where they do testing on various

The most unique aspect of the

regulation of chemicals in commerce,

product formulations, which includes

coatings sector in Canada is the fact

while companies in Canada do 75 per

the use of bio-based materials

that it has a very large neighbour

cent of their business with the United

international PAINT&COATING magazine - MARCH/APRIL 2020 - N. 62

MARKET CLOSE UP

States, where regulations may vary

The Red Tape Reduction Act also

the past 13 years CPCA has been

with those in Europe. This is a recipe

includes a ‘one-for-one rule’ wherein

engaged in the assessment of 2000

for regulatory misalignment and it has

one regulation must be removed

of those chemicals used in thousands

presented challenges for businesses

every time a new regulation is

of Coatings, Adhesives, Sealants and

manufacturing in Canada. Further,

created. Industry remains hopeful

Elastomers (CASE) products, which

the Canadian Chamber of Commerce

that this will be the approach going

requires a significant investment of

released a report last year noting that

forward as new regulations are being

time and effort by the association

Canada was already over regulated

considered for lower VOC limits

with the critical input of our members

with more than 130,000 regulations

for greater emissions reduction.

with respect to the data needed to

at the federal and provincial levels

This is being done despite the

fully inform the assessment for better

of government. As a result, there

fact that Canada’s architectural

outcomes. The goal is to ensure those

is now a regulatory modernization

coatings segment has reduced

chemicals can remain in commerce

effort underway in Canada to reign in

VOC emissions since 2009 by 42

for our members’ products and to

out-dated regulations. The goal is to

kilotonnes, the equivalent to the

date we have been lucky as there

ensure any new regulations take into

emissions of 150,000 average size

have been very few bans and use

account the regulatory burden it will

automobiles. This also applies to

restrictions for chemicals used by our

impose on industry vis-à-vis the Red

the federal Government’s Chemicals

members. The federal government

Tape Reduction Act that was passed

Management Plan, assessing all

will continue this program for the

several years ago under the previous

chemicals in commerce to determine

foreseeable future and may go back

Government.

if they negatively impact both human

and re-assess some of the chemicals

health and the environment. Over

that have already been assessed.

N. 62 - MARCH/APRIL 2020 - international PAINT&COATING magazine

MARKET CLOSE UP

How does your Association

several hundred still being assessed.

work. However, it continues to be a

position itself in relation to

The association is on the frontline

challenge for the coatings industry

the current market? What

of chemical assessment for the

as the federal government is now

advantages can companies get in

CASE sector in Canada and works

moving to another phase of chemical

becoming members?

hard to provide the relevant data in

assessment over the next five years

the hands of coatings companies,

(2020-2025). The government will

The association’s core competency

which is often critical to inform the

also be broadening the lens for

revolves around issue management

assessment process and thereby

that assessment and will include

related to legislative and regulatory

ensure chemicals used in coatings

areas such as the role of potential

development with focused advocacy.

for thousands of SKUs can remain in

alternatives or informed substitution

That effort consumes 90 per cent

commerce.

for certain chemicals of concern. It is also using a workplace safety lens to

of CPCA’s staff time, working closely with technical committees to

Lack of relevant and robust data

assess exposure scenarios, which has

advocate for better legislation and

points to positively support various

been the sole purview of other Acts

regulations. This has been challenging

exposure scenarios is the biggest

of Parliament related to WHMIS/GHS.

over the past fourteen years under

concern for the association as it could

The association’s focus will remain on

Canada’s Chemical Management Plan

lead to chemicals being severely

ensuring all members can remain in

assessing thousands of chemicals

restricted or banned outright. Over

full regulatory compliance throughout

in commerce. More than 2000 of

the past fifteen years there have been

the chemical assessment process

those substances assessed are used

very few bans or use restrictions

and thereafter. This requires CPCA

in the Coatings, Adhesives, Sealants

imposed on the coatings sector

to collect and aggregate mandatory

& Elastomers (CASE) sector with

in Canada as a result of CPCA’s

industry data - under existing

Visionaries have no rivals.

s at Visit u

the

020

ACS 2

1931 Booth

Look into these eyes. Can you see it? Trace the purple paint with your ﬁnger. Can you feel it? It’s the motivation to discover superior solutions for the challenges of tomorrow in our everchanging world. It’s the passion exuding from our global network of employees. It’s the conﬁdence that we can deliver true value for your coating formulations. Now, look into these eyes. Join us in shaping the world of coatings.

www.coating-additives.com

MARKET CLOSE UP

legislation - for more informed

countries. This issue has become

What short-term developments

chemical assessment, which mitigates

more pronounced over the past

do you think the coating sector

the risk to companies doing business

several years due to the differences

can achieve, i.e. in terms of

in Canada now and into the future.

in the policies of the respective

technology and production?

Governments in the two countries, What are the effects on

which are arguably based on two

The coatings industry is now focused

the coating sector of the

different political ideologies. This

more than ever on digitalization

international political and

will continue to be a challenge for

across supply chains and within

economic situation and of the

the foreseeable future not only in

their own production processes,

economic agreements signed

North America, but among other

thus impacting both intra- and

between the United States and

trading blocks including Europe

inter-company movement of

Canada?

and countries in Asia, as it relates

materials. The industry has already

to raw material supply and various

achieved a great deal with respect

When NAFTA was signed several

challenges along the supply chain.

to more sustainable products, while

decades ago it proved beneficial for

There are increasing calls for more

maintaining performance; there has

the coatings sector in both Canada

transparency along the supply chain

also been an increase in bio-based

and the United States, with the

requiring greater collaboration

materials for a variety of products;

elimination of paint-related tariffs.

and engagement with all major

nanotechnology has emerged as

There is still the issue of the exchange

trading countries. This is especially

a field where there are great gains

rate, but by and large it works for

important for Canada with 80% of

in advancing coatings technology;

both countries based on the various

the raw materials used in coatings in

and new formulations have been

business models used by different

Canada originating outside Canada.

moving increasingly to lower VOC use

segments within the industry. Despite

Increasingly this will likely require

beyond just architectural coatings.

recent challenges in negotiations

more focus and a greater role for the

These approaches will continue with

of the new free trade agreement,

World Coatings Council, which has

large investments in R&D to secure

the USMCA, the larger challenge

been in place for the past 25 years

the innovation that is required to

remains regulatory alignment, or

and seeking to align regulations and

grow organically and create wealth.

the lack thereof, between the two

best practices globally.

A big part of that effort will be the ongoing efforts to improve hazard

communications related to every aspect of chemicals in products, including coatings. This is critical to continue to evolve the coatings sector’s ‘social license’ to operate in a world more focused than ever on sustainable and safe products for the benefit of human health and the environment. The coatings industry has proven that it has the motivation and bandwidth to get this done based on past experience in not only reducing the environmental footprint of their own company, but also the environmental footprint of their customers.

N. 62 - MARCH/APRIL 2020 - international PAINT&COATING magazine

www.infragas.com

INFRARED RADIANT GAS SYSTEMS FOR THERMAL TREATMENTS

RAW MATERIALS

Natures: Fully Biobased Polyesters for Coil Coating Applications Guglielmo Catel, Matteo Sitta Novaresine Srl – Colà di Lazise (Verona), Italy

catel.g@novaresine.com - sitta.m@novaresine.com

The increasing interest towards the

impacting on the carbon footprint.

highly pollutant and energy consuming

development of polymeric materials from

Then, from the scientific point of view,

processes to be oxidised.

bio-derived sources featured the last decade.

chemicals derived from biomasses offer

Thus we can formulate the “biorefinery”

The environmental benefits of sustainable

the potential advantage to skip many

concept, the place where this pre-

processes and renewable sources have been

functionalization steps in syntheses, which

functionalization becomes the main

widely studied and discussed.

are instead necessary in the conventional

advantage in manufacturing chemicals

As first thing, the launch of a chemical

oil-based chemistry. An interesting example

through the organic synthesis processes,

industry less dependent upon the crude-oil

is the introduction of oxygen-containing

bearing oxygen-based functional groups.

business is likely to be a subject showing

functions into an organic building block:

Most parts of the chemicals obtained from

great appeal on the audience, as much as the

molecules obtained from crude oil are

lignocellulosic biomasses and carbohydrates

increasing need to reduce pollutant emissions

exclusively hydrocarbons and they need

are either dicarboxylic acids or polyols, which

N. 62 - MARCH/APRIL 2020 - international PAINT&COATING magazine

ÂŠ Novaresine

RAW MATERIALS

are among the commonly used monomers in

of the bio-based building blocks: despite of

of the liquid resin can be considered aligned

polyesters production.

the claims of several producers, there are

with those one of a Novasynt standard

In fact polyesters are commonly obtained

few functional bearing monomers ready at

assumed as resin reference.

through polycondensation reactions

the industrial scale. So to assure the fast

between diacids and diols (Scheme 1):

industrialization of its products, Novaresine

In particular the committing task to reach

bio-based monomeric units can be used for

made a thorough selection of suppliers

a polymer glass transition temperature

manufacturing polyesters.

and bio-based raw materials involved in the

(Tg) exceeding 10Â°C required a relevant

project.

endeavour in terms of lab work and polymer

Therefore biobased polyesters represent a

Nevertheless an essential requirement is the

design engineering. A new approach was

convenient way to exploit the potential of

independence of the renewable feedstocks

necessary to upset the technicians common

biobased monomers, considering both high

used in the polyesters formulation from

synthesis experience: the lack of aromatics

molecular weight thermoplastic products

the food and fodder supply chain: the

availability pushed in a new direction, to move

as well as lower molecular weight resins for

Novaresineâ&#x20AC;&#x2122;s efforts were aimed to offer to

from aromatic acids towards hindered glycols

coatings and adhesives. This is the reason

its customers a new range of products fully

easily recoverable from renewable sources.

why we can find many papers showing the

sustainable.

Hence this research paper required to gather

possibility to introduce bio-based monomers

Novaresine started working on this ambitious

new experience to re-build a new databank

in the syntheses of polyesters, leading to a

project from scratch at the beginning of 2015:

about the correlations between the polymer

partial to total replacement of the common

the encouraging results already obtained on a

backbone composition, structure and

fossil-based ones.

partially biobased polyesters were the driver

functionalization, and the final properties of

Novaresine took up the challenge and started

to set up a partnership with the Politecnico di

the resin.

its investigations and experimentations in

Milano, very profitable from the point of view

The main step to overcome was to obtain

order to achieve the ambitious target to

of the study development and the technical

a resin generating a cured film of clearcoat,

realize a fully biobased polyester suitable for

achievements. Hence Novaresine could

stoving cured with hexamethoxy-methyl-

the formulation of coil-coating paints.

exploit the precious experience in research

melamine (HMMM), responding to the

Many producers can offer resins with a

and development and the wide availability of

indentation cycle in reasonably acceptable

certain percentage of renewable monomers

high-tech equipment of a such prestigious

trend after hydrolytic attack by means of

that generally consist in a maximum of 40

institute.

water immersion. (Table 2).

to 60% by weight of renewable carbon.

Furthermore the open relationship and the

This result is relatively easy to achieve

unceasing sharing of technical information

Moreover the mechanical characterization

since in some cases traditional monomers

with its customers resulted in a strong

of a standard formulations top-coat paint,

are available also as biobased building

support that allowed Novaresine to keep

applied on a primerised steel substrate,

blocks. A total replacement of fossil based

investigating on this promising path.

demonstrates that Natures 4100 brings to the

monomers is instead more difficult, especially

Novaresine succeeded in this tough technical

coating interesting characteristics (Table 3).

considering the limited availability of biobased

challenge and now it can introduce to its

aromatic monomers at an acceptable cost.

customer a polyester resin for top-coat

The high resistance to the solvent, expressed

In addition, requirements for coatings are

formulations fully biobased, showing

by means of the double rubs value, which

typically demanding, and concern not only

performances at the same level as the

exceeds 200, can support the hypothesis of

the mechanical properties of the coating

standard polyesters belonging to the

a higher crosslinking density, effect of the

material but also, and relevantly, its aesthetic

Novasynt series: Natures 4100 the fully

functionality distribution in the polymeric

appearance and durability properties.

biobased polyesters, 65% solution in standard

chain, as well as the lack of aromatics inside

Another relevant issue is concerning the

blend of solvents.

can results in the better aesthetical initial

real availability on the raw materials market

As reported in Table 1 the main properties

properties. Another highlighting point is that the glass

n HO

OH + n HO O

transition temperature of the cured paint film

O OH

-n H

H n

is surprisingly pretty close to same parameter of the standard one in spite to be absolutely aromatic-free. This aromatic-free structure takes its effects

Scheme 1: General scheme of the polycondensation reaction between diacids and diols.

international PAINT&COATING magazine - MARCH/APRIL 2020 - N. 62

the significantly rusted metal surface for the severely stressing

GLOSS RETENTION vs UV/CON TIME

weathering conditions, the coated part with the paint formulated by

120

the use of Natures 4100 still resists and keep whiteness and gloss.

Gloss retention (%)

100

This behaviour can be considered completely matching to that of a top-coat paint formulated with a Novasynt reference (Fig. 2).

At the end of the day Novaresine can summarize that all tests, even those most demanding, confirm that the new fully bio-based

60 40

Novasynt

polyester Natures 4100 can replace the standard Novasynt series

Natures 4100

products in the formulation of top-coat paints for coil coating, opening a new way for a sustainable supply chain extended from

20 0

the raw materials to the finished goods. 0

500

1000

1500

Of course Novaresine keeps investing on green chemistry projects

2000

time (hours)

and is still investigating on similar papers to include in its products portfolio fully biobased resins for direct to metal applications and

Graph 1: Gloss retention trend in an accelerated weathering assessment through UV/Condensation exposure cycles.

a typical coil coating cured paint film. The

even on the durability and weatherability of

superdurable coating.

following graph reports the gloss retention trend in a severe accelerate assessment, in sequential cycles of exposure to UV A light and moisture, performed according to standard ASTM G154 (Graph 1). As it can be observed the coating formulated by using the biobased resin keeps its gloss 60° higher than the reference. A comparison picture of the specimens exposed to the test are displayed below (Fig. 1): in spite of

Figure 1: Panels coated with a top-coat paint formulated by using Novasynt 4100, before (SX) and after (DX) 2000h accelerated weathering.

Figure 2: Panels coated with a top-coat paint formulated by using Novasynt Reference, before (SX) and after (DX) 2000h accelerated weathering.

Bio-content %

AV mgKOH / g

Tg °C

Mn g/mol

PDI

Solid Content %

Viscosity Pa∙s 25°C

Natures 4100

100

10 ± 2

5500 ± 300

3.5 - 5.0

65.0

3.2

Novasynt

14 ± 2

4300 ± 300

3.5 - 4.5

65.0

3.3

Table 1: Comparison table of liquid resin characteristics.

Natures 4100

Average indentation resistance (1/L) 85

Δ (%) 170h -0

Δ (%) 288h -2

Δ (%) 552h - 10

Novasynt

104

-3

-6

Table 2: Average indentation resistance change of a clearcoat stressed by hydrolytic attack.

T-Bend test (nT)

Erichsen cupping Adhesive T-bend Cross-Cut Double Rubs Tg test (mm) test (nT) Adhesion (0 – 5) Acetone (n°) (°C)

Gloss 60° White (%) Index

Natures 4100

9,3

1.5

>200

55.0

91.4

Novasynt

8,2

145

51.7

89.8

Table 3: Table reporting the results of characterization tests of a top-coat paint realized by using respectively Natures 4100 and a Novasynt Reference.

N. 62 - MARCH/APRIL 2020 - international PAINT&COATING magazine

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

Safim is a leader in the production of hydraulic and electro-hydraulic braking systems.

FOCUS ON TECHNOLOGY

SPECIAL PaintExpo

A Coating Plant 4.0 with an Automatic Positioning Device to Paint Braking Systems for Off-Highway Vehicles: Safim’s Choices Alessia Venturi ipcm®

N. 62 - MARCH/APRIL 2020 - international PAINT&COATING magazine

FOCUS ON TECHNOLOGY Safim, an Italian company among the world's leading manufacturers of hydraulic and electro-hydraulic braking systems for agricultural machines, earth-moving machines, and other off-highway vehicles has insourced the brake systems coating department to reduce the lead time and has entrusted its management to Pieffeci company (Turin, Italy). The company, specialized in the management of on-site coating processes, suggested the CMV plant manufacturer. In addition to providing a highly flexible coating plant, it designed a fully automated process control and tracking system managed by the SQLPaint software, with two anthropomorphic robots integrated by HUBO Automation.

Safim, defined as a “pocket multinational

Safim insourced its coating operations

the past1. Pieffeci creates and implements

company” by its own CEO, has its

by installing a highly automated, Industry

rationalisation projects on coating processes

headquarters as well as main production

4.0-oriented plant designed by CMV Srl

by managing their operation, workflow,

plant in Modena (Italy). It is among the

(Pesaro, Italy), a company with twenty

and machinery and handling maintenance

five global leaders in the manufacturing

years of experience in the design of

directly on site, operating through specific

of hydraulic and electro-hydraulic

customised, complete coating systems,

procurement contracts. In particular, it

braking systems for agricultural

which collaborated with HUBO Automation

assesses new construction or retrofitting

machines, earth-moving machines,

on this project. However, Safim opted

solutions to guarantee efficiency, continuous

and other off-highway vehicles and the

for an indirect management solution by

process optimisation, and innovation.

undisputed European leader in its target

entrusting it to a partner specialising in

“We decided to entrust the management

market. “We stand out in the hydraulics

coating processes, Pieffeci (Turin, Italy),

of our coating plant to an industrial partner

industry for three reasons: very high

which has already been the protagonist of

because our core business is hydraulics: we

product customisation, excellent

two success stories reported by ipcm® in

are not painting experts,” states Santoro. “We therefore deemed it appropriate to

times, and high braking performance,”

rely on experts not only for the in-house

production flexibility with short response states Safim CEO Pietro Santoro.

management of our process but also for

In its Modena plant, Safim treats cast

the choice of the most suitable system

iron through CNC machining operations.

supplier based on our requirements. We

The workpieces are then ground,

met Pieffeci for the first time on January 3,

cleaned, and assembled with other

2018: in the following months, they have

purchased or in-house produced

helped us to select a plant engineering

parts. The acceptance tests carried

partner through a technical and financial

out on all end products to check their

analysis of offers and to finally choose

functionality are followed by the liquid

the right company to build our system.

coating, packaging, and shipping phases.

Our choice fell on CMV (Pesaro, Italy). We

Coating, in particular, was outsourced

ordered the plant at the end of 2018,

up until last year, but in early 2018 Safim

submitting all our technical and coating

decided to make a structural investment

specifications; they delivered it in less than

to also insource the finishing process in

four months, at the end of April 2019. After

order to manage its whole production

obtaining approvals from all our customers,

cycle.

we started production in early June 2019,

“There were several reasons for this

that is, six months after giving a purchase

choice,” explains Pietro Santoro. “The

confirmation.”

first and most important one was the need to reduce our lead time. By investing in a coating plant, we have

reduced it by one week. Currently, we take 6 hours to manufacture a finished product, ready for packaging.”

Finished products in the packaging phase.

A. Venturi, Pieﬀeci Torino: the smart way for painting, in ipcm® International Paint&Coating Magazine no. 57 (May/June 2019), pages 70-82. M. Fumagalli, “High Automation and Continuous Monitoring via PLC for the Eﬃcient Outsourcing of Coating Operations” in ipcm® International Paint&Coating Magazine no. 45 (May/June 2017), pages 16-26.

international PAINT&COATING magazine - MARCH/APRIL 2020 - N. 62

SPECI AL PaintExpo

The new coating plant.

Integrating automation and the Industry 4.0 principles

handling any new products or variants.

“When choosing this plant, of course, we

automatic system for the interpolation of

Industry 4.0-oriented SQLPaint management software and the automatic positioning system

focussed on its Industry 4.0 and automation-

the robots’ arm movement with the rotary

One of the peculiarities of the CMV

oriented features,” says Pieffeci CEO

movement of each load bar: in this way, the

system supplied to Safim is the

Paolo Cornacchia. “We asked for a fully

robots detects each workpiece as well as

complex automation system designed

automated process control and tracking

each hook’s angular position, thus giving the

and integrated by HUBO Automation

system, managed through CMV’s SQLPaint

robot programmer all the tools needed for

(Civate, Lecco, Italy). It is an automatic

software package and equipped with two

optimising paint consumption and coating

positioning system for arranging the

robots, one for the primer application and

effectiveness.”

workpieces in front of the coating robots

one for the top coat, to be integrated by

“Automation is a typical feature of Safim’s

so as to achieve maximum process

HUBO Automation and programmed on a

production flow: our machining department

efficiency. “Before entering the primer

product number basis. Safim deals with a

includes several CNC milling-boring systems

application booth, the parts are free to

very high number of different workpieces:

with a robot each,” notes Santoro. “Our

rotate on their hanging hook,” explains

we have created over eighty different coating

logistics department is also equipped

Sergio Castagna from HUBO. “The

programs. The programming system uses

with robots for material handling within

robot, therefore, does not know where

off-line editing and simulation software

the factory. Therefore, we could not avoid

the incoming component, or cluster

in order to improve flexibility, quality, and

implementing a complex automation system

of components, is located. A reader

application effectiveness and allow easily

on our coating system, too.”

above the entrance of the coating booth

HUBO also integrated the line with an

N. 62 - MARCH/APRIL 2020 - international PAINT&COATING magazine

IMAGINE IT

DIFFERENT

WHAT WOULD BE YOUR BUSINESS WITH A POKER IN YOUR HAND?

z PREMIUM

y WIDE

We produce according to the highest quality standards thanks to QUALICOAT速, GSB速, POLYESTER MED, QUALISTEELCOAT速, QUALIDECO速, ISO EN 45545 certifications.

We developed more than 16.000 items and special product lines, with a choice of almost 1.000 stock products, immediately available, minimum quantity: one box.

We guarantee the fastest delivery times and an extreme pre/post-sales support, thanks to our 10 warehouses in Italy and 20 distribution points in Europe.

QUALITY

RANGE

www.stpowdercoatings.com

FAST DELIVERY

x LOW

IMPACT

Our high energy-saving coatings allow better production efficiency than standard products, consumption cost cuts and low environmental impact.

20.000 M 2 HEADQUARTERS MORE THAN 16.000 COLOURS 1.000 PRODUCTS IN STOCK RESPECT OF THE ENVIROMENT IN THE PRODUCTION PROCESS NEW PRODUCT DEVELOPMENT ISO 9001, ISO 14001, OHSAS 18001 CERTIFICATIONS

ST Powder Coatings S.p.A. Via E. Segrè, 46 36075 Montecchio Maggiore ITALY Tel.: +39 0444 165400 info@stpowdercoatings.com

ST Powder Coatings España S.L. C/Batalla de Brunete, 11 28946 Fuenlabrada - Madrid ESPAÑA Tel. +34 916 977 292 espana@stpowdercoatings.com

ST Powder Coatings Portugal L.d.a. Rua R.B. Rodrigues, 210 4475-132 Maia - Porto PORTUGAL Tel. +351 220 944 229 portugal@stpowdercoatings.com

Barten S.r.o.

Porfesték Kft.

Ružová 307, Louky 763 02 Zlin CZECH REPUBLIC Tel. +420 573 332 198 barten@barten.cz

Szurdokpart u. 70 3200 Gyöngyös HUNGARY Tel.: +36 37 505 050 hungary@stpowdercoatings.com

www.stpowdercoatings.com Subscribe to our Newsletter

FOCUS ON TECHNOLOGY

detects the hooks’ position and brings them to their “zero position”, which the robot recognises as the correct position to start the coating process. In other words, the workpieces rotate according to the requests of the robot itself to increase coverage effectiveness. Another salient feature is the possibility to program the

Get more from water

coating robot off-line, starting from the workpieces 3D drawings. This avoids any downtime for programming activities.” Automation is closely related to the use of the Industry 4.0-oriented SQLPaint system management software package, exclusively owned by CMV and protected by trademark. “The production flow of Safim’s coating

Turn key solutions for industrial wastewater treatment

line is organised by colour batches,” says CMV owner Saimon Frati. “When the operator hooks a part during

Design and manufacturing of plants and chemicals for industrial wastewater treatment

loading, SQLPaint software detects it and automatically

Chemical-physical plants

knows which workpiece has been loaded, thus

Sludge treatment and compactor systems

matching it with the treatment cycle to be performed

Ion exchange demineralization systems and reverse osmosis systems

and the colour to be applied. The SQLPaint software package also records all the main parameters of every

Oil separators

process stage, i.e. about 70 process variables, including

Filtering systems

pump pressure, bath temperature, pH value, and

Batch type systems

concentration, conductivity, drying and polymerisation

Flotation units

temperatures, booth status, chemical and painting

Chemicals and spare parts for water treatment

product consumption, any alarms from the robots,

Technical service, support and maintenance of wastewater treatment plants

and any changes made to the coating program. In short, the software program continuously monitors all significant parameters, instantly flagging any deviation from the expected values, each with its preset tolerances.” “The robots need four data to work: load bar number, part program, colour code, and load bar filling level,” says Pieffeci project manager Renato Piazzolla. “Safim sends its assembly order strings to Pieffeci, including the part numbers. Pieffeci fills out the industrialisation bill with the information needed for coating those workpieces: colour code, part program, type of hook to be used from the over thirty modular solutions available, and some other process information that will be automatically displayed in the near future, when the workstations of the coating line will be completed with the installation of some Smart TVs. After the reading of the work order note, the parts reach the loading area and they are subjected to the ‘quality gate no. 1’, necessary to check and register any non-compliance of the workpieces received. Then, the operator records the quantity of compliant parts that are to be loaded on the line. “Once the process order has been validated, the

visit us at

Messe Karlsruhe - October 12-15, 2020 - Hall 2, booth 2242

info@waterenergy.it

www.waterenergy.it

SPECI AL PaintExpo

gate no. 2’ is in the unloading area, where the operator performs a visual inspection of all parts and he then declares any coating non-compliance or validates the workpieces. He can then disassemble the cluster and return the parts to Safim, with a list of the processes carried out to certify their quality. Any post-process rework can be managed with the small manual booth provided with the line. Workpiece traceability is always ensured because the SQLPaint system also records all the rework operations.”

Line characteristics From left to right: Renato Piazzolla and Paolo Cornacchia from Pieﬀeci, Simon Frati and Paolo Gostoli from CMV Impianti.

“Like all our plants - says CMV sales manager Paolo Gostoli - the system provided to Safim was fully designed and built in-house by CMV, including its conveyor. In this case,

set for the type of workpieces involved,

we opted for a one-rail conveyor with

operator the identification number of the

the SQLPaint system automatically

load capacity of 40 kg/hook, considering

load bars with which the batch loading

calculates the required amount of load

the small dimensions of the workpieces.

operation must start and finish. Based on

bars and prepares the line for any colour

The line speed is deliberately very low for

the part quantity and the bar load factor

change operation needed. The ‘quality

optimal order management. We used two

SQLPaint system communicates to the

The fully automated system designed by CMV with HUBO automation system.

N. 62 - MARCH/APRIL 2020 - international PAINT&COATING magazine

FILTRAZIONE PER IMPIANTI DI VERNICIATURA FILTERING FOR FINISHING LINES

rotoli, pannelli e celle in fibra di vetro

rolls, panels and cells of glass fiber

celle filtranti per alte temperature

filtering cells for high temperatures

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

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

FILTRO ALVEOLARE MAX PAINT distributori esclusivi per l’Italia

massima efficienza massimo accumulo di vernice massima durata

minori costi di smaltimento minori costi di manutenzione

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

www.defil.it

SPECI AL PaintExpo

Workpieces loaded on the line.

avoid any sudden accelerations or decelerations when starting or

flow and its tanks are heated by an indirect exchanger located in the

stopping the conveyor. This prevents any load bar swinging and

thermal plant outside the building, also designed by CMV. Its cycle

chain shaking, thus ensuring the best working conditions for both

includes degreasing, phosphating, rinsing with mains water, rinsing with

the line operators and the automatic application of paint.

demineralised water, and passivation phases. Bath concentration and

The pre-treatment tunnel is built in AISI 304 steel; we also designed

other characteristics are monitored continuously for each load bar and

its discharge pipes and relaunch devices from the collection wells

sent to the SQL software package. The system automatically selects the © ipcm ®

to the storage tanks for water treatment. It works with a continuous

synchronised driving units to guarantee uniform feed speed and

The robot detects each part as well as each hook’s angular position.

N. 62 - MARCH/APRIL 2020 - international PAINT&COATING magazine

A detail of the hanging pins.

pre-treatment liquids according to bath pH,

FOCUS ON TECHNOLOGY

conductivity, and temperature values. At the exit of the pre-treatment tunnel, air blades favour draining before the blow-off and oven drying phases. The oven is equipped with an air vein burner guaranteeing excellent ventilation.” “Safim and Pieffeci paid particular attention to the part hanging operation. Together with CMV, they industrialised a standard sub-hook and then customised some hook types to be selected according to the shape of parts. A “cluster” composition is therefore created, varying according to the workpieces to be painted. Because of their limited mass, the parts must in fact be hooked firmly in order not to swing while automatically rotated in the coating booth: the paint nebulisation air alone would be enough to make them move during

The SQLPaint system records all rework operations.

application. Moreover, the hanging system was conceived to also perform a masking

of two pressurised booths, with a 3-stage

owner Saimon Frati. “According to customer

function on some specific surface areas (e.g.

dry filtration device to which Pieffeci adds

requirements, the parts can be coated

interface flanges). The masking of individual

an additional non-woven fabric pre-filter,

with the primer only or with a complete

components is then completed after drying.”

replaced every 4 hours of activity, in order to

primer+top coat system. Between the

“The coating application area is composed

increase the service life of filters,” says CMV

application of the primer and that of the top

Research, Sustainability, Flexibility, and Safety since 1977 Safim was established at the beginning of the 1970s based on the entrepreneurial initiative of two boys in their early twenties, Eronne and Omer Mamei, with vast mechanical knowledge and unbridled passion for the braking systems of earthmoving and agricultural machinery. Encouraged to start a business by their family, they decided to design pumps for such braking systems and present them at a trade fair. This started an adventure that within a few years gave birth to Safim, a company specialising in braking systems for off-highway vehicles, which has grown over the years up to achieving a turnover of 28 million Euros and a staff of 170 employees in 2017. “We work for all the major international OEMs in the sector: CNH, John Deere, Claas, Caterpillar, Volvo, Komatsu, Kubota, and Liebherr,” says CEO Pietro Santoro. “We have 150 customers

and 4 business sectors: earth moving machines, agricultural machines, logistic handling machines, and other off-road vehicles such as road or airport sweepers. Our headquarters is our production plant in Modena (Italy), manufacturing brake valves and hydraulic components for offhighway vehicles, which account for 90% of Safim’s business. Hydraulic valves performing other functions in the vehicles on which they are mounted account for the remaining 10%.” “I like to call Safim a pocket multinational company,” adds Santoro. “We have commercial subsidiaries in the USA, Germany, and France, whereas in India we have a small production plant. We also have local distributors in China and Japan. Currently, we are the undisputed European leader in the production and marketing of braking systems for off-highway vehicles. Globally, we face the competition of four other big players in the sector, but we are also consolidating our leadership

in the USA thanks to the acquisition of important businesses with customers such as John Deere, Caterpillar, and JLG.” In 2017, Safim was acquired by the Milanese private equity fund Ambienta, which guaranteed and supported its further growth through major investments and organisational changes at the managerial level. Turnover grew to 55 million in 2019. “Having achieved the goals set for 2022 in advance, we revised our business plan increasing our target by 100 million Euros for the following four years, and thanks to the industrial partner which is the new owner of the company we will support this new expansion. The refernce is to the US group DexKo, with a 1.8 billion dollar turnover and 40 investee companies, which in turn is linked to the American private equity fund KPS. Our new challenge will be growth through acquisitions in order to become the global leader for hydraulics in the off-highway sector.”

international PAINT&COATING magazine - MARCH/APRIL 2020 - N. 62

SPECI AL PaintExpo

The pre-treatment tunnel.

The oven is equipped with an air vein burner.

about 70 minutes. The booths are equipped

area where the workpieces remain for

with an auto-recovery system to optimise

about 50 minutes. After the top coat

the thermal consumption of the system. The

The water-soluble coating system and the automatic colour change operation

application, the parts remain in a second

hot air exiting those passes through a heat

“Safim and Pieffeci preliminary selected

flash-off station for 25 minutes at 30 °C,

exchanger and transfers heat to the intaken

the coating products to be used through

followed by a final polymerisation phase

air. This allows reducing energy consumption

careful assessment of the solutions offered

in the oven at 60 °C, with a lead time of

by 30-40%.”

by the market,” indicates Piazzolla from

coat, we have included a 60 °C flash-off

One of the cluster compositions that vary according to the parts to be coated.

N. 62 - MARCH/APRIL 2020 - international PAINT&COATING magazine

FOCUS ON TECHNOLOGY

Pieffeci. “Safim was particularly interested

wildcard pump for special tints.”

during the execution of the programs.

in preferring any available solution with a

The coating management unit is made

Atomisation is performed through

low environmental impact. Therefore, the

with frames equipped with stainless steel

an automatic low pressure robot gun

new coating system had to be composed

short stroke diaphragm pumps with 1:1

(Sames Kremlin A35 Convenzionale type),

of water-soluble products. At the same

compression ratio (new Sames Kremlin

in order to guarantee the best finishes

time, however, Safim’s customer impose

01D140 type) and stainless steel tanks

with homogeneous thicknesses even on

particularly strict coating resistance

with 50 litre agitators; these can collect

very different, complex-shaped parts.

standards, often defined through

the three primers, the related catalyst

“The colour change operation is

specifications and rigorous homologation

and the solvent, as well as the six finishing

automatic for both the primer and

processes. After a careful technical and

colours with their catalyst and solvent,

the top coat: the robot understands

functional screening of the available

and feed the two-component mixing and

when it is time to perform it, whereas

options, assessed by also considering the

dosing system. This is managed by two

the SQLPaint system knows the

pre-treatment system, the choice fell on a

last generation 2K machines, one for the

time required for the operation and,

water-soluble system supplied by Inver, a

primer and the other for the top coat,

therefore, the space to be left between

brand of the Sherwin-Williams Company,

featuring gear pumps driven by brushless

one load bar and another during loading

including a 2K epoxy primer from the

motors. This solution enables Safim to

in order to minimise production losses,”

Idroxinver/03 series and a 2K polyurethane

achieve great flexibility and quick colour

explains Renato Piazzolla. “The colour

top coat from the Inverpur series. The

change times with minimum paint waste

change phase takes about 1.5 minutes:

primer and top coat management units

and very limited consumption of cleaning

therefore, it suffices to leave two empty

are identical: they both have three feeding

solvents, combined with the possibility

load bar spots must between one colour

circuits for the most used colours and one

to instantly manage the coating flow

batch and the other.”

SPECI AL PaintExpo

Workpiece masking.

According to customer requirements, the parts can be coated with the primer only or with a complete primer+top coat system.

the solvent-based ones used by our

states Pietro Santoro. “I am convinced

The Safim plant was the result of great

coating contractors. We have also gained

that everyone must do their job: it is

teamwork among Safim, CMV, HUBO,

remarkable production flexibility. We

better to outsource a whole service to

Sames-Kremlin, and Pieffeci, starting from

are very pleased with our decision to

a contractor with specific knowledge,

the part hanging system designed by

outsource this process to Pieffeci and,

rather than trying to hire someone with

Pieffeci and industrialised together with

consequently, with their choice to rely

the required skills, with much longer

CMV. “The creation of this plant lasted a

on CMV and HUBO as our suppliers,”

operating times.”

year,” states Paolo Cornacchia. “The first phase, devoted to the definition of the

Teamwork

process and production parameters, was followed by the analysis of the various plant solutions offered by different suppliers. We chose CMV because its solution was the most technically and financially suitable for Safim’s production needs, which we had summarised in the technical specifications used by the plant designers to develop their proposed project. After ordering the plant, Pieffeci kept cooperating with the selected plant engineering firm for the construction site, start-up, and post-sales management.” “This plant has brought us significant benefits in terms of both coating quality and eco-friendliness, since we use a water-soluble system with a reduced environmental impact compared with

The coating management unit.

N. 62 - MARCH/APRIL 2020 - international PAINT&COATING magazine

Master RemoverÂŽ 7000 A superior approach to paint removal

Ő&#x201C;Ő&#x201C; oohÄˇ u-1h -m7 CÂ&#x160;|Â&#x2020;u; r-bm| u;loÂ&#x2C6;-Ń´ ruo1;vv =ou roÂ&#x2030;7;u r-bm|v

Features and benefits â&#x20AC;˘ b]_Ń´Â&#x2039; ;==;1|bÂ&#x2C6;; r-bm| u;loÂ&#x2C6;-Ń´ ruo1;vv =ou - Â&#x2C6;-ub;|Â&#x2039; o= roÂ&#x2030;7;u r-bm|v â&#x20AC;˘ omĹ&#x160;-tÂ&#x2020;;oÂ&#x2020;v vbm]Ń´; r_-v; ruo1;vv

Master RemoverÂŽ 7000 was developed with the highest level of versatility in mind. Capable of operation in spray or immersion as well as off-line or in-line applications, Master RemoverÂŽ 7000 is a robust and rapid paint removal process for hooks, racks and fixtures. It is compatible with ferrous and light metals (aluminum, zinc, magnesium) and can be used in conjunction with proprietary filtration to extend solution life, offering a sustainable and flexible paint removal process.

Atotech Group +49 30 349850 info@atotech.com Global head office

atotech.com

ON THE ROAD TO ipcm

Â®

n. 62

international PAINT&COATING magazine - MARCH/APRIL 2020 - N. 62

La ﬁera leader mondiale per le tecnologie di verniciatura industriale World‘s Leading Trade Fair for Industrial Coating Technology

12 – 15 October 2020 Exhibition Centre Karlsruhe, Germany

www.paintexpo.com In collaborazione con: In cooperation with:

Agenzia per Italia, Spagna e Portogallo: Agency for Italy, Spain and Portugal: EOS Mktg&Communication Srl Tel +39 0362 503215 info@eosmarketing.it

SPECIAL PaintExpo

ANALYSIS

SPECIAL PaintExpo

110

Blasting with Stainless Steel Abrasives. Lifecycle Assessment of Abrasives: From Cradle to Grave

38 44

BRAND-NEW INNOVATION Graco Will Exhibit Complete Industrial Paint Kitchen at PaintExpo

52 54

BRAND NEW

72 76

BRAND-NEW FOCUS ON TECHNOLOGY

128 132

SUCCESS STORIES

136 140 150

SUCCESS STORIES A Hanging System to Improve the Efficiency of Coating Processes: Rostirolla Presents P25

FOCUS ON TECHNOLOGY

INNOVATIONS Optimising Painting of Plastic Workpieces: Economically Fulfilling Stricter Requirements for Quality and Sustainability

154

FOCUS ON TECHNOLOGY From Railways to Architecture, up to the General Industry: A Nano-Technology Pre-treatment Process Becomes Strategic for Product Resistance and Appearance

160

FOCUS ON TECHNOLOGY Higher Productivity for a Contracting Coating Line Thanks to the Integration of a High Temperature Infrared Gas Oven

FOCUS ON TECHNOLOGY A Digitised Cataphoresis+Powder Coating Plant Like a Tailored Suit for OMR Spa, a Manufacturer of Excellence in the Industrial Vehicle Sector

106

INNOVATIONS

SLA Industrie: A Last Generation Vertical System to Increase the Productivity of a Service Company in the Aluminium Profile Sector

INNOVATIONS TIGITAL® 3D Materials: Revolutionising Additive Manufacturing

INNOVATIONS UV Coatings and PVD Process, an Innovative Combination that Opens New Frontiers for Surface Finishing

Please Blast, Dip, Powder a 100 Times

FOCUS ON TECHNOLOGY Hannex Increases Painting Efficiency and Quality with ProMix PD2K

HIGHLIGHTS OF THE MONTH The Versatility of a Multifaceted Company: IBIX Srl’s First 20 Years of Business

INNOVATIONS Increasing Productivity, Reducing Emissions

PhoenixTM Company History

A Pioneering Nanotechnology Process Based on Phosphorus Compounds for Higher Corrosion Resistance. An Innovative Process Creates a New Payoff for VIV Group: Grow Up

124

HIGHLIGHTS OF THE MONTH Artisanal Quality in Highly Industrialised Coating Systems: Why Eurotherm Chose to Go Against the Tide

SUCCESS STORIES Transparent Information for A Simplified Management of The Coating Process 4.0

FOCUS ON TECHNOLOGY MS Srl’s Revolution in the Furniture Industry: Dense Phase Powder Coating also Effective on MDF

120

HIGHLIGHTS OF THE MONTH Tras-mec Srl: A New Management Focussing on Innovation and Quality

FOCUS ON TECHNOLOGY Product Industrialisation and Circular Economy in the Automotive Coating Field: A Possible Combination for IMR Industriale Sud, Thanks to an Innovative Automatic and Sustainable Paint Supply Technology

164

HIGHLIGHT OF THE MONTH HangOn Wins SEB Award for Best International Growth 2019

Dust-free blasting with GRITTAL®.

ANALYSIS

SPECIAL PaintExpo

Blasting with Stainless Steel Abrasives. Lifecycle Assessment of Abrasives: From Cradle to Grave Christian Hoﬀmann VULKAN INOX GmbH – Hattingen (Germany)

christian.hoﬀmann@vulkan-inox.de

By using stainless steel grit the environmental impact can be reduced significantly when compared with mineral blast abrasives. In addition, stainless steel abrasives substantially cut down on process costs and dust pollution.

N. 62 - MARCH/APRIL 2020 - international PAINT&COATING magazine

ANALYSIS

Sustainable blast abrasives can save energy

packaging material, transport and landfill space,

and costs. However, which media has proven

were also recorded but not taken into account

to be the best? The Dutch government agency

in this press report for simplicity. In this specific

Agentschap NL compared brown aluminium

case they exist equally for all blasting abrasives.

oxide and garnet sand with stainless steel grit

How do these significant differences come

GRITTAL . The entire life cycle was recorded,

about?

from raw material to waste. The result: The

Mineral abrasives like garnet sand or aluminium

corrosion protection industry can avoid

oxide are highly brittle and break every time they

thousands of tons of CO2 every year and save

hit the surface being shot blasted. In contrast,

several million euros.

angular stainless steel grit is much more robust

The life cycle assessment (LCA) is a technique

and only begins to break after many blasting

to assess environmental impacts associated

cycles. The result is a much lower level of grain

with all the stages of a product’s life, from

breakdown and abrasive consumption. The

raw material extraction through materials

stainless steel abrasive achieves significantly

processing, manufacturing, distribution, use,

more operating cycles and the very long service

repair and maintenance, and disposal or

life leads to a better ecological balance.

recycling.

For example, a specialist for interior coatings

of chemical tanks was able to reduce its

Energy demand and CO2 emissions

consumption from 85 tons of aluminium oxide

To measure this, it first makes sense to map

to 3 tons of stainless steel grit GRITTAL®. This

out the individual production chain of each

corresponds to a consumption factor of 28:1.

blast abrasive to draw up a lifecycle inventory

The current purchase costs for blasting abrasives

(LCI). In the LCI all environmental inputs and

alone dropped from € 70,000 to € 25,000!

outputs, for example, material and energy flows as well as emissions to air, water and land,

In addition to the advantageous environmental

are recorded. The second step determines

balance and economic efficiency, stainless steel

the blasting process and its energy demand.

abrasive offers further advantages.

A corrosion protection company that uses GRITTAL® stainless steel grit, but has worked

More reliable processes

with aluminium oxide and garnet sand

Due to the brittleness and rapid breakdown of

previously, provided all the necessary data.

mineral abrasives, there is a very rapid reduction

Here it became clear that the service life of the

in grain sizing. The broken-down grains have

blasting media had the greatest impact on the

to be removed from the process very quickly to

ecological balance.

keep the operating mix balanced and efficient. In contrast, wear to GRITTAL® occurs only very

For evaluation, the energy demand for the

gradually and the individual grains retain their

production of one kilogram of blasting media

shape and size for a long period.

was multiplied by its hourly consumption in the

Therefore, the operating mix of GRITTAL® is

blasting system. In this constellation, the brown

highly consistent and the blasting process can be

aluminium oxide required 782 Megajoules

easily controlled. The performance and results

(MJ) per blasting hour, the garnet sand 383 MJ

of the blasting process are completely reliable,

and the stainless steel grit GRITTAL® 102 MJ.

which is reflected in the consistent roughness

Converted into a carbon dioxide equivalent, the

and uniform appearance of the blasted surfaces.

aluminium oxide emits 48,5 kg CO2, garnet 30,5

kg and GRITTAL® 8,3 kg per blasting hour.

Blasting with almost no dust At the end of its life, every blasting abrasive turns

Other aspects, such as providing electrical

to dust. Due to the tremendously longer service

energy for compressed air and filtering, as well

life of GRITTAL® and its slow grain breakdown,

as the necessary things for disposal, such as

significantly less dust is generated for disposal.

SPECI AL PaintExpo

Lifecycle inventory (LCI) production chain.

Graph comparison Mj and CO2.

Analogous to the reduced consumption,

to GRITTAL®, the service life of the spare

of hot-dip galvanized steel before

the waste disposal was also reduced by

parts tripled.

coating, where the zinc layer is gently cleaned and enlarged, or the surface

82 tons.

preparation of cooking pots before

improves the working conditions for the

Also suitable for wheel blasting machines

operators and the cleanliness of the

Due to its wear-friendly operating

If a switch to centrifugal wheel

blasted surface. Rework is effectively

behaviour, stainless steel abrasives can

technology is possible, the

avoided and necessary checks of

also be used in centrifugal wheel blasting

environmental balance will improve even

roughness and cleanliness can be

systems if the parts have a simple shape

more. This is due to the fact that for

reduced to a minimum. Blasting nozzles

and are easily accessible for the abrasive.

every thrown kilogram of blast abrasive,

and blasting hoses also benefit from the

The centrifugal wheel technology enables

the energy demand is reduced by 20-30

absence of dust, because mineral dust in

the user to achieve significantly higher

times compared to air-blast system.

the operating mix is highly aggressive and

area outputs or quantities in the same

causes significant wear. After the switch

time. Examples include the sweep blasting

Interior blasting of chemical tanks.

N. 62 - MARCH/APRIL 2020 - international PAINT&COATING magazine

applying a non-stick coating.

The almost dust-free atmosphere clearly

Dust pollution with mineral abrasives.

BRAND-NEW

SPECIAL PaintExpo

WAGNER Expands Its Portfolio in The Automatic Liquid Coating Sector with a New, Universally Applicable AirSpray Gun The new automatic airspray gun TOPFINISH GA 1030 for industrial liquid coating convinces with excellent atomizing properties and a high-quality spray pattern. The universal unit for automatic applications is particularly low-wear, which reduces spare part costs and halves maintenance costs. This enables process-safe coating in continuous operation.

The TOPFINISH GA 1030 from WAGNER

In order to keep storage and investment

various base plates. Optional rear or side

impresses with its high reliability,

costs low, these and the needles are

connections support optimal movement.

minimal overspray and particularly low

identical to the spare parts of the manual

Several adapters are available depending

paint mist. Due to its modular design,

TOPFINISH airspray gun GM 1030P. The

on the type of mounting required and

the automatic airspray gun can be

TOPFINISH GA 1030 can optionally be

for robot mounting. In addition, there is

used for a wide variety of applications

supplied with several circulation variants,

a robot version with fixed needle stroke

for coating workpieces made of wood,

with and without flushing valve and with

without air valves.

appearance with high-quality surfaces is essential. “Thanks to a particularly large material passage of the nozzle, water and solvent-based media can be applied

metal or plastic where a perfect

just as easily as low to high viscosity materials and paints with a high solids content. Especially for coating with UV and highly abrasive materials, the automatic gun is available as TOPFINISH GA 1020 version with membrane seal - for switching times of less than 20 milliseconds and particularly fast position changes in the coating process,” explains Peter Neu, Senior Product Manager Industrial Solutions at WAGNER.

Modular design for all coating requirements The new gun can be converted into different variants in no time at all. Several air caps and nozzles are available for applying different paints.

The new automatic airspray gun TOPFINISH GA 1030 for industrial liquid coating.

N. 62 - MARCH/APRIL 2020 - international PAINT&COATING magazine

BRAND-NEW © Wagner Group

SPECIAL PaintExpo

The optimised, particularly durable packing and the specially coated needle support uninterrupted operation. “Even after one million switching operations, there were no leaks in the field test. Accordingly, the number of maintenance operations is considerably reduced. Thanks to the modular and service-friendly design, the wear and spare parts can then be replaced very quickly. This increases productivity and at the same time reduces maintenance and spare part costs,” says Peter Neu. For further information:

The automatic airspray gun can be used for a wide variety of applications for coating workpieces made of wood, metal or plastic.

www.wagner-group.com

Eﬃcient material use Overspray and thus material consumption are minimised by the optimised design of the air duct. This allows a transfer efficiency of up to 85 percent very precisely via a needle adjustment knob with micrometre screw. The gun is available with internal and external air regulation, via buttons on the gun or remote control. No matter which version of the TOPFINISH GA 1030 a user chooses: For a reliable coating process, the air supply to all variants of the new airspray gun is automatically interrupted during the coating process as soon as the needle closes.

Long maintenance intervals and low spare part costs Just like the manual TOPFINISH GM 1030P, the automatic TOPFINISH GA 1030 is equipped with a two-part nozzle consisting of nozzle head and nozzle nut, saving costs. In case of wear, only the nozzle head has to be replaced. All parts in contact with the material are made of durable stainless steel and the needle has an additional wear-resistant and low-friction coating.

Competence in Shot Blast Technology We offer new and second-hand wheel blast machines including conveyor and filter systems. Our range of products and services include: • Wear and Spare Parts • Repair and (remote) maintenance • Services … for wheel blast machines of other makes as well.

AGTOS

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

www.agtos.com

234-05/17-4c-GB

to be achieved. The material flow is regulated

BRAND-NEW

SPECIAL PaintExpo

Walther Trowal: Integration of the Rotamat into Digital Networks At the PaintExpo Walther Trowal presents the Rotamat system for coating of mass-produced parts with several new technical features. They facilitate the integration of this machine into digital networks, expand the range of coating applications and make its operation even easier.

systems or uploading them to the cloud,

Even, homogeneous coating thickness

plastic, metal or wood, the Rotamat

irrespective of who the equipment

New sensor technology and an

coaters have proven themselves

manufacturers are.

electro-pneumatic valve on the spray gun

numerous times. Based on various

With the integration of various pieces

permits Walther Trowal to precisely regulate

customer suggestions Walther Trowal has

of equipment into an industrie 4.0

the spray volume of the coating media.

adapted the Rotamat machine range to

environment Frank Siegel, the sales

This ensures that the precise quantity

today’s requirements.

manager for “coating technology” at

of coating material arrives at the work

Walther Trowal, expects numerous

pieces during the entire coating process.

Future-oriented communication

customer benefits: “With the new interface

The result: Even, homogeneous coating

Since manufacturing processes are

the Rotamat coaters can be easily

thickness and a high life expectation of the

increasingly integrated into digital

integrated into networked manufacturing

applied coating material.

networks, Walther Trowal will be

processes. It will allow us to provide higher

equipping its Rotamat systems

efficiencies along the complete coating

Intensive cooling

with a touch panel and integrated

process chain. And, of course, it will also

Some paint systems or coatings demand a

OPC-UA communication protocol.

allow the Walther Trowal specialists to

quick, sometimes abrupt, cooling phase of

This allows sending process data from

perform on-line trouble shooting.”

the work pieces after the coating operation.

various machines to higher level control

mass-produced small parts made from

When it comes to the precise coating of

The new Rotamat units, including the exhaust air filter, can be operated from a touch panel.

N. 62 - MARCH/APRIL 2020 - international PAINT&COATING magazine

The Rotamat is ideal for coating of mass-produced small parts, for example, made from elastomers (photo) or metal.

BRAND-NEW

ÂŠ Walther Trowal

SPECIAL PaintExpo

ÂŠ Walther Trowal

The tilting angle of the drum can be set at any value. The cover is opened mechanically.

For this reason, Walther Trowal has added a by-pass that, upon completion of the coating process, circumvents the heating unit and guides ambient air into the coating drum. This prevents the work pieces from sticking to each other, when they are discharged from the machine. The result: A higher ratio of finished work pieces in premium quality.

Safe filling of the pressure vessel To date, when working with solvent-based coating materials, the pressure vessel containing the coating material had to be disconnected from the material panel for the filling operation, because it could only be opened in the explosion-protected filling room. Since now the air is suctioned off before opening the lid, the pressure vessel can remain at the machine or on the weighing scale. This eliminates a complete operational step. For unloading of the finished parts a pneumatic cylinder tilts the drum downwards.

For further information: www.walther-trowal.de

SPECIAL PaintExpo

BRAND-NEW

Arsonsisi Launches New Coatings for UV LED Lamps: An Innovative Technology and a Sustainable Choice for Industrial Coating The industrial coating market is constantly searching for innovative solutions to meet the needs of high productivity and a reduction in process and management costs, with a special focus on environmental sustainability. For this purpose, at its R&D laboratories in Berlingo, Arsonsisi has recently developed a new line of coatings for UV LED (Light Emitting Diodes) lamp curing.

Coatings for UV LED lamps are 100% dry

lamps, which emit a spectrum with different

residue, i.e. they do not contain volatile

wavelengths.

- guarantee the option of placing several lamps side by side, obtaining continuous irradiation

organic compounds, water or solvents,

- crosslink coatings instantly

whereas crosslinking using UV LED lamp

UV LED technology offers many advantages

curing technology allows significant energy

over the use of traditional Hg UV lamps. For

savings to be achieved.

example, UV LED lamps:

UV LED lamps are used with excellent results

A UV LED lamp can also be combined, on

- do not emit ozone

for crosslinking inks, coatings and adhesives.

the coating line, with a traditional Hg UV

- are free from mercury and hazardous

The new UV LED lamp coatings by Arsonsisi

lamp - with mercury vapours - using “dual

substances

- last about 10 times longer.

are ideal for coating metal and plastic

cure” hybrid UV coatings.

- do not emit UV-B and UV-C rays

materials. They are widely used mainly in

Each UV LED lamp emits UV rays in the

- have low heat emission

cosmetic packaging, and in components

UV-A/UV-V area, using the emission of single

- are equipped with instant on/off switching

produced in large batches, such as bottle

LED diodes mounted in arrays.

- have adjustable power from 0-100%

caps.

UV LED lamps are monochromatic lamps

- have a partial irradiance width

(365nm, 385nm, 395nm and 405nm) with

- have very small dimensions that allow them to

www.arsonsisi.com © Arsonsisi

be easily inserted in production machinery

very low consumption, unlike traditional

For further information:

UV LED lamps.

N. 62 - MARCH/APRIL 2020 - international PAINT&COATING magazine

Example of application of coatings for UV LED lamps on bottle caps.

SPECIAL PaintExpo

BRAND-NEW

The New edrizzi® Type for Paint Shops with Low Initial Pressure edrizzi® developed a special type of edrizzi® dry separator: the edrizzi® combi.

Due to constant development in the edrizzi®

system, which has been built and retrofitted

absorption capacity and therefore long service

technical centre and in close cooperation

in the international surface industry since

life of edrizzi®.

with the industry, a special type of edrizzi

2003. The framework inside the new dry

The degree of separation of the patented,

dry separator evolved. edrizzi® combi was

scrubber is designed to meet the edrizzi®

original edrizzi® paint mist separators is up to

specifically developed for applications where

usual high degree of separation, when used

97%. Their absorption capacity of 100 kg/m²

high air volume hits small separation areas.

in applications with low initial pressure and

and more, depending on the type of surface

The new type consists of a 350 mm deep dry

high air volumes, such as paint shops of the

material used, remains unrivalled in dry

separator with integrated slow-down zone

automotive industry. Alternative cardboard

absorption.

for airflow and a 150 mm deep follow up

scrubbers with conventional filter materials

filtration. With a total depth of 500 mm the

such as paper mesh reach a tolerable degree

For further information:

type fits into the proven edrizzi® modular

of separation, but fail by far to reach the high

www.edrizzi.com

The new type edrizzi® combi with a particularly developed framework.

edrizzi® combi can be used in applications with low initial pressure and high air volumes, such as paint shops of the automotive industry.

ATEX Certified Oven Temperature Profiling System Safety • • • • • •

Certified for ATEX classified Zone 2 use Intrinsically safe Epsilon-x data logger (Group II Cat 3G) Ten points of measurement Thermal Barrier Protection (over 3.5 hours @ 200 °C) Custom designed range of thermocouples Regulatory compliant monitoring

Simplicity

New ation innov y et f a s &

• Easy to interpret PASS/FAIL graphical cure • Paint cure QA reports shared easily and efficiently • Local technical support, service and ISO17025 calibration - quick help if you need it

PhoenixTM GmbH www.phoenixtm.de info@phoenixtm.de +49 5731 30028 0

Karlsruhe 12-15.10.2020

The Graco Intelligent Paint Kitchen is a smart, modular, easy, and cost-eï¬&#x20AC;ective system that allows to monitor and control the paint mix room components without the use of a PLC.

INNOVATIONS: PRESENT&FUTURE

SPECIAL PaintExpo

Graco Will Exhibit Complete Industrial Paint Kitchen at PaintExpo Philippe Godbil Graco, Maasmechelen - Belgium

philippe.godbil@graco.com

N. 62 - MARCH/APRIL 2020 - international PAINT&COATING magazine

INNOVATIONS: PRESENT&FUTURE

Graco has addressed all these challenges by offering a superior and smarter solution. The Graco Intelligent Paint Kitchen is a smart, modular, easy, and cost-effective system that allows to monitor and control the paint mix room components without the use of a PLC. And if you’re thinking that this sounds complicated, it’s not. “The beauty of the Graco IPK is that it’s pre-programmed, which means that the user just sets the parameters to his preferences and he is ready to start painting,” adds Godbil. Let’s look through the benefits that this approach offers.

Superb results Firstly, the Graco IPK optimizes the balance and performance of paint supply and circulation system(s). Smoother pump operation, flow and pressure control lead to a perfectly finished end product. Constant pressure due to smart sensors, monitoring and adjustment ensures consistent quality, while the control of paint flow and pressure reduces paint shear and keeps paint in optimal condition.

Maximum eﬃciency The IPK monitors and controls pressure, flow rates, tank levels, and agitator speeds to ensure your system is operating at © Graco

Graco is introducing its Intelligent Paint Kitchen (IPK) at PaintExpo 2020, (12-15 October). It consists of a smart set of sensors, actuators, and control modules that communicate with each other to optimize the performance of paint supply and circulation systems. To demonstrate total paint mix solution during PaintExpo, Graco will have an IPK feeding ProMix PD2K proportioner, which in turn feeds ProBell rotary applicator that's installed on the robot.

peak efficiency. Plug and play hardware and ready-to-use software ensures easy installation, configuration, start-up, operation and troubleshooting. Its design is modular and scalable. It’s possible to start with pump control and gradually add components as user’s need and budget allow; from one to multiple stations. Moreover, maintenance and human intervention is brought down to a minimum; for example, flushing of the system is done in no time at all.

Under the slogan “Take full control of your paint

Product Marketing Manager. “For a start, it’s

Advanced control

room,” Graco is introducing its Intelligent Paint

difficult to keep up and running, and expensive

Real-time access to key paint circulation data

Kitchen (IPK) at PaintExpo 2020.

to maintain. As it offers limited control and

from inside and outside the paint mix room

“For too long, companies have struggled with

monitoring possibilities, it relies too heavily on

enables quick diagnosis of issues. What does

the significant challenges of a conventional

humans. Not surprisingly, the conventional

this mean in practice? For a start, remote

paint room,” says Philippe Godbil, IPD Finishing

paint room is not Industry 4.0 ready.”

monitoring. You can control all tasks and

international PAINT&COATING magazine - MARCH/APRIL 2020 - N. 62

SPECI AL PaintExpo

The Graco IPK gives an inexpensive way to take full control of the paint mix room.

functions of paint supply and circulation

hardware, adapt some parameters and it’s

How does it work?

system from outside the hazardous area

ready to go. It increases competitiveness,

“The Graco IPK consists of a smart set of

via an HMI. It’s possible to work with or

because investment and installation

sensors, actuators, and control modules

without a PLC; the IPK can be implemented

costs are much lower than a custom-built

that communicate with each other to

as a stand-alone self-controlling system

system.

optimize the performance of paint supply

or integrated with your PLC by a simple

and circulation systems,” explains Godbil.

‘handshake’. And all data can be visualized

Top productivity

These can be divided into pump control,

and stored, allowing to analyse and trace

With the IPK, paint circulation systems

tank control and overall (remote) control.

complete finishing process.

are operational at all times, informing and

Smooth pump control ensures consistent

adjusting when necessary. This reduces the

fluid pressure and flow rates, keeps

Reduced costs

risk of unexpected downtime; especially

pressure and flow stable and in balance,

The Graco IPK gives an inexpensive way

downtime caused by maintenance. The

and reduces paint shear. Key components

to take full control of paint mix room. It’s

system is always on and connected; it can

include a Paint Circulation Pump, Pump

possible to save on installation, operating,

run on its own and will continue to collect

Run/Stop Switch, Fluid Pressure Sensors,

programming, and paint costs. It’s thus a

data and adjust accordingly, even if PLC is

Back Pressure Regulator (BPR), and Electric/

highly cost-effective way to control your

down. The Graco IPK is also future-proof.

Pneumatic Transducer. All these are

paint room, especially when compared to

Connected via internet, the system is ready

connected to and monitored by the Pump

traditional custom-built systems. It requires

for Industry Standard 4.0 and has the

Control Module.

no expensive programming; just connect all

technology on board for IoT.

Tank control incorporates control of both

N. 62 - MARCH/APRIL 2020 - international PAINT&COATING magazine

INNOVATIONS: PRESENT&FUTURE

tank levels and agitator speeds, and keeps your fluids at level and in perfect condition. Key components here, all of

Applied solutions.

which are connected to and monitored by the Tank Control Module, are the Refill Pump and Remote Pump, Radar Level

System coatings from one source.

Sensors, Supply Tank, Production Tank, and Electric/Pneumatic Agitators. Overall (remote) control allows to control the paint mix room from outside the hazardous area and gives access to real-time key paint circulation data. Key components are the Supervisor Box, HMI Touchscreen, Variable Frequency Drive (VFD) and Power Supply.

IPK components in close-up The (literally) beating heart of the Intelligent Paint Kitchen is the E-Flo DC Paint Circulation Pump. This energy-efficient electric reciprocating piston pump delivers smooth pressure and flow rates to paint circulation system. Local control makes installation and operation easy; all its sensors easily connect to

the control module.

Best results. Traditionally, w we develop and produce all coating systems under one roof. Therefore, we do not merely provide you with all the important coating technologies, but also tailor them to your individual needs with regard to coating composition and optics. The advantages: Best material properties, consistent colour results (even with varying products and coating types) and the needs-based conﬁ guration of individual coatings – and all from one source. Thanks to its Ultralife Series ceramic coating, its sealed 4-ball lower can withstand the harshest materials, including waterborne paints.

New date. Same solutions.

www.freilacke.com

SPECI AL PaintExpo

The Pump Control Module is the connection point and power source for all pump control components.

The E-Flo DC is up to 5x more efficient

monitoring and control of the pump, and has its

switch to start and stop the pump

than an equivalent pneumatic pump,

own software to send instructions between the

without switching off the AC power to

lowering energy bills and saving money.

non-hazardous and hazardous areas. One

the DC motor.

It also eliminates icing, which leads to

Pump Control Module is needed for each

Fluid Pressure Sensors measure fluid

smoother pump operation and better

pump; it can be mounted on the pump or

pressure inside the paint circulation line.

finished products. A more consistent

remotely. The Pump Run/Stop Switch is

Two pressure sensors can be installed:

finish is also the result of less pulsation

mounted close to the pump and is the physical

one at the pump outlet and one close to the Back Pressure Regulator (BPR).

Integrated runaway protection protects

Both sensors connect to and are

the pump from premature wear and

and smooth, rapid changeovers.

controlled by the Pump Control Module.

prevents costly material loss. The

Fluid pressure can be read out on the

E-FloDC is approved for hazardous

Pump Control Module. The pump outlet

locations: Class I, Div 1, Group D, T3

sensor can be used to reduce pulsing

(North America); Class I, Zone 0, Group

at the pump outlet. The sensors can

IIA, T3 (Europe).

be activated to run in a closed loop

Thanks to its Ultralife Series ceramic

function.

coating, its sealed 4-ball lower can

The Back Pressure Regulator (BPR)

withstand the harshest materials,

maintains the back pressure in the paint

including waterborne paints. In

circulation system based on profiles set

addition, because the lower is

in the Pump Control Module.

completely sealed it can be used for

It’s easy to switch from production to

every pumping application in the paint

non-production profiles. Its function is to

mix room, including catalysed coatings.

ensure stable pressure at any time. This

So much for the heart; what about

results in less paint shear and maximum

the brain? This is the Pump Control

material life, while also increasing energy

Module, which is the connection point and power source for all pump control components. It allows advanced

Graco’s new generation 2K proportioner ProMix PD2K is based on unique technology of electrically powered and controlled positive displacement dosing pumps.

N. 62 - MARCH/APRIL 2020 - international PAINT&COATING magazine

savings. The Electric/Pneumatic Transducer converts a current input signal to

eosmarketing.it

INNOVATIONS: PRESENT&FUTURE

ProMix PD2K is particularly ideal for short pot-life materials, as it mixes the material close to the gun so the flush zone is significantly smaller.

control components. It sends instructions

pressure, based on a closed loop pressure

between non-hazardous and hazardous

feedback system. It closely controls output,

areas. The Refill Pump and Remote Pump

compensates for supply pressure variations,

Solenoid incorporates a pneumatic

and adjusts the BPR according to the required

controlled air valve that enables control of

target back pressure. The Refill Pump is an

the pneumatic Refill Pump. It starts the Refill

air-operated double diaphragm pump that fills

Pump when the fluid level in the production

the production tank from the supply tank, when

tank falls below a user-specified level, and

needed, and stops automatically when the fluid

stops the pump when the fluid level reaches

target level is reached. It includes a Reed Switch

the user-specified level. To detect and

for cycle detection.

communicate the fluid levels in the supply

The Tank Control Module allows advanced

and production tanks, contactless Radar

monitoring and controlling of tanks and is the

Level Sensors are installed. They generate

connection point and power source for all tank

an alarm if the minimum or maximum level

a linearly proportional pneumatic output

GLI SPECIALISTI DELLA SVERNICIATURA SABBIATURA e SGOMMATURA di telaistica in ferro

SVERNICIATURA CRIOGENICA per recupero di telai e ganci

SVERNICIATURA CHIMICA

per pezzi in alluminio e di design

SVERNICIATURA TERMICA per il recupero di telaistica in ferro

. sas

ProMix PD2K is field serviceable in less than 20 minutes, which means there’s no need for costly factory rebuilds like gear pumps.

www.pspsverniciature.it

SPECI AL PaintExpo

The ProBell’s compact size and small diameter make it ideal for spraying in tight spaces, while its light weight means it is suitable for lower payload robots.

Graco ProBell Rotary Applicator is designed to deliver a superior quality, high transfer eﬃciency and precision spraying.

is exceeded. Mounted on the supply and

our Graco ProMix PD2K proportioner,

high transfer efficiency and precision

production tanks are Graco’s Electric

which in turn feeds our ProBell rotary

spraying. Its compact size and small

or Pneumatic Agitators. They keep the

applicator that’s installed on the robot.”

diameter make the ProBell ideal for

paint mixed and homogeneous without

Graco’s new generation 2K proportioner

spraying in tight spaces, while its light

incorporating air into the fluid. Their

ProMix PD2K is based on unique

weight means it is suitable for lower

speed depends on the tank level and can

technology of electrically powered

payload robots. System complexity is

be varied with a Variable Frequency Drive.

and controlled positive displacement

further reduced – and safety enhanced –

The Supervisor Box is the communication

dosing pumps. The use of 100% positive

by its 100 kV power supply and low voltage

hub for the IPK. It links with your PLC

displacement technology allows accurate

cable connection. A stainless steel air cap

and contains the software to run the

mix ratios and consistent performance.

cover protects the bell cup and air cap.

IPK. One box can control up to 20 paint

It’s particularly ideal for short pot-life

Dual shaping air improves pattern shape

supply and circulation systems. Acting as

materials, as the ProMix PD2K mixes the

and transfer efficiency for better overall

remote interface between the IPK and

material close to the gun so the flush

finish quality. Configurations include

the operator is the HMI Touchscreen.

zone is significantly smaller. This allows

Hollow Wrist Robot, Solid Wrist Robot,

It displays all paint kitchen conditions

for faster colour changes, less material

Fixed Mount or Reciprocator Mount.

and settings and allows users to change

usage, and reduced disposal costs. In

parameters and preferences or install

fact, up to 80% reduction in flushing

Further information

updates, and schedule production and

waste is possible compared to the

Come along to the Graco booth at

non-production times.

most efficient traditional proportioning

PaintExpo (October 12 to 15, Hall 2,

systems. It also stalls under pressure for

booth no. 2424) and see for yourself

IPK integration with proportioner and applicator

consistent, on-ratio results (within 1%

the extensive capabilities of the Graco

accuracy), and is field serviceable in less

Industrial Kitchen, the ProMix PD2K and

“A fully equipped Industrial Paint Kitchen

than 20 minutes, which means there’s no

the ProBell Rotary Applicator. “Our paint

isn’t all that’s on display at the Graco

need for costly factory rebuilds like gear

specialists at our booth will be delighted

booth at PaintExpo,” explains Godbil.

pumps.

to answer any questions you might have

“To demonstrate Graco’s total paint

The Graco ProBell Rotary Applicator is

on these products and how they can fit

mix solution, we have an IPK feeding

designed to deliver a superior quality,

your specific application,” says Godbil.

N. 62 - MARCH/APRIL 2020 - international PAINT&COATING magazine

powder coatings 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

SPECIAL PaintExpo

Functional Coatings with Precise System Technology Sprimag has developed the appropriate equipment to respect the requirements of coating thickness distribution and layer thickness.

The demand for functional coatings such as

At PaintExpo (October 12-15, 2020, booth

a branch in the USA. The product range

anti-friction coating or corrosion protection

no. 1310) Sprimag will demonstrate some of

includes coating systems for functional and

has increased considerably in recent years.

these coating techniques live on automotive

decorative coating of serial parts on the one

Sprimag provides the appropriate equipment

components such as brake discs, bearing

hand and systems for internal coating and

for the various requirements of coating

shells and wheel bearings.

drying of metal packaging such as tubes, cans

thickness distribution and layer thickness.

and beverage bottles on the other hand.

About Sprimag Spritzmaschinenbau GmbH & Co. KG

The product range is supplemented by our

pre-assembled wheel bearings can be applied precisely. Components with complex coating

Sprimag Spritzmaschinenbau GmbH & Co.

and lacquer supplies.

requirements such as internal coatings are

KG designs and manufactures automated

also reliably coated with special extensions,

coating and painting systems. The company

For further information:

centrifugal guns or rotating extensions.

has its headquarters in Kirchheim-Teck and

www.sprimag.com

ÂŠ Sprimag

Even partial coatings such as those used for

Anti-corrosion coating on a Chain-on-Edge coating machine.

N. 62 - MARCH/APRIL 2020 - international PAINT&COATING magazine

own application technology as well as paint

BRAND-NEW

SPECIAL PaintExpo

Sustainable Treatment of Industrial Wastewater - H2O GmbH at the PaintExpo 2020 ÂŠ H2O

H2O GmbH presents VACUDEST vacuum distillation system, a high quality rinsing water treatment that saves costs.

H2O will present VACUDEST at PaintExpo 2020 at its booth 1611 in hall 1.

Due to increased demands on painting technology manufacturers are faced with economic challenges. The answer of H2O GmbH: A high quality rinsing water treatment that saves costs! The experts for wastewater-free production will explain how this can be achieved at PaintExpo 2020, the worldâ&#x20AC;&#x2122;s leading trade fair for painting technology, which will take place from 12 to 15 October, 2020 in Karlsruhe, Germany. On site, H2O GmbH from Steinen in Baden presents its VACUDEST vacuum distillation systems. How exactly the technology works and for whom the use of the system is significantly worthwhile, will be explained by H2O GmbH at their booth 1611 in hall 1. Leading companies already rely on VACUDEST vacuum distillation systems for the treatment of used rinse water. The quality of the treated rinse water sets high standards thanks to patented innovations. For example, the Clearcat technology produces crystal clear, oil-free distillate, which enables excellent cleaning results in surface technology processes. It is ideally suited for a reuse in the process and thus reduces disposal costs enormously. Companies with an annual wastewater volume of 200 to 30,000 cubic meters can benefit from the highest savings potential. Wastewater from a wide variety of manufacturing processes can be treated, such as paint pre-treatment, degreasing, electroplating, stainless steel pickling and many more. For further information: www.h2o-de.com

segr@italgard.it - www.italgard.it

An overhead conveyor built by Tras-mec.

HIGHLIGHT OF THE MONTH

SPECIAL PaintExpo

Tras-mec Srl: A New Management Focussing on Innovation and Quality From an interview with Claudia Zanelli Tras-mec Srl (Casalromano, Mantua, Italy)

During an interview with ipcm®, Tras-mec Srl CEO Claudia Zanelli told us about the story of her company, the generational change that took place a few years ago, and the new course of the company. Tras-mec is a company specialising in the

sector, especially in the design and

Tras-mec Srl nowadays

design, construction, and installation of

production of conveyors for internal

The experience gained over the years in

systems for handling parts on production

handling operations. Tras-mec is now a

the internal handling sector has made

lines. Silvio Zanelli established it as a

leader in its industry: it has a 2000 m -

this company, based in Casalromano

metal carpenter’s shop in 1978. 1984

wide plant, manufacturing customised

(Mantua, Italy), a benchmark in the

was a turning point: the firm began to

systems in a short time and with a high

industrial automation field, able to offer

specialise in the industrial automation

quality degree.

customised solutions as well as assistance

N. 62 - MARCH/APRIL 2020 - international PAINT&COATING magazine

HIGHLIGHT OF THE MONTH

and maintenance services. Its corporate structure

working here in 2012, when our father asked us

and flexibility enable it to produce custom-made

to support him, and we have learned as much as

handling systems while always meeting the

possible from him for a year and a half. Actually,

deadlines agreed with its customers.

thirty-six months are not a long time, especially for two women approaching the metalworking

ipcm : How has the company evolved over

sector. However, we have worked hard to be

the years?

able to run this company. I am the CEO while my

CZ: Tras-mec has always operated in two separate

sister Daniela is a technician: she takes care of the

industrial sectors: coating and meat slaughtering.

design of the systems.

In the last few years, we have specialised in the

The first challenge arose from my different

design of conveyors for the industrial coating field.

point of view. I had, and still have, a much more

We produce any type of conveyor and, thanks to

innovative perspective. Tras-mec now focusses on

our technical department, we are able to meet

efficiency and innovation, although these are not

any requirement. We mainly focus on conveyors

always easy to achieve. It is difficult to innovate

for small to medium-sized businesses, with plants

layouts and components while guaranteeing

up to 600-700 metres in length and with a loading

absolute efficiency, when you also have to comply

capacity of 3000-3500 kg. Besides conveyors,

with your customers’ specifications.

we also manufacture automatic elevators and

Our customers are mainly installers, but we also

pneumatic systems for side shifters. We produce

carry out a maintenance and/or revamping service

any type of accessory for the handling sector.

on existing plants.

ipcm®: What happened to Tras-mec following

ipcm®: With what kind of business are

the generational change?

Tras-mec’s customers faced?

CZ: After our father’s death in 2014, my sister

CZ: This is certainly a young and dynamic

and I took the reins of the company despite

business. When I took the lead, we were fourteen

neither of us had studied for this job. We started

people. We now have seventeen employees.

P25 system

fewer components to handle tested and always clean joint

fewer parts to be stripped robust and easy to position

HANGING SYSTEMS

COMPLETE SOLUTIONS FOR HANGING AND MASKING

Tras-mec manufactures internal handling systems with a loading capacity of 3000-3500 kg.

www.rostirolla.it

SPECI AL PaintExpo

A detail of a Tras-mec internal handling system.

A detail of a conveyor’s hook.

Our oldest employees, who already worked

My ambition is to focus on our company’s

We design our conveyors with SolidWorks and

with my father, have remained and they are the

know-how and make it known to the surface

we rely on engineers to carry out constant

cornerstones of Tras-mec: we could not have

treatment industry. Indeed, we have been

checks on components and designs. Specific

grown so much without them. Under the new

operating in this sector for over forty years:

technical inspections set us apart. We also

management, however, a few young people

we are perfectly aware of the problems that

manage to be very flexible with our customers:

have joined them. My goal is to revolutionise

customers might encounter and we have

being a growing company, we need to make

the obsolete owner-employee relationship

everything we need to solve them.

ourselves known – and the best way to do this

by favouring a less hierarchical and vertical

is to fully satisfy our customers.

approach. I would like to create a team that

We must focus on our know-how and invest

collaborates and works together in order to

in promotion. We are going to participate

offer all-round assistance to our customers.

in PaintExpo 2020 (October 12 to 15), the world’s leading trade fair for industrial painting

ipcm®: Are there any plans in sight?

technologies: we will be at Stand 1152 (Hall

CZ: We are currently working on several

1). We decided to participate in this exhibition

projects that we aim to complete by the end of

mainly because we want to take advantage of

the year and we are gradually adapting to the

the opportunities it offers for meeting both

Industry 4.0 principles.

potential and existing customers. We have an ace up our sleeve and we are working on our stand project together with a team of experts.

ipcm : How does Tras-mec present itself ®

on the market? CZ: The previous management had never

ipcm®: What do you expect for 2020?

really focussed on marketing. In the last

CZ: I firmly believe that it will be a very

few years, however, the market has evolved

interesting year. We have already received

and we realised this had to change. A new

several orders, but we are also working on a

generation took over, and the technological

few innovations in terms of both service and

expertise gained in forty years of activity had to be communicated to the market.

conveyor design. We are investing heavily in Claudia Zanelli.

N. 62 - MARCH/APRIL 2020 - international PAINT&COATING magazine

these developments.

N. 62 - MARCH/APRIL 2020 - international PAINT&COATING magazine

FOCUS ON TECHNOLOGY

SPECIAL PaintExpo

MS Srl’s Revolution in the Furniture Industry: Dense Phase Powder Coating also Effective on MDF Monica Fumagalli ipcm®

MS Srl, a company founded by Sauro Macrolei in 1979, designs and manufactures wooden furniture components distributed all over the world. Specialising in the processing of MDF, this firm has recently installed a powder coating booth with Nordson’s dense phase technology, supplied to it by Siver, the exclusive Italian distributor of Nordson. The coating quality results are amazing and they will open the doors to the use of MDF panels in the furniture sector.

Medium-Density Fibreboard (MDF) is

optimisation of the pre-heating (if required)

with market trend changes, which

one of the most versatile materials

and curing cycles with the IR technology

are more frequent in the furniture

derived from wood. Introduced in Italy

are now making this technique relevant

sector than in other fields. However,

in the 1970s to make up for the lack

again. In particular, the development of

one goal has never changed: showing

of raw material due to deforestation,

dense phase application equipment and

to our customers the advantages of

it has become widespread above all

the coating quality level it guarantees

applying powder coatings on MDF

in the furnishing sector, especially for

have led MS Srl (Osimo, Ancona, Italy),

panels, which we were among the first

shelves, platforms, furniture, doors,

a European leader in the research and

companies in Italy to recognise. The

chairs, and tables. MDF powder

development of MDF powder coatings, to

development of ever more efficient

coating, introduced about twenty

return to focus in this material.

epoxy powders and of advanced

years ago, has never conquered

application technologies has enabled

the market despite its undoubted

“MS has always believed in the resistance,

us to reach a high quality level and,

advantages: it is sustainable (powders

eco-compatibility, and versatility

above all, consistent results, which

do not generate any VOC emissions)

characteristics of MDF and in the quality

was the main challenge faced in the

and efficient and, above all, it could

results that could be obtained by powder

early years of studying this application.

open up several new applications for

coating it,” states Andrea Macrolei, the son

Eventually, the increased demand for

MDF in the mid-range furniture sector.

of the owner of this company, whose long-

powder coated MDF panels eventually

However, powder coaters treating

standing R&D activity in the field of MDF

pushed us to renew our paintshop to

MDF panels can still be counted on

power coating was described in an article

create the best conditions for facing

the fingers of one hand all over the

published in our magazine in 20131. “In

any future demand peaks.”

world.

the seven years passed since our previous

MS chose to install a new powder

This is due to the technical difficulties

meeting,” says Macrolei, “MS has further

coating booth to replace its previous

associated with painting such a

grown by diversifying its production as

two machines. It turned to Siver Srl

non-conductive and heat-sensitive

much as possible in order to optimally cope

(Corciano, Perugia, Italy), a firm

material. However, the development of powder application technologies, the formulation of low-curing temperature powders, and the

designing and manufacturing coating 1 F. Stucchi, “MDF powder coating: MS Macrolei celebrates 10 years of success”, in ipcm International Paint&Coating Magazine no. 23 (September/October 2013), pages 42-48.

systems that has been the exclusive distributor of Nordson in Italy since 2015.

Dense phase powder application on MDF panels.

international PAINT&COATING magazine - MARCH/APRIL 2020 - N. 62

SPECI AL PaintExpo

A detail of MS’ paintshop.

MS selected the dense phase powder

“The main difference between our

application technology that Nordson is

competitors and us,” indicates Macrolei,

offering since 2004.

“lies in the fact that our company was established in 1979 as a carpentry shop:

Powder coating: MS’ competitive advantage

our experience as woodworkers has always

“Since when we decided to invest

to be coated and select the ones with the

in MDF powder coating in 2005,”

most suitable thicknesses and shapes for

states Macrolei, “we have faced and

their final use.”

helped us thoroughly check the materials

overcome considerable difficulties,

One of two manual guns Encore® HD.

especially the problem of finding

Paintshop revamping

a MDF panel suitable to powder

The old booth had to be replaced due to

coating. However, MS has continued

the need to speed up process times and,

to experiment and fully believe in the

therefore, increase production capacity, as

potential of this process: this has been

well as improving the appearance of the

our strength, in the last few years.”

applied film. “Our previous coating plant

Indeed, MS has been able to establish

was not flexible enough to meet our new

itself as a benchmark in the MDF

production needs,” says Macrolei. “We

powder coating field, thanks to the

therefore tested the booths of several

origins of its business and the know-

manufacturers. In the end, our choice

how acquired during the fifteen years

fell on a machine from the SILVER Booth

of development of this technology.

series created by Siver in partnership with

N. 62 - MARCH/APRIL 2020 - international PAINT&COATING magazine

FOCUS ON TECHNOLOGY

side. It is equipped with the powder feed

phase manual guns Encore® HD, in

centre Top Color Change Dual, launched

order to dispel any doubts about the

about two years ago by Siver. Combined

performance degree of this technology at

with the Nordson dense phase technology,

high temperatures, as we can reach

it can switch from one colour to another

42 °C in our region, in the summer

in 90 seconds by performing the colour

months. Then, in December, we installed

change operations during coating, with

the new booth, integrating it in our

virtually no downtime. This characteristic

department equipped with a pre-heating

is crucial for the efficient management

oven with gas IR panels used before

of batches for which powder recovery is

coating and an IR curing oven for the final

not worthwhile. The innovative system is

process stage.”

based on the presence of two fluidised

“This PVC booth,” explains Siver CEO

containers: while one is operating, the

Luca Tomassoni, “includes a workstation

other can be cleaned to prepare for

for manual pre-retouching operations,

the next colour, thus avoiding that the

followed by the automatic application

downtime for booth cleaning lasts too

process with six Encore® HD guns per

long, thanks to the advanced pneumatic

Nordson. We first tested two dense

COMPLETE SOLUTIONS for

HANGING and

MASKING

The inside of the coating booth. October 12-15, 2020- hall 2 - stand 2520

www.rostirolla.it

SPECI AL PaintExpo

The powder feed centre.

One of the two fluidised containers of the powder centre.

exchanger that can switch from one tank to another

panel and caused overspray. In addition to product

in a few seconds. In MS’ cycle, this operation lasts on

savings, the improvements in the finishing results are

average 60-90 seconds, including gun blow-off. Another

visible to the naked eye: better powder film, reduced

feature of the new booth is an innovative gun control

orange skin effect, greater coverage, and more compact

system. Compared with conventional ones, it is a digital,

coating layers even to the touch. In short, the use of

modular, automatic device, which is simple to use, has

the dense phase technology to paint MDF guarantees

pneumatic and electrostatic operating parameters with maximum precision. It also allows adjusting electric

low energy consumption levels, and enables adjusting

current intensity down to decimals, even down to microamperes.”

Dense phase application: advantages with MDF panels The advantages of dense phase powder coating are now well known and they have been extensively described in our magazines. For the first time, however, MS has obtained surprising results also on MDF. “We opted for this technology because we appreciated the way in which the powder is treated and then applied on panels: the powder cloud reaches the substrate in a more delicate way, thus favouring adhesion. This is a decisive step forward compared with old conventional guns, which used to spray a considerable amount of powder that actually moved the one already on the

N. 62 - MARCH/APRIL 2020 - international PAINT&COATING magazine

Gun control interface.

FOCUS ON TECHNOLOGY

an aesthetic result similar to that of lacquered panels with a textured effect, which should be valued rather than denigrated.” “Such lighter powder jet,” explains Tomassoni, “is created by the minimum pressure guaranteed by speed reduction. Speed is equal to one third of that of Venturi devices; it also remains constant over time. The system works over a very long time, up to 4,000 hours, without any need of maintenance. The guns maintain the same flow rate and the same speed over a long period, in order to avoid the risk of product decay and help further save paint products.” One of the most innovative elements of the

Nordson dense phase technology is the

Ready for savings – with optimized powder coating process Advanced spray system technology for greater productivity and operating efficiency delivers top performance at the lowest operating cost. Meet our powder coating application experts at Surface World Show and learn more about the Nordson solutions for future-proof powder coating operations •

Data collection and analysis

•

Remote connectivity

•

IOT readiness

This and more is delivered by the next generation of Nordson powder coating system controls in combination with the highst level of the process control offered by the Encore HD spray systems. Get in contact with Nordson today for more information.

ics.eu@nordson.com www.nordson.com/powder

Encore HD Pump Cabinet with HDLV Pumps.

Performance by design

SPECI AL PaintExpo

The PVC booth’s floor, with central suction and integrated blow-oﬀ systems.

Luca Tomassoni (left) with Andrea Macrolei.

uniformity of its coating film.

regards the choice of powders,

establishment of this technology in

“It guarantees powder deposit

which must guarantee the highest

our sector is still long, but we hope

consistency down to micrometres,”

possible quality degree.”

to have opened a breach in the wall of preconceptions spread about this

adds Tomassoni. “We have

application system over the years.

reaching a δ value of 5 microns with

The future of MDF powder coating

100-micron film thickness. We have

“Thanks its reduced speed and

and Nordson, which have strongly

managed to apply film-thickness up

very low amperage intensity

believed in this project, MS can now

to 140 microns without finding any

characteristics,” states Andrea

continue its R&D activity to promote

defect.”

Macrolei, “the dense phase

its finishes and disseminate

Due to the different densities of the

application technology with

knowledge about the potential of

fibre within the panel, one of the

the HDLV pumps of the Encore

MDF powder coating in the indoor

most significant challenges of the

HD Spray System guarantees

furniture sector in general and in

MDF powder coating process is the

uniform thicknesses, avoids edge

the children’s room, recreation, and

coverage of edges. “If the paint is not

overloading, and offers exceptional

school fields in particular. Indeed, as

applied perfectly, the difference in

distension results, also thanks to the

mentioned, it produces completely

density on the edges is immediately

absence of air. All these factors lead

non-toxic coated panels, with zero

noticeable,” says Andrea Macrolei.

to amazing finishing results, both

environmental impact, as well as

“Therefore, we are trying to perfect

technically and aesthetically. Finally,

very resistant and easy to process

our cycle especially considering this

powder coating allows managing

thanks to the material they are

aspect. We are very familiar with the

orders with a just-in-time system

made of. Our sector is increasingly

two-coat system that we have been

thanks to the short duration of its

attentive to these issues. We are

applying so far; with our new booth,

application cycle, which is difficult

sure that it will not be long before

we are assessing the possibility of

to achieve with other types of

it sees the validity of this solution,

using a one-coat system. The results

products.

which MS was once again the first

are still being optimised, also as

“We are aware that the road for the

company to test out.”

performed numerous tests,

N. 62 - MARCH/APRIL 2020 - international PAINT&COATING magazine

Thanks to the collaboration of Siver

Eurotherm’s headquarters in Volpiano (Turin, Italy).

HIGHLIGHT OF THE MONTH

SPECIAL PaintExpo

Artisanal Quality in Highly Industrialised Coating Systems: Why Eurotherm Chose to Go Against the Tide From an interview with Paolo Ghiazza Eurotherm (Volpiano, Turin, Italy)

paolo.ghiazza@eurotherm.eu

In the plant engineering sector in general and in the coating field in particular, the term “industrialisation” often has a negative nuance, as it seems to indicate a standard product that cannot be adapted to the requests of individual users. Eurotherm has shown that it is possible to industrialise the production of coating systems without losing sight of clients’ needs, thus managing to customise each plant and meet even particular requests by paying attention to details in each production phase.

N. 62 - MARCH/APRIL 2020 - international PAINT&COATING magazine

The word “industrial” is often considered the opposite of “artisan”, as it is believed that the result of an industrial

HIGHLIGHT OF THE MONTH

process cannot maintain the care and flexibility levels that are typical of handcrafted products. It is indeed difficult to find a compromise between these two elements. However, Eurotherm (Volpiano, Turin, Italy), a company specialising in the design and construction of complete coating lines for over fifty years, has managed to do it, thus giving a new meaning to the term “industrialisation” as the “evolution of artisan know-how”.

Over half a century of history: Eurotherm’s growth “Our corporate history,” explains Eurotherm CEO Paolo Ghiazza, “started in 1958, when this company, founded by

The metal carpentry department.

three brothers, started manufacturing industrial ovens. In 1983, a type of plants that the two firms would not have been able to

manufacturing industrial coating systems. Finally, in 1990, the

build individually. “Thanks to this merger, strongly desired by both

current management acquired the company, but it maintained

companies, we have been able to offer a wider range of systems,

coating plants as its core business. The real turning point

thus conquering difficult-to-penetrate markets and joining the

occurred in 2005 with the merger of Eurotherm with Riva Italia

small circle of European coating system manufacturers.” Another

(Verona, Italy), a company specialising in the design of large-

important stage in the growth path of Eurotherm was the opening

sized and high-engineering level coating machines.”

of its first agencies in Toulouse (France) in 2015 and in Stuttgart

The combination of these two expertises, one focussed on

(Germany) in 2016, as these countries are its main target markets

design and one on production, led to the development of

besides the Italian one.

a new owner took over and converted the activity into the

The coating department.

international PAINT&COATING magazine - MARCH/APRIL 2020 - N. 62

SPECI AL PaintExpo

The headquarters’ oﬃces.

The insourcing of the coating process

sectors through Colortec1, a company owned by

Simultaneously with its commercial evolution over the

Eurotherm. We can now provide our customers with

last decade, Eurotherm has gradually developed and

plants that not only present high-level engineering

expanded its production structure by insourcing some

and operational peculiarities, but are also aesthetically

of the most important stages in its work flow. “This

pleasing, an aspect not to be underestimated because it is

choice,” says Ghiazza, “was motivated by the critical

our best introduction.”

issues we were encountering with some outsourced

The insourcing of its coating operations brought several

phases, especially coating. Few coaters were able to

benefits to Eurotherm: higher coating quality, significant

properly treat our material due to the large size of

lead-time reduction (from fifteen to two working days),

our components, which can reach 8 metres, and to

and simplification of the packaging phase. It now occurs

improve their aesthetic and functional performance. The

directly in the painting department, as a further guarantee

insourcing of our coating department began in 2011.

of the optimal conditions in which the products reach

Despite a rough start, we managed to reach full capacity

their destinations.

quickly, so much so that, currently, it no longer only treats our systems’ components, but is also offers a coating contracting service for parts mainly intended for the machine tool, furniture, and outdoor architecture

N. 62 - MARCH/APRIL 2020 - international PAINT&COATING magazine

M. Fumagalli, “The key role of sheet metal preparation in the manufacture of coating systems and outdoor structures” in ipcm International Paint&Coating Magazine no. 49 (January/February 2018), pages 82-91.

HIGHLIGHT OF THE MONTH

Insourcing all the main production stages: Eurotherm’s winning choice

decision was again motivated by our need for higher-

“Following the benefits obtained with the insourcing of our

clean and, therefore, kept away from other metals that can

coating process,” says Ghiazza, “we decided to also insource

contaminate it, it can lose its performance qualities and

all other operations, in order to achieve total control of our

even rust.”

quality surface treatments: if stainless steel is not kept

production flow. Therefore, in 2017, we acquired a new

The Eurotherm team

department, equipped with integrated, Industry 4.0-oriented

Eurotherm now has two factories: the 3500 m2-wide

machinery. The department became fully operational in late

headquarters, housing all offices and the carpentry and

2018. In the wake of these successes, last year we took a

coating departments, and the new building acquired in

further step by insourcing our carpentry processes.”

2017, where the sheet metal processing, assembly, storage,

These strategic choices have enabled the company to

and shipping operations take place. “82 people work at

consolidate its presence at both the national and European

Eurotherm,” indicates Ghiazza. “26 of them deal with our

levels: in 2018, it installed 150 coating plants all over the

coating processes, while the rest is divided between the

continent. “We could not stop there,” states Ghiazza. “The

technical office and the production departments. Another

last insourcing project started this year concerned the

against-the-tide decision we have taken is to directly hire

processing of stainless steel, which we use for structures

the operators who make up our seven assembly teams, all

in contact with more or less aggressive liquids, such as

composed of experienced, highly specialised, and

cleaning tunnels and water-based coating booths. This

well-trained people. Finally, I would like to point out that one

5300 m2-wide plant to house a sheet metal processing

The assembly of components.

international PAINT&COATING magazine - MARCH/APRIL 2020 - N. 62

SPECI AL PaintExpo

third of our employees are under the age of twenty: our

now be obtained from systems 4.0, our goal is now to create

company has always invested in young people, so much so

systems that can reduce waste production and energy

that in 2019 we hired ten graduates of a vocational school,

consumption, especially in terms of electricity and gas.”

who became excellent operators within six months. This is

The latest cutting-edge coating line solutions developed by

a way to guarantee continuity to our organisation, which will

the Eurotherm team will be presented at PaintExpo 2020

remain composed of young, yet experienced people also in

(Karlsruhe, Germany).

future.”

Conclusions The market has positively welcomed the new production

The company started to produce automatic coating lines

organisation that Eurotherm has built up in the last few

capable of interfacing with their operators and their users’

years. “Our customers,” says Ghiazza, “are positively

management systems in 2015, when the definition of

surprised by the industrial structure we have given to our

“Industry 4.0” was not yet known. “We provide the same

processes, which are typically performed as craft operations.

automation level that we require from the machinery we

We are able to meet any customisation request while

install on our premises,” states Ghiazza, “with the aim of

providing excellent-quality, highly industrialised plants. This

managing a large number of orders in a short time and

is further proof that our against-the-tide decisions can open

with little labour thanks to the traceability of the whole

up development opportunities even in an “artisanal” sector

production cycle. Given the high amount of data that can

such as that of the production of coating systems.”

Eurotherm and Industry 4.0

The sheet metal working department.

N. 62 - MARCH/APRIL 2020 - international PAINT&COATING magazine

we keep an eye on your AUTOMATION needs. vertical&horizontal axis reciprocators | color centers | dimensional detection systems | control panels | accessories

i gent e a i s r a cerc one libe z per

www.reind.it

BRAND-NEW

SPECIAL PaintExpo

Superdurable Powder Coatings for the Agricultural Sector Ecopolifix has always been sensitive and careful to the demands of the market and is constantly developing powder coating solutions that guarantee high outdoor resistance and increasingly ambitious performance.

Recently, Ecopolifix complemented its product portfolio with a new

In addition to various technical advantages of standard super durable

super durable polyester series – specially developed for the ACE

paints, the super durable polyester is an even more environmentally

(Agricultural, Construction and Earthmoving) sector: The pure polyester

friendly solution by offering a significant reduction of CO2 and fuel

(HAA-polyester) powder cures at low temperature and offers a valid

consumption and causes practically zero VOC emissions.

alternative to traditional super durable polyester systems hardened with

Super durable polyester powder can also be used for aluminium windows,

TGIC or TGTMA (PT910). Due to its excellent UV resistance and other

facade elements, cars components and other metal objects that require

properties, the new series is particularly suitable for the application

excellent resistance to intense UV radiation, high degrees of humidity,

on large machinery in the agricultural, construction and earth-moving

temperature changes and adverse weather conditions.

sector. The products of these series are compliant with Qualicoat Class

Contact our experts at PaintExpo 2020 (October 12 to 15) to find out

2 specification and with the strictest quality standards required by the

more about the super durable powder coatings.

demanding ACE sector as well as the architectural and automotive For further information:

product solutions can be designed in all RAL colours.

www.helios-group.eu

sector. In compliance with the customers’ wishes the Qualicoat Class 2

N. 62 - MARCH/APRIL 2020 - international PAINT&COATING magazine

BRAND-NEW

SPECIAL PaintExpo

Caraibi: Varnish Art Studio’s Work is a Fine Example of Robot Art

Varnish Art Studio donated Caraibi, a work created with the Robot Art technology, for the auction organised by EOS Mktg&Communication on its tenth anniversary.

The auction organised by EOS Mktg&Communication on its tenth anniversary.

EOS Mktg&Communication celebrated its ten years of activity with the

works of Varnish (Galliate, Novara, Italy), a company with forty years of

event “Art in Surfaces”, combining art, nature, and industry at the Rossini

experience in the industrial coating sector, especially for the automotive

Art Site (Briosco, Italy). During the evening, a charity auction was held: the

and plastic fields. With Varnish Art Studio, the firm aims at exploring the

proceeds were donated to the Municipality of Monza for the restoration

potential of robotics in the artistic field.

of the epigraphs of the War Memorial monument installed in Trento e Trieste square. All works sold at the auction highlighted the link between

For further information: www.varnish.it © ipcm ®

art and surfaces, which was the leitmotif of the whole event organised by the Cesano Maderno-based company. One of them was Caraibi, a couple of paintings made by Varnish Art Studio by using robots that are normally employed in industrial coating applications. The two 80x80 cm canvases were made in 2003 as a part of the Diva collection. Both the colour and B&W versions depict the face of a Creole woman. Their processing method, of course, is their most surprising aspects, as they were made by a robot normally employed for coating plastic parts, using tempera on canvas. Robot Art is the most recent technique developed to use robots to create paintings on canvas and it proves that everyday life is now influenced by robotics in all its aspects. Robotics, art, and culture are inextricably linked by brilliant innovative products, exactly like the ones created by Varnish Art Studio. Varnish Art Studio is the branch devoted to the production of artistic

Caraibi, the couple of paintings made by Varnish Art Studio and donated for the auction organised by EOS Mktg&Communication.

international PAINT&COATING magazine - MARCH/APRIL 2020 - N. 62

ÂŠ Adobe Stock

do you like it printed? do you like it digital? are you a social media addict?

no matter how you like to read, ipcm is the answer!

for subscriptions, visit www.myipcm.com

the smart journal

BRAND-NEW

SPECIAL PaintExpo

Functional Surfaces Provide Value Added Bundled technologies give surfaces new functions. According to Wolfram Alber, Managing Director of Pulvercoat, the trend is to “smart coatings”, products

Pulvercoat will present a large selection of “smart coatings” at its PaintExpo stand 1138 in Halle 1.

with special qualities. Together with IBA Kimya, Pulvercoat, its sales partner for the German speaking area, will present a large selection of these functional surfaces at the fair stand. Some examples are: intelligent surfaces that prevent the development of bacteria; coatings that are approved for contact with drinking water or foodstuffs; ESD surfaces which avoid spark generation. Employees in research and development will advise visitors on individual solutions for surfaces of complex components. In addition, four new design series of high-quality metallic coatings will be presented that are produced by our own premium bonding technology. Up-to-date design catalogues will be freely available. For further information: www.pulvercoat.de

Pulvercoat will present a large selection of “smart coatings” at its PaintExpo stand 1138 in Halle 1.

INNOVATIVE FINISHING TECHNOLOGY FOR SOPHISTICATED SURFACES

Venjakob Maschinenbau – more than 50 years of innovation in surface technology made in Germany Surface pretreatment | Coating | Drying technology | Automation | Exhaust air cleaning www.venjakob.de www.venjakob.com

VIV Group is a liquid and powder coating contractor.

FOCUS ON TECHNOLOGY

SPECIAL PaintExpo

A Pioneering Nanotechnology Process Based on Phosphorus Compounds for Higher Corrosion Resistance. An Innovative Process Creates a New Payoff for VIV Group: Grow Up Barbara Pennati ipcm®

Coating contractor VIV Group implemented Pronortec, Chemtec’s innovative nanotechnology process based on organic compounds of phosphorus, which guarantees high corrosion resistance degrees, in order to solve some critical issues related to its pre-treatment cycle.

N. 62 - MARCH/APRIL 2020 - international PAINT&COATING magazine

FOCUS ON TECHNOLOGY

investment has enabled us to achieve

overall, VIV Group turned to Chemtec

Italy) was established fifteen years

greater production flexibility and meet

(Corbetta, Milan, Italy), specialising in

ago by combining the skills of the

the needs of different sectors. We

the formulation of chemicals for the

Bertipaglia brothers, who created a

now treat workpieces in iron, steel,

pre-treatment of metals.

company specialising in contracting

aluminium, and cast iron for the indoor

powder coating together with a

and outdoor furniture sector, for large

dozen people who boasted extensive

gates and modular fences, and for the

A highly versatile production flow

experience in the painting field.

agricultural sector.”

VIV Group’s production takes place

Currently, VIV Group has thirty-three

After opening up to new industries

in two coating plants designed by

employees and a

and starting treating several products

Eurotherm, operating according to

5000 m -wide factory equipped with

intended for outdoor use, however,

the size of the parts to be treated.

cutting-edge technologies for the

new needs arose for greater corrosion

“The first one is an in-line system with

surface treatment of parts intended

resistance and long-term quality.

an automatic booth that can powder

for the most varied sectors, from

“One of the major problems

coat workpieces up to 3000 x 2000 x

architecture to agriculture.

encountered in our process was

900 mm. The second one is a manual

“Over the last decade, we have

related to the pre-treatment phase:

system for powder coating large-sized

experienced strong growth, also

we were struggling to achieve the high

parts, up to 9000 x 2500 x 3500 mm.

thanks to the skills developed

corrosion resistance level required by

As for our pre-treatment process, we

gradually and the innovative drive

our customers,” explains Bertipaglia.

have both a shot blasting cabin linked

that has always characterised us,”

“Moreover, for a particular die-cast

to the manual plant and a 25-metre

states VIV Group Strategy Manager

workpiece intended for outdoor use,

long chemical pre-treatment tunnel

Leonardo Bertipaglia. “In 2016 we

very porous and with a peculiar shape,

integrated in the in-line system.

started working on two shifts and in

we could not reach the salt spray

This production structure gives

2019 we integrated our in-line plant

resistance hour value required by the

us maximum flexibility in terms of

with a new manual coating system for

specifications and paint adhesion was

batch management. The batches are

large-sized components, able to treat

not optimal.” In order to solve this issue

processed on one plant or another

parts up to 9 metres in length. This

and improve its pre-treatment cycle

based on the size of the workpieces

The manual system designed by Eurotherm for coating large parts, up to 9000 x 2500 x 3500 mm.

VIV Group (Bagnoli di Sopra, Padua,

The entrance to the pre-treatment tunnel.

international PAINT&COATING magazine - MARCH/APRIL 2020 - N. 62

SPECI AL PaintExpo

and subjected to chemical or mechanical pre-treatment depending on the material and customer needs,” explains Leonardo Bertipaglia. “However, as mentioned, with some die-cast aluminium alloy products intended for outdoor use, which have a particular surface porosity, we got disappointing results in terms of salt spray resistance due to problems related to the phosphodegreasing phase. Therefore, we started a renewal project on our pre-treatment cycle, in order to identify the best solution and achieve results in line with the specifications of our customers.”

The innovation brought by organic compounds of phosphorus VIV Group embarked on a six-month trial period with Chemtec, which analysed its process and made changes until reaching the optimal solution. “The first change we made involved moving from phosphodegreasing to alkaline degreasing, which we believed was most suitable based on both the tunnel characteristics and the type of parts treated,” says Tommaso Giovenzana, Scientific Research & Business Development expert at Chemtec. “This led to a significant improvement in the resistance degree. However, since we had not achieved the desired results yet, we also suggested installing a passivation The spraying bar for the application of Pronortec.

bar and using the spraying bar at the end of the existing tunnel for the application of demineralised water. This

second change certainly improved the cycle further, but salt spray resistance problems remained for those highly porous aluminium die-cast products.” “In the meantime, we had begun developing a new product and we were able to test it also thanks to VIV Group, which was among the first companies to try it: Pronortec1. This product is based on organic compounds of phosphorus, creating a very thin layer capable of forming covalent bonds with the organic polymers of liquid or powder finishes. The nano coating created by the Pronortec process is highly hydrophobic because it is free of hydrophilic metals: therefore, it guarantees high corrosion resistance, with a ten times higher value than that obtained with silane-based nanotechnology pre-treatment processes. Furthermore, Pronortec also simplifies application, as it uses a one-component product that can be applied by spraying, dipping, or nebulising, as happens for VIV Group. The nebulised product is diluted just before use, so it is always fresh,

A reverse osmosis system that supplies purified water to the Pronortec process.

N. 62 - MARCH/APRIL 2020 - international PAINT&COATING magazine

1 “The new frontiers of metal pre-treatment: the organic compounds of phosphorus”, ipcm® International Paint&Coating Magazine no. 61, January-February 2020, pages 32-35

FOCUS ON TECHNOLOGY © ipcm ®

Efﬁcient and reliable solutions for surface coating since 1988.

The bell oven for drying the workpieces after pre-treatment and for curing.

it does not require a final rinse, and it guarantees constant quality on all types of metal,” notes Giovenzana. “The results obtained after the adoption of the Pronortec process have been excellent,” says

electrostatic systems for liquid painting

Bertipaglia. “Those highly porous die-cast parts achieved a 100-hour salt spray resistance value with the conventional silane-based passivation process: now, with Pronortec, we reach a 500-hour value,

electrostatic systems and spraying booths for powder coating

whereas with other aluminium parts we exceed the 1000-hour mark.” "Ours is a no-rinse process" states Giovenzana. "We, then, introduced a demineralized water spraying

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

stage before the Pronortec process. To sum up, the pre-treatment cycle includes as follows: alkaline degreasing, two rinses, DI water spraying, and

IR and UV drying systems

passivation". For some sheet metal parts presenting oxidation problems after pre-treatment, a last stage is added for applying a corrosion protection product. After pre-treatment, the parts enter a

robot and reciprocators

bell drying oven, which also acts as a curing oven. Coating is done in a quick-colour change booth with two reciprocators with four guns each and two manual pre and post-retouching stations, as well as a Lesta robot for mass coating processes. “We apply one-layer systems. Polyester powder coatings account for 95% of our operations. We get to perform up to thirty colour change operations a day. Finally, we have a Ciroldi paint stripping system, clean our load bars and frames twice a week,” says Leonardo Bertipaglia.

www.cmspray.it

eosmarketing.it

which was revamped in 2018 and with which we

CM SPRAY s.r.l.

SPECI AL PaintExpo

VIV Group - Grow Up: an innovative process

meeting all our quality and corrosion resistance requirements. Together

“VIV Group has always stood out as a

with Chemtec, we embarked on a six-

competitive business that, thanks to its

month trial period, which was to be

resources and expertise, tries to make

followed by an additional six-month

the best of every experience and to

trial period with another supplier.

always focus on innovation, in order to

However, the benefits and advantages

offer a service capable of guaranteeing

found with Chemtec’s processes were

optimal results. Our customers come

unmatched, so we interrupted the

from different sectors and also sell

second trial period and definitively

their products abroad: this means that

adopted Pronortec.”

their specifications and requirements

“Despite having a reduced number

in terms of quality and corrosion

of pre-treatment phases, Chemtec’s

resistance are very high and diverse.

solution has enabled us to reach the

That is why it is essential for us to

required standards while remaining

collaborate with equally innovative

competitive and flexible. We have

suppliers, which know how to meet

been getting positive feedback from

different needs and can intervene

our customers, from which we have

timely in case of need. Chemtec

not received criticisms of any kind.

is one of them,” states Leonardo

In future, we would like to continue

Bertipaglia. “We got in touch thanks

to optimise our pre-treatment

to a common acquaintance who

phase by installing smaller tanks

had already worked with them and

and implementing an additional

therefore knew the quality of their

stage, but also to integrate a new

technologies. And, when the need

last generation coating booth, for

arose to solve the problem related to

The quick-colour change coating booth is equipped with two reciprocators with four guns each and two manual pre and post-retouching stations.

our pre-treatment cycle, we decided

some suppliers,” says Leonardo Bertipaglia.

to rely on them to find a solution

which we are already assessing

The Lesta robot for mass coating operations.

From left to right, Leonardo Bertipaglia from VIV Group and Tommaso Giovenzana from Chemtec.

N. 62 - MARCH/APRIL 2020 - international PAINT&COATING magazine

Zaniolo CdA-2.20

QUAL TY Europolveri offers a wide range of powder coatings that are available in several different

finishings and gloss level. A stock of approximately 1000 different colors is always available

and developed to assure the highest quality level as to satisfy the widest needs of the market.

advanced

solutions for

metal surfaces treatment

R&D laboratory steadily works in the development of new products and performance improvement in order to enable the company to be an innovation leader and to give solutions to the many technical requests coming from the market. Products development, their industrialization and their use are always directed to obtain the best results and the highest respect for the environment.

EUROPOLVERI S.p.A. - Sandrigo (VI) Italy - Ph. +39.0444.750643 - Fax +39.0444.750653 FILIALI/Branch Office: Cernusco sul Naviglio (MI) Ph.+39.(0)2.92148001 - Erbusco (BS) Ph.+39.(0)30.7704158 DEPOSITO/Depot: Iori Colori, Reggio Emilia Ph.+39.(0)522.327248

info@europolveri.it - www.europolveri.it

P O W D E R C O AT I N G S I N C E 1 9 8 2

IBIX’ headquarters.

HIGHLIGHT OF THE MONTH

SPECIAL PaintExpo

The Versatility of a Multifaceted Company: IBIX Srl’s First 20 Years of Business Giorgia Ricchiuti ipcm®

IBIX Srl, a leader in the ecological cleaning, sandblasting, and surface treatment fields, tells its story to ipcm®, from its origins to the participation in PaintExpo 2020. Sisters Susanna and Caterina Giovannini

low environmental impact and featuring a

Giovannini. “Under the brand IBIX Industrial,

challenged the market by establishing IBIX

technology that is recognised internationally for

the company designs, manufactures, and

Srl in 2000. Initially called Tecno Supply, over

its versatility, ecology, and innovation degree,

sales manual and automatic systems for

the years the company began to be mainly

as well as in the supply of coating consumables

thermoplastic powder flame spraying, a

identified as IBIX, the brand originally reserved

and thermoplastic powder application

specific evolution of different powder coatings

for its sandblasting and cleaning division. IBIX

equipment.

grades of Axalta and Plascoat, brands that IBIX

is now a leader in the production of surface

“We operate on the international markets

represents since the beginning for all their

treatment and sandblasting plants with a

through various divisions,” says Susanna

versions (immersion, electrostatic spraying,

N. 62 - MARCH/APRIL 2020 - international PAINT&COATING magazine

HIGHLIGHT OF THE MONTH

use of curing ovens. Thermoplastic powders have manifold applications: besides metals,

Your Leaders in Zero Liquid Discharge

they can be used for coating porous surfaces subject to degradation such as concrete (accounting for 60% of our market), industrial flooring, containment tanks, and swimming pools. The number of flame spray machines sold worldwide increases every year and the number of customers that have confirmed they have found great advantages in terms Susanna and Caterina Giovannini.

of coating performance and durability, too.” It was precisely thanks to the discovery of this technology that Susanna and Caterina

flock spraying). Tecno Supply, which maintained

Giovannini had the idea of founding IBIX, which

the original name of our company, is now

has experienced great growth over the years,

the division devoted to the industrial coating

up to having more than twenty-five employees

sector in the Italian market, which we provide

dealing with technical, construction, assembly,

with the hanging and masking systems of

design, sale, and customer service activities

Swedish manufacturer HangOn. Finally, we

– the latter being the real strength of this

have recently launched a new division with a

company, beside the continuous research and

new website: IBIX Biocare, which deals with

development of innovative technologies.

services and technologies for the restoration

IBIX represents the Plascoat and Axalta

and conservation of stone surfaces through

thermoplastic powder brands on the Italian

selective aero-mechanical cleaning with

market and sells its own brand’s powders in

IBIX patented systems and the subsequent

combination with the related equipment on

application of last generation protective

the international scenario, particularly in the

products.”

US. “We offer a wide range of thermoplastic

“One of our strengths is our thermoplastic

powders and our job is to provide them

powder flame spray technology,” adds

together with an effective application

Susanna Giovannini, “which we discovered

technology,” says Susanna Giovannini.

in Canada in 1996 and that impressed us

“For instance, IBIX has specialised in the

for its effectiveness. In fact, it is the only tool

construction of systems for the treatment

capable of applying powder paints without the

of fire extinguishers, a sector in which

thermoplastic products are used for the

Industrial Wastewater Treatment

Simple Principle

Effective Result

lamination of internal parts in order to prevent metal corrosion caused by extinguishing agents. Specifically for this field, we have developed fully automatic application systems capable of coating 100-120 fire extinguisher cylinders per hour. Another very important market for IBIX is the Oil & Gas one, where the flame spray technology is widely applied, in particular for the application of 3LPE/3LPP systems.” Its R&D and staff training activities have also enabled IBIX to create a diagnostic division looking for new solutions in the restoration,

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

special cleaning, urban decoration, and The masking item’s warehouse.

info@h2o-de.com www.h2o-de.com

SPECI AL PaintExpo

industrial cleaning sectors. This is why it established IBIX Biocare as its new division devoted to building restoration and conservation. “Another strength of ours is our ability to support our customers during both the preliminary assessment and implementation phases,” states Caterina Giovannini. “In addition to supplying them with the required equipment, we offer them training sessions and we assist them along the whole project. Solving customer issues also enables IBIX to keep up to date and discover always new applications.” “In the Italian industrial coating market, our Tecno Supply division’s technicians can assist our customers and help them solve their masking and hanging issues, but also offer them application solutions that take advantage of the flame spray technology developed by our company, which is now within everyone’s reach,” The assembly line.

indicates Luciano Brunner, sales director of Tecno Supply and

IBIX Industrial divisions. “We sell 25% of the machines we produce in Italy, whereas foreign markets account for over 55% of our turnover.” In 2020, IBIX will participate for the first time in PaintExpo, the world’s leading trade fair for industrial coating technologies. “After years of presence as visitors or as HangOn and Axalta assistants, for the first time this year we will participate as an exhibitor (Hall 3, Stand 3133, Ed.). It will be an opportunity to show our sandblasting systems and promote our new machine type, Atlantis, which combines the flame spray and flock spray technologies in a semiautomatic plant,” says Susanna Giovannini. In future, the company aims at expanding the application and sales potential of its sandblasting and flame spray machines by building increasingly efficient and performing equipment. In order to do so, IBIX is going to move into a new building with a double working space, which will also feature exhibition and training areas.

Besides metals, thermoplastic powders are also used on many other materials.

Pipeline maintenance systems.

N. 62 - MARCH/APRIL 2020 - international PAINT&COATING magazine

The conference and training room.

Salcomix è il marchio di AkzoNobel per un sistema di prodotti vernicianti industriali dal design modulare, che può essere utilizzato per fornire vernici per una grande varietà di applicazioni per l‘industria leggera, in modo rapido e flessibile. Questo è possibile grazie a un sistema di miscelazione che offre una superiore precisione del colore con la massima varietà di prodotto. Salcomix is AkzoNobel's brand for a modularly designed industrial coatings system that can be used to provide paints for a variety of small-industry applications, quickly and flexibly. This is possible thanks to a mixing system that offers superior color accuracy with maximum product diversity.

www.akzonobel.com infosalcomix@akzonobel.com

0087–04019

www.salcomix.com

SUCCESS STORIES

SPECIAL PaintExpo

Please Blast, Dip, Powder a 100 Times Truck trailers are useful, but also big and heavy. This does not make their transport in the paintshop easy. Giga Coating GmbH recently built a completely new surface treatment plant in Twist. Here, up to 15.7 m long and 9 t heavy large parts are not only coated, but also blasted, dipped, swiveled and heat treated in hanging furnaces. The automated circulation principle creates capacities for up to 100 trailers and special parts per day in two construction stages.

manufacturing depth. So far, the chassis

“And we wanted to solve that,” explains Ralf

demand for truck trailers in Europe is

was given to external partners only for the

Saatkamp, Managing Director of System

high. At System Trailers Fahrzeugbau

coating process. “We had been thinking for

Trailers Fahrzeugbau. At the same time,

GmbH in Twist on the Dutch border in

some time about taking over the coating

he realized that contract coating of large

Lower Saxony, more than 3500 of these

ourselves. In our production line, we have

parts in Emsland is a growth market. The

leave the production line every year - 70

achieved a high degree of automation

dimensioning of the new coating plant was

to 80 vehicles a week. The specialist

and could thus shorten the cycle times by

therefore planned with buffers for external

designs and manufactures on behalf of

30%. The remaining bottleneck was the

orders and at the same time the subsidiary

well-known manufacturers and has a high

capacity for coating outside the company.

Giga Coating was set up as a contract

Whether semi-trailers or trailers - the

At Giga Coating, large parts weighing up to 9 t and over 15 m long are coated in circulation.

N. 62 - MARCH/APRIL 2020 - international PAINT&COATING magazine

SUCCESS STORIES © Vollert

coater. Vollert from Weinsberg,

SPECIAL PaintExpo

in southern Germany, supported the planning. The heavy-duty intralogistics experts have decades of know-how in the design and commissioning of large part painting systems for buses, excavators or railway wagons and effortlessly move loads of up to 50 t and more. Nevertheless, the new system technology from Giga Coating offered a number of innovations: “On the one hand, of course, these are large parts, but also the combination of cathodic dip painting (KTL) and powder coating, combined with a high variety of variants and the desire for an efficient automated circulation concept challenged us,” explains Jochen Keinath, Sales Project Manager at Vollert. In addition to the crane technology and the complete

After blasting, two manipulators take over the loading of the 12 dipping tanks.

material flow system, the team also coordinated with the other system © Vollert

manufacturers: Wheelabrator supplied the sandblasting technology, Afotek the dip coating and furnaces, and Nordson Germany took care of the powder application.

Circulation principle Pre-treatment, Dip Coating and Powder Coating All plant areas at Giga Coating are placed in a floor space of 60 x 110 m and arranged in such a way that a complete circulation for multiple coatings is possible. “Due to different material thicknesses, we expect different dwell times for the workpieces, which is why it was important to us that we automate the parts, but also convey them individually,” explains Ingo Wildermann, Managing Director of Giga Coating GmbH. At the heart of the system there are two cathodic

For maximum energy eﬃciency, the ovens at Giga Coating were designed to be suspended and open at the bottom.

international PAINT&COATING magazine - MARCH/APRIL 2020 - N. 62

SUCCESS STORIES

SPECIAL PaintExpo

A total of 7 manipulators ensure the fully automated distribution of the workpieces.

dip painting furnaces and two powder

technology automatically sorts the

kilns, around which the blasting cabin,

workpieces according to drying time

Pre-treatment and Cathodic Dip Painting

dipping tank, buffer stations and

in interaction with the higher-level

At Giga Coating the trailer parts can

powder coating booths are grouped.

material flow system and optimally

reach dimensions of up to 15.70

Seven manipulators with spans up to

designs the processes. “Another special

m x 2.70 m x 1.50 m. After these

18 m pick up the goods carriers for

feature of the system is that the goods

have been turned in a belt turner to

lateral travel and distribute them to

carriers pass through all work stations,”

remove residual blasting material,

the workstations. In the longitudinal

reports Jochen Keinath. “The product

a loading manipulator from Vollert

direction, stationary friction wheel

carriers are not exchanged after dip

takes them over after the blasting

drives convey the workpieces. This

painting, but accompany the workpiece

cabin and introduces them into the

makes it possible to feed individual

along the entire path from cathodic dip

further circulation. The stator racks

product carriers individually at any

painting until into the furnaces.” The so-

with the workpieces are moved to

time. Buffer positions between the

called wedding - the connection of the

two buffer locations and picked

areas allow different dwell times and

product carriers with the workpieces

up by two dip manipulators. These

also allow individual workpieces to

- is a permanent combination at Giga

serve a length of 55 m 12 tanks for

be pulled forward and overhauled as

Coating. The seamless circulation

pre-treatment - degreasing, rinsing

required. In order to guarantee fast,

process saves time and simplifies goods

and zinc phosphating - and for

efficient processes, Vollert’s control

carrier management.

cathodic dip painting. They lower

N. 62 - MARCH/APRIL 2020 - international PAINT&COATING magazine

SUCCESS STORIES

SPECIAL PaintExpo

the parts from above into the tanks

as possible, the ovens are therefore

KTL furnace, a manipulator distributes

and place the product carriers there.

suspended. Since hot air rises and a

the trailer or foreign parts to eleven

As a result, the manipulator can move

lot of heat would escape when the

storage locations for cooling before

more workpieces during the dwell time.

workpieces are moved in and out, the

the transport to the powder plant

The second immersion manipulator

furnaces are closed at the top and

starts. â&#x20AC;&#x153;After a detailed examination of

then automatically takes over the

on the sides and are operated from

all options, we decided on a combined

stand frames after the specified time

below instead. A total of two KTL and

cathodic dip painting and powder

has elapsed and takes them to the

two powder furnaces are installed in

application because it enables us to

next immersion tank and finally to

parallel next to each other - with an

produce in a more environmentally

the draining area. It is also possible

expansion option already prepared.

friendly way and at the same time

to swivel and tilt the parts on the

A manipulator guides the workpieces

achieve automotive quality,â&#x20AC;? says Ingo

manipulators - for perfect, area-wide

into the ovens from below, lifts the

Wildermann. The oven manipulator,

priming results.

parts weighing up to 9 t to a height

which serves the two powder ovens in

of 10 m and hooks in the goods

addition to the cathodic dip painting

The Hanging Furnaces of Twist

carriers. As with dip painting, it can

ovens, once again takes over the

Giga Coating pursued three objectives

transport further workpieces during

powder coating process. The cycle

in the planning of the overall plant:

heat treatment and operate all four

then ends again at the eleven buffer

coating results in automotive quality,

ovens in parallel - up to four product

positions, from where the finished

energy efficiency and environmental

carriers per hour, depending on the

coated workpieces return to the cycle

friendliness. To avoid heat loss as much

drying time. After the treatment in the

via an unloading manipulator for truck

VULKAN INOX Stainless Steel Blast Media

Lowest consumption Less waste disposal Surface enlargement

Dust-free blasting Consistent blasting results

Cleaning

VULKAN INOX GmbH

Finishing

www.vulkan-inox.com

Sweep Blasting

info@vulkan-inox.de

SUCCESS STORIES © Vollert

SPECIAL PaintExpo

The parts are automatically tilted during insertion and removal.

The product carriers pass through the powder line fully automatically.

the pre-treatment and coating”, Ingo

thing of the past and at the same time

“With this system configuration and

Wang says pleased. In June 2018 Giga

the plant offers sufficient capacity for

equipment, we achieve all of the goals

Coating started regular operation of

processing external orders.

in terms of quality and speed and are

the new coating line. Bottlenecks in

at the same time extremely flexible

the completion of trailers and semi-

For further information:

for all variations and combinations of

trailers from System Trailers are a

www.vollert.de

loading or multiple coating.

The manipulator lifts the workpieces to 10 m and hangs them in the furnaces. In this way all four furnaces can be operated with only one manipulator.

N. 62 - MARCH/APRIL 2020 - international PAINT&COATING magazine

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

DISCOVER OUR SOLUTIONS www.graco.com/ďŹ nishingproducts

TIGITAL 3D Materials oﬀer entirely novel and unique properties for SLS printing systems and carbon-based additive manufacturing (CBAM) and can be finished with powder coatings. ®

INNOVATIONS: PRESENT&FUTURE

SPECIAL PaintExpo

TIGITAL® 3D Materials: Revolutionising Additive Manufacturing Dr. Baris Kaynak Tiger Coatings GmbH - Wels, Austria

baris.kaynak@tiger-coatings.com

TIGER Coatings launched TIGITAL® 3D Materials, the new thermoset materials for SLS printing systems and carbon-based additive manufacturing (CBAM). They offer new properties and unique advantages compared to the usual thermoplastics, because TIGITAL® 3D Materials do not melt when exposed to heat and can be refined with powder coatings.

N. 62 - MARCH/APRIL 2020 - international PAINT&COATING magazine

INNOVATIONS: PRESENT&FUTURE

Forward-looking partnerships RICOH – a company specialising in printers, document management solutions, digital cameras and IT services – has recognized the huge potential of this development and pooled its hardware know-how with TIGER’s research expertise. Together, the companies are working on refining the material itself and how it is used and processed to introduce even more innovations into the emerging SLS 3D printing market.

Numerous advantages: TIGITAL® 3D Materials oﬀer compelling, innovative features in the SLS 3D printing market.

TIGER is also collaborating with US 3D printer manufacturer Impossible Objects on the development of composite thermoset-based

TIGER Coatings is known around the world as a

highly weather-resistant properties, are

materials. This collaboration is set

leading supplier of high-quality surface finishes

approved in accordance with strict quality

to revolutionise the use of additive

and digital inks and powders for industrial

standards such as GSB and/or QUALICOAT,

manufacturing in the aerospace and

printing systems. With the development of

and have been successfully used for many

automotive industries.

high-performance thermosetting polymers

years on buildings in southern regions of the

“TIGER provides a complete solution

for additive manufacturing, the company is

USA. Chemical stability requirements can

integrating both chemistry and

once again demonstrating its pioneering spirit,

also be modified as appropriate.

mechatronics under the brand name

drawing on more than 50 years of experience

TIGITAL Inks & Powders open up further

Chematronix®” Clemens Steiner, TIGER

and expertise in polymer technology.

options for customizing 3D components.

Coatings’ CEO states. “We are working

TIGITAL 3D Materials offer entirely new

Using the materials options provided by

with highly skilled partners to take 3D

properties and unique advantages compared

TIGER, these digital inks and powders can be

SLS printing to the next evolutionary

to the thermoplastics predominantly used

perfectly coordinated with each other, thus

level, from rapid prototyping to

in SLS 3D printing. The printed components

allowing for an enormous degree of creative

small production runs and ultra-high

remain solid even at high temperatures

flexibility in customising objects.

performance hybrid parts.”

and display excellent isotropic mechanical © TIGER Coatings

properties in x-, y-, and z-direction. Furthermore, unlike thermoplastics, TIGITAL® 3D Materials do not melt when exposed to heat. There is no polymer melt drip or loss of shape. When combined with flame retardant formulations, TIGITAL® 3D Materials are also ideal for electrical insulation.

Enormous creative flexibility Another truly unique feature: 3D models printed with TIGITAL® 3D Materials can then be refined with powder coatings. The extensive range of TIGER Drylac® products includes over 1,500 exclusive colours, spectacular metallic finishes, sophisticated anodizing solutions and aesthetically appealing dull matte effects. Many of these powder coatings also have

Clemens Steiner, CEO TIGER Coatings.

international PAINT&COATING magazine - MARCH/APRIL 2020 - N. 62

The show room of OMR Spa’s headquarters in Remedello (Brescia, Italy) displays the wide range of components for industrial, commercial, and oﬀ-road vehicles produced by the company.

FOCUS ON TECHNOLOGY

A Digitised Cataphoresis+Powder Coating Plant Like a Tailored Suit for OMR Spa, a Manufacturer of Excellence in the Industrial Vehicle Sector Alessia Venturi ipcm®

N. 62 - MARCH/APRIL 2020 - international PAINT&COATING magazine

SPECIAL PaintExpo

FOCUS ON TECHNOLOGY Compact design, production versatility, loading and unloading ergonomics, operating cost reduction, consumption minimisation, and high productivity combined with digitalisation, predictive maintenance, and full traceability of coated parts: these are the main features of the cataphoresis+powder coating line that Trasmetal Spa (Milan) supplied to an Italian manufacturer of excellence in the commercial, industrial, and off-road vehicle sector: OMR Spa (Remedello, Brescia).

“Coating plants are not plug-and-

products’ added value. Indeed, it has

company in the production of steel

play systems. They are designed like

just completed the industrialisation

components for industrial, commercial,

a tailored suit: it takes ten to twelve

phase of a new cataphoresis+powder

and off-road vehicles. Nowadays, with

months before they fit a customer’s

coating line designed and supplied by

500 employees, a covered surface of over

production needs perfectly. But when

Trasmetal Spa (Milan, Italy), a company

70,000 m2, and a turnover of about 104

they do, they become the main added

with over fifty year of experience in

million Euros in 2019, OMR has an almost

value of its production flow.”

the creation of customised coating

fully vertically integrated production

These are the words of Ruggero Ceriali,

systems for the automotive, aluminium,

and it is able to turn raw steel into end

the CEO of OMR Spa (Remedello,

household appliances, and general

products almost without relying on any

Brescia, Italy), one of the main European

industry sectors.

contractor.

manufacturers of components for

“We deal with eleven different production OMR Spa was established in the 1970s

processes in-house, such as laser

earthmoving vehicles. This firm believes

as a small craft carpenter’s shop. Over

cutting, welding, bending, machining, and

that coating accounts for 10-15% of its

time, it has become a benchmark

coating,” explains Ruggero Ceriali.

commercial, industrial, agricultural, and

A bird’s eye view of the plant designed by Trasmetal from its loading and unloading areas.

international PAINT&COATING magazine - MARCH/APRIL 2020 - N. 62

“The other feature that makes OMR

SPECI AL PaintExpo

unique are its back-up solutions for each department and plant: this enables us to guarantee business continuity in any situation. We applied the same approach to our coating plant, too. With the installation of the new line, we have not dismantled our previous plant, bought fifteen years ago: we decided to use it as a support system to further increase our production capacity and treatment quality degree.” The vertical integration of its production and the back-up solutions available for all processes have made OMR an invaluable partner for the players of the European industrial vehicle sector: Iveco, Daimler, and Volvo in the lorry field, New Holland in the tractor one, and CNH Industrial, Caterpillar, and Komatsu in the earthmoving machine one. “The

The storage buﬀers near the loading station.

reasons behind the investment made with Trasmetal for our new coating line were both economic and technical,” to increase our production capacity and, above all, improve the quality of

indicates Ceriali. “Quite simply, we needed

our products. The plant installed fifteen years ago had several defects due to our total inexperience in the finishing field: with the new one, we corrected all the problems we had encountered in those fifteen years of work. Moreover, we wanted a plant that enabled us to coat in-line and with a continuous flow by performing both cataphoresis and powder application operations.”

Digitalisation, automation, and versatility: the characteristics of the new line The installation of the cataphoresis+powder coating plant supplied by Trasmetal began in December 2018 and ended in June 2019. The new line design was based on the concepts of compactness, production versatility, loading and unloading ergonomics, operating and maintenance

The Conveyors Nord power & free conveyor taking the workpieces to the powder application area.

N. 62 - MARCH/APRIL 2020 - international PAINT&COATING magazine

FOCUS ON TECHNOLOGY

cost reduction, consumption

in both of them and then send the

the loading and unloading ones. This

minimisation, and high productivity

bars to the pre-treatment station

eliminates any waiting time due to bar

combined with digitalisation, predictive

according to the production order.

flow management activities,” explains

maintenance, and full traceability of

Before the loading area, there is

Giuseppe Groppelli, product manager

coated parts. “Trasmetal’s project

a workstation for the preparation

at Conveyors Nord. “The plant also

focussed on improving OMR’s coating

of the empty load bars with the

features other storage buffers. Some

productivity and optimising the loading

frames needed to hang the incoming

of them allow cooling the parts down

and unloading phases, thus guaranteeing

workpieces. The unloading area is

upon leaving the ovens. Others

operational flexibility despite the very high

equipped with two stations working

house the load bars leaving the pre-

number of different components to be

the same way as the loading ones.”

treatment/cataphoresis unit during

handled,” explains Carlo Zucchetti, project

The cataphoresis+powder coating

the tank system emptying operations,

manager at Trasmetal. “One of the most

line features a power & free conveyor

typically performed at the end of the

challenging aspects was finding the right

day, in order to protect the parts,

size for the load bars, now higher and

Milan, Italy). It does not include any

which are in a delicate phase. Finally,

longer than those of the first plant. We

elevator because the plant was

other storage buffers compensate for

opted for the use of one 1500 mm-wide

designed for ergonomic hanging

the variations in the bar flow intensity

bar or two 600 mm-wide ones. The line

operations. “The use of storage

in some areas of the line, due to the

was equipped with two loading stations,

buffers in both the loading and

fact that each load bar is matched

one for handling heavy components and

unloading stations allows managing

with a specific cycle and therefore

the second for the lightest ones. The

the load bars during the feeding and

takes a slightly different path than the

operators can simultaneously load parts

return phases, which are functional to

others.

visit us at

Messe Karlsruhe - October 12-15, 2020 - Hall 1, booth 1242

eosmarketing.it

AUT O MO TIV E

liquid or powder spray applications

over 60 years of experience in surface finishing lines

www.trasmetal.net

SPECI AL PaintExpo

“Trasmetal developed a bar code part management system that identifies each workpiece during loading and shows relevant information on the smart TVs installed along the line: hanging instructions, any masking required after cataphoresis, treatment program, and packaging instructions upon unloading,” adds Carlo Zucchetti. “The plant is set up to treat a 5 metre long, 1.5 metre wide, 1.80 metre high load bar every 3 and a half minutes. During loading, the shape control device communicates to the bridge crane linked to the pre-treatment and cataphoresis tanks the number of load bars to be picked up, that is, one or two. With 1500 mm-wide bars, the bridge crane picks up only one of them at a time, whereas in the case of “narrow”, 600 mm-wide bars, two of

A loaded bar.

The bridge crane picks up the load bars to transport them along the pre-treatment and cataphoresis line.

N. 62 - MARCH/APRIL 2020 - international PAINT&COATING magazine

them can be picked up simultaneously.

eosmarketing.it

PAINT STRIPPING OVENS NEW PIROMAX OVEN

FOR METAL WORK SUPPORTS Thermal paint-stripping is performed only through heat, paint is incinerated without altering the piece dimensionally or mechanically. Pieces can be washed and/or shot-blasted after the treatment based on the subsequent use. It enables to recover an item making it perfectly polished for subsequent applications.

visit us at Messe Karlsruhe - October 12-15, 2020

hall 1, booth 1449

ciroldi.it

ciroldi@ciroldi.it

+39 059 386012

SPECI AL PaintExpo

rinses with ultrafiltrate, and blow-off before curing. Condoroil Stainless, Trasmetal’s partner in this project, supplied the electrodialysis cells for the cataphoresis tank. “Due to the peculiarity of the components treated by OMR, Condoroil provided ‘protected cells’, that is, equipped with a protective net wrapped around the membrane to safeguard it against accidental impact and damage,” explains Condoroil sales manager Alessia Sinigaglia. “The cells are equipped with ion exchange membranes and they are created with a wrapped, welded polymer sheet, featuring low deformability and electrical resistance but long service life and greater current intensity

The exit from the cataphoresis tank.

characteristics. With minimum thickness and therefore with limited The pre-treatment tunnel (which

electrical resistance, this generates

process, but also to guarantee a high

uses Chemetall's products) includes

little heat, which is the first cause of

treatment quality level by avoiding the

14 stages, including spray and

premature ageing of membranes;

use of any shielding between parts

immersion treatment operations,

moreover, its poor extension

loaded on an oversized bar.”

cataphoresis (supplied by Basf), two

prevents any short circuits from

This helps to optimise the coating

The cooling station with fresh air insuﬄation devices in its front part.

100

N. 62 - MARCH/APRIL 2020 - international PAINT&COATING magazine

FOCUS ON TECHNOLOGY

contact between the membrane and the electrode. “Whereas in conventional cells the water flow enters the electrode by touching it physically, in Condoroil’s ones it flows through a plastic tube closed at the opposite end by a cap, in order to prevent the liquid from returning back to the electrode. In Condoroil’s tubular cells, the electrolyte is flushed from above inside the electrode and any excess product leaves the cells by going up from the bottom. In the event of an electrode breakage, this solution eliminates any risk of preferential water flow, resulting in the accumulation of electrolyte in the space between the electrode and the membrane. The advantage for users is that, in case of breakdown, it is not necessary to replace the whole

OMR Spa plant manager Fausto Toninelli (left) with CEO Ruggero Ceriali.

SPECI AL PaintExpo

One of the two automatic powder application booths, each equipped with 2 reciprocators and 6 guns per side.

The Gema Opticenter powder management unit with dense phase feed pumps.

component: these cells allow changing

bars reach a cooling station with a hot

masking. Here, there is another storage

only the electrode while maintaining the

air intake system in the back and fresh

buffer that can be used for different

membrane. Finally, the cells are supplied

air insufflation devices in the front.

purposes, for example to “park” small

with their upper part open, in order

Afterwards, the bars continue along the

colour batches to be included in the

to guarantee ease of inspection and

main line towards the powder coating

planning.”

maintenance.”

booths; however, if the loaded parts

“The powder application area consists

“Trasmetal located the cataphoresis

only need a cataphoresis treatment,

of two Gema controlled-temperature,

drying oven and the powder curing one

they are diverted along the bypass line

controlled-humidity, dust-free

on a mezzanine,” says OMR Spa plant

and directly taken to the unloading

pressurised booths,” explains Toninelli.

manager Fausto Toninelli. “They are both

area. The load bars that proceed

“Each of them is equipped with 12

canopy ovens: the workpieces enter them

towards the powder coating booths

automatic guns and 3 manual touch-up

by following a continuous path along the

pass along two conveyor rings with

ones, that is, 1 for pre-retouching and

internal conveyor. Once out, the load

optional stations, such as sanding and

2 for post-retouching operations. We

102

N. 62 - MARCH/APRIL 2020 - international PAINT&COATING magazine

FOCUS ON TECHNOLOGY

choice in this regard.”

pumps and last generation Opticenter

“Trasmetal’s plant was also designed by

Part hanging and hook maintenance strategies

powder management unit, with individual gun

focussing on environmental sustainability.

“The bars are loaded differently

control modules. A shape detection bar at the

First of all, the firm strived to limit the

through the use of specific frames or

booths’ entrance programs the reciprocators

energy consumption of the drying and

hooks depending on the incoming

and adjusts their stroke height and distance

curing ovens, which are both vertical

workpieces. Frames and hooks were

from the treated parts in order not to

canopy systems featuring a separate

developed based on component

waste paint. We chose Gema’s technology

conveyor with a different pitch than the

families or, in some cases, on

because we had already successfully worked

main one. This prevents any unnecessary

individual workpieces.

with them: after installation, we have never

heating of the chain, resulting in a waste of

We build them in-house and we

needed any product assistance. Moreover,

energy. Therefore, these ovens consume

deal with their cleaning in a Ciroldi

we found their dense phase technology very

10 to 15% less energy than other systems

pyrolytic paint stripping oven

interesting and effective in terms of finishing

of the same type, on average,” says

combined with a sand blasting

results.

Carlo Zucchetti. “Secondly, Trasmetal

system that removes any ashes from

“On average, we perform five-six colour

integrated its coating plant with a zero-

pyrolysis,” says Fausto Toninelli from

change operations per day, sometimes up

liquid discharge water treatment plant, as

OMR Spa. “Paint stripping plays an

to ten. We apply standard colours, mainly

OMR operates in an area not connected

important role with a continuous

in the grey ranges. We have three main

to public sewage. All waste water is

flow coating plant like ours, applying

powder suppliers, in compliance with the

recovered, treated, and recirculated

powders after cataphoresis.

specifications of our customers, which

wherever possible, whereas sludge and

Whereas the former can stand small

often even specify their approved products’

the evaporation concentrate are disposed

paint deposits on hooks without

numbers: OMR, therefore, has a very limited

of by specialised companies.”

compromising the electrostatic field

selected Gema’s Optispray dense phase

Parts entering the vertical canopy oven for powder curing.

SPECI AL PaintExpo

The zero-liquid discharge water treatment system and the demineralisation plant.

during spraying, with cataphoresis

Conclusions

After eight months, we are very pleased

hooks and frames must be

“The new plant has provided us with

with it.

perfectly clean in order to ensure

great space for further economic

“The collaboration with Trasmetal was

proper electrodeposition. This is

growth,” states Ruggero Ceriali.

perfect: we provided them with all

why we paint strip our hooks and

“The coating line closes the entire

design drivers, as we had clear ideas

frames in the Ciroldi oven after

production cycle and, therefore, it

about the type of system we wanted.

every process cycle.

must keep up with the capacity and

The plant they designed for us was

In the past, we gained some

productivity of the other departments

very interesting both technically and

experience by working with

and plants. Coating used to be a

financially and they managed to follow

paint stripping contractors using

bottleneck for us: we increasingly

our whole vendor list for components.

different technologies and we

needed to rely on contractors and

They provided us with a system tailored

knew that the pyrolytic technology

many of our customers did not like it.

to our needs, which took some time

guaranteed the best benefit-cost

The installation of this new state-of-

to reach full capacity, but now gives us

ratio.”

the-art system was a real success.

excellent quality results.”

104

N. 62 - MARCH/APRIL 2020 - international PAINT&COATING magazine

OptiCenterÂŽ OC07 Fastest colour change and stable powder output

Clean, efficient and superior perior application technology The OptiCenter OC07 powder management center combines state-of-the-art OptiSpray application pump technology with automatic fresh powder feed for fast and clean color changes. The system is the basis for constant and reproducible coating results and significant powder savings.

www.gemapowdercoating.com

SUCCESS STORIES

SPECIAL PaintExpo

A Hanging System to Improve the Efficiency of Coating Processes: Rostirolla Presents P25 Office equipment subsupplier Temo Srl turned to Rostirolla, specialising in hanging and masking systems, with the aim of improving its line efficiency. Both companies heavily focus on the automation of internal manufacturing processes interfaced with advanced management software. Rostirolla will present its newest hanging and masking solutions at PaintExpo 2020 (Hall 2, Stand 2520, October 12 to 15).

the other hand, Temo Srl, a firm specialising

for their shape and size.

essential elements of a coating line for the

in the production of components for

“Temo got in touch with us,” explains

correct management of processes. However,

office furniture, grasped its relevance for

Simone Rostirolla, the owner with his

it is also one of the most neglected aspects,

the optimisation of its coating operations.

brother Pierluigi of Rostirolla Srl, which

often considered secondary within a plant’s

Indeed, it managed to eliminate any

has been manufacturing hooks, bars, and

structure, because its importance in terms of

downtime due to the hanging of its parts on

masks for industrial powder, liquid, and

production efficiency is underestimated. On

frames and load bars that were not suitable

cataphoresis coating processes since

A proper hanging system is one of the

The hanging system created by Rostirolla for the Temo’s paintshop.

106

N. 62 - MARCH/APRIL 2020 - international PAINT&COATING magazine

Surface coating

SUCCESS STORIES

of heavy-duty workpieces and large-scale components Made M d in i G Germany. Since

1990, “for the development of a hanging

SPECIAL PaintExpo

system that was suited to their needs. Following the greater automation degree

1925.

Hall 3 | Booth 3334

it achieved with the new coating booth installed in 20181, Temo was faced with the need for a hanging solution that would speed up the loading phase by using the available space in the most efficient way.”

The development of Temo’s project Rostirolla started with an analysis of the products coated by Temo. “Their technical staff was very helpful,” states Simone Rostirolla. “They provided us with the 3D drawings of the parts they need to paint, which we used to develop the most suitable load bar system. Temo’s team knows all aspects of the coating process very well: their expertise is comparable to that of a coating contractor. Therefore, they already knew the number of parts per bar, the chain speed, and the results they wanted to achieve. Above all, they knew very well the possible coating issues related to each product. This facilitated us so much so in the development of the right solution that the samples produced in the second project phase were already close to the desired end products.” “The selection of a hanging system,”

The P20 and P25 hanging systems.

says Paolo Rizzo, the export manager and plant manager of Temo Srl, “is the result of a research study carried out

simplified the coupling phase and they

together with the supplier in order to be

managed to guarantee maximum flexibility

able to hang as many parts as possible

in switching from a product type to

while meeting the coating plant’s

another, even while the chain is moving.

cycle time requirements.” Rostirolla’s

A further advantage is the shape of the

technical staff created a very detailed

load bars, which enables the operator to

computer simulation. “They were

apply powders in a simple and linear way.”

highly professional,” adds Rizzo. “They

Temo was able to present to Rostirolla all

When it comes to the surface coating of heavy workpieces or large-scale components, customers worldwide rely on high-performance plant technology and material ﬂow systems from Vollert.

types of components it produces at the 1 M. Fumagalli, “Maximum booth automation for the coating of metal components and oﬃce furniture,” in ipcm® International Paint&Coating Magazine no. 56 (March/April 2019), pages 72-78.

same time. “This further simplified our job,” states Simone Rostirolla. “It often happens that customers ask for a hanging

vollert.de

SPECIAL PaintExpo

SUCCESS STORIES

with Temo. In their case, we customised the spacing between the supporting pole’s brackets as well as the “combs”, which were adapted to the dimension and shape of Temo’s parts.”

The Industry 4.0-oriented evolution of Rostirolla Rostirolla has decided to invest in machinery and software in order to better control its internal production processes and present itself on the market as a highly innovative company keeping pace with technological developments. “For our hook production department,” says Pierluigi Rostirolla, “we have recently invested in two new machines: one for the CE marking of our products and the other for bending hooks from 10 to 25 mm. For our bar production department, on the other hand, over the last five years we have chosen to invest in two new software programs to Hook marked by new machine introduced in the factory and, on the right, the detail.

improve our order and process management activities. Our goal is to integrate software that can interface with the machines of

product, which, however, can

Features of the hanging system

be modified over time in terms

Temo opted for Rostirolla’s flagship

aim of gaining total control on

of both structure and size: for

product, the P25 system , whose

our workflow.” This is proving a

us, this means re-analysing the

characteristics of strength and

winning strategy: in 2019, the

component and offering a new

durability are the result of years of

company reached a production

solution. As Temo immediately

study. “P25’s structure,” says Pierluigi

peak of about 25,000 P25 combs

provided us information on its

Rostirolla, “has now reached a level of

and 8,000 brackets. “We expect

whole range, we could perform an

optimisation that we can hardly further

to achieve even greater results

in-depth analysis to find solutions

improve. If necessary, this standard

this year,” says Rostirolla. “We aim

that were suitable for the largest

system can be customised according to

at offering ever more innovative

possible number of products at

specific needs, precisely as it happened

and advanced hanging and

system intended for a particular

our production plant with the

masking solutions.”

the same time, thus also reducing the load bars’ production times, since they were manufactured together.”

108

“Rostirolla introduces new accessories to its handing system P25” in ipcm® International Paint&Coating Magazine no. 58 (July/August 2019), page 21.

N. 62 - MARCH/APRIL 2020 - international PAINT&COATING magazine

For further information: www.rostirolla.it

G R

IMR Industriale Sud is among the Italian leaders in the production of both internal and external car components.

FOCUS ON TECHNOLOGY

SPECIAL PaintExpo

110

N. 62 - MARCH/APRIL 2020 - international PAINT&COATING magazine

FOCUS ON TECHNOLOGY

The automotive industry is characterised

units: IMR’s exteriors segment and

by very high chromatic variability. Colour is

Industriale Sud’s interiors segment.

one of the main variables of a car purchase

The exterior part range, including

decision, not only in terms of tint, but also

both coated and uncoated external

of effects – metallic, mica, matte, pearl,

components for vehicles, has in fact

pastel. According to a recent study , in 2018

been integrated with Industriale Sud’s

two thirds of all the vehicles produced were

know-how in the production of internal

coated with special effect paints. More and

components such as ceilings, car

more daring solutions are being sought,

parcel shelves, door interiors, and so

aimed at making a car’s appearance unique

on.” Besides its headquarter in Carate

for differentiation purposes. At the same

Brianza (MB, Italy) and the interiors

time, however, the entire European and

segment’s plant in Teramo, the firm has

world production chains are increasingly

nine production plants and ten Justin

aware of sustainability issues such as waste

in Sequence (JIS) factories throughout

and emission reduction, material recovery

Italy, Germany, Spain, and Poland. The

and reuse, and production optimisation

latter are production units located near

aimed at saving energy and creating a

car manufacturers’ plants, which they

circular economy.

provide with the necessary components

The car sector companies are constantly

‘in sequence’, according to requests and

looking for ways to combine customisation

without the need to create stocks.

and efficiency with green policies. This

“Our clientele is wide-ranging,” adds

is why they are investing in innovative

Ceppi. “With our coated external parts,

technologies to cope with the boom

we have gained high-end customers

in the demand for special colours and

such as Maserati, Ferrari, Lamborghini,

effects witnessed in the last few years. IMR

Porsche, Aston Martin, and McLaren,

Industriale Sud, among the Italian leaders in

just to name a few, but we also produce

the production of automotive components,

large volumes of uncoated functional

is an excellent example of this trend. Its

components for vehicles such as

investment in a new industrial management

Volkswagen Golf. With our interiors

technology for high quality paint products,

parts, we range from niche productions

supplied by Verind (Milan, Italy), a Dürr

devoted to handmade leather

group company, has enabled it to meet the

components for Rolls Royce, AMG, and

increasingly complex stylistic requirements

BMW to mass production operations for

of its customers while achieving a high

Volkswagen, Skoda, and many other.”

environmental sustainability degree.

The main strength of the company is

IMR Industriale Sud is among the Italian leaders in the production of automotive components, which it has always coated in-house. Recently, it has installed the EcoSupply P system of Verind, a Dürr group company, whose coating management unit can handle up to seventy different tints in an efficient and sustainable way, thanks to incredibly low paint loss and cleaning product consumption degrees and to very quick colour change times.

the strong vertical integration of its

IMR Industriale Sud’s evolution

production, as all phases are carried out

“IMR Industriale Sud was established two

in-house, from design to manufacturing,

years ago with the acquisition of Industriale

coating, and assembly. “We start with

Sud by IMR. The merger between these

a co-design stage, that is, the design

two equal-sized firms has enabled us to

of a product in collaboration with the

expand our presence in Europe,” says

customer, and we proceed with the

Gianluca Ceppi, the Industrialisation and

construction of moulds. Although we still

Technologies Director of the company.

buy most of our moulds, we now have a

“Currently, the group has around 2,500

system in our Carate Brianza plant that

employees and it operates through two

manufactures a few of them for some

distinct, but equally strategic business

specific market niches,” explains Ceppi. “We use many different production

1 Ipcm no. 55, January/February 2019 – pages 116-118

technologies: conventional injection

international PAINT&COATING magazine - MARCH/APRIL 2020 - N. 62

111

SPECI AL PaintExpo

The existing Paint Mix Room.

mostly manual process. We also use a

Part production is followed by coating

of bumpers, rigid polyurethane injection

few technologies patented by us, such

and assembly. This also includes the

moulding for low-volume productions

as multilayer moulding with multilayer

installation of any sensors, cameras, and

of bumpers, compression moulding

sandwich material plates. Our production

radars, in order to provide customers

for under-engine reinforcement plates,

process has a very high variability

with products that can enter their

and thermoset moulding for composite

and complexity level, and so do the

assembly line ready to be mounted on

materials calling for a highly complex and

technologies we use, all highly automated.”

car bodies.

moulding for high-volume productions

The Verind EcoSupply P system.

112

N. 62 - MARCH/APRIL 2020 - international PAINT&COATING magazine

A detail of the PIG cleaning system.

FOCUS ON TECHNOLOGY

The new coating management unit

and special effects. Conventional

crucial. Typically, a painting line

three-coat systems have now been

has fixed circulation pumps for the

IMR has always coated its exteriors

replaced by four-coat ones. The

most used colours, integrated with

components in-house. “We have

former typically include the wet-on-

wildcard pumps for all other tints.

two coating lines. One is highly

wet application of two base coats

However, the increase in production

flexible and treats most of our

and they are not well with suited

volumes and colour variability has

components, mainly for customers

to one-component water-based

forced the company to increase the

who apply body colours themselves,

base coats, which are the only one

use of wildcard pumps. “There are

so that we only have to apply a

we use. The latter, on the other

two main problems when handling

primer layer; the second one is a

hand, include the application of

a high number of tints: downtimes

special bumper coating system

a primer, a base coat with a clear

for each colour change operation

designed in 2015,” indicates Ceppi.

intermediate coat, and a second

and cleaning times. In addition,

“Initially, it only painted Maserati

base coat with another transparent

each colour changeover requires

components but, over the past

layer, thus guaranteeing greater

the removal of paint residues and

year, we have gradually added

stability especially in terms of

the cleaning of pipes, resulting in a

other parts for several high-end

adhesion. So we went from

waste of time and of both coating

customers. At the same time, we

managing about twenty-five colours

and detergent products,” emphasises

have witnessed a boom in the

to managing seventy.”

Ceppi.

demand for different colours, driven

For IMR, the role of coating

A turning point occurred when IMR

by the increasingly daring search

pumping units and the related paint

decided to invest in the EcoSupply P

for product differentiation elements

management has therefore become

technology of Verind, a Dürr group

Painting for all industries

Bringing your surface to perfection. Dürr offers painting solutions from manual to automatic application, high-quality and easy to integrate. www.verind.it

SPECI AL PaintExpo

Concept of Dürr’s PIG system to feed multiple robot stations.

company specialising in the development of equipment and eco-technologies for coating processes. “Dürr devised its EcoSupply P technology to specifically meet its customers’ requests to recover painting materials, to reduce the waste of paint and cleaning products in production lines with frequent colour change operations,” explains Marco Assorgia, Industry Area Manager at Verind. “It is an innovative, flexible, modular, and efficient coating feeding system, able to manage the countless colours required by the automotive sector. Paint circulation is based on the PIG technology, suitable for both waterbased and solvent-based products.” IMR’s PIG systems feed the two already-existing coating robots through A robot performs a pre-treatment cycle with the innovative CO2 snow jet technology devised by German firm acp Systems AG.

114

N. 62 - MARCH/APRIL 2020 - international PAINT&COATING magazine

dedicated interfaces. In general, the main characteristic of the PIG technology is the

WEâ&#x20AC;&#x2122;RE OBSESSED WITH COLOR YEARS OF EXPERIENCE IN RESEARCH & DEVELOPMENT OF CUSTOMIZED INDUSTRIAL COATINGS A complete range of industrial coatings Powder | Waterborne | Solventborne | High Solid | E-Coat

Inver and Syntha Pulvin are brands of The Sherwin-Williams Company

The Sherwin-Williams Company | Contact: gi.emeai.marketing@sherwin.com | Visit: www.sherwin-williams.eu

SPECI AL PaintExpo

scraper probe that runs in the calibrated coating circulation tubes to remove any paint residues and take them back to their drums, thus leaving the pipes clean for the injection of the next tint. This happens in a very short time and creates a circular economy. “PIG systems can also be used for non-standard coatings and for limited paint volumes and batches. EcoSupply P keeps coating processes efficient, with incredibly low paint loss and cleaning product consumption values, as well as very short colour change times. Its return on investment is significant compared with traditional systems, which is an important innovation for the market,” says Assorgia. “We implemented this technology in two stages,” states IMR Process Engineering Director Paolo Buratto. “We initially installed two PIG lines. We then decided to integrate a third one due to an

Robots for base coat and clear coat application.

Bumpers coated with a four-coat system.

116

N. 62 - MARCH/APRIL 2020 - international PAINT&COATING magazine

increase in the quantity of low-frequency

FOCUS ON TECHNOLOGY

colours we had to manage and, above all, because we were very pleased with the first two lines. This system has brought us enormous benefits. Our operators’ activity has been greatly simplified and our paint waste is now of just a few grams. We have estimated that, considering about 30 metres of pipes, we save more than one kilogram of paint products. Last but not least, Verind’s technical assistance staff has always been helpful and precise with documents.”

The coating cycle for external components The plant currently consists of a preparation/overhead cleaning booth, a robotised primer application booth with its oven, an overhead flame hardening booth for polypropylene, and an advanced coating booth with two robots applying the coloured base coats and the clear coats. Before primer application, a preliminary phase is performed that includes manual cleaning and degreasing with isopropyl alcohol and, afterwards, pre-treatment with the innovative CO2 snow jet technology, devised by German firm acp Systems AG. This system uses a dry and residue-free process for in-line cleaning the components’ surface areas that need to be coated. For this operation, liquid carbon dioxide is fed through a two-component anti-wear circular nozzle and it then expands to form thin crystals. These are aggregated by a circular jet of compressed air and accelerated to supersonic speed. When the non-abrasive jet of CO2 snow and compressed air hits the surface of the workpiece at a temperature of -78,5 °C, a combination occurs of thermal, mechanical, sublimation, and solvent actions. These four cleaning actions enable the system to reliably remove film contaminants, such as residues of release agents, silicone, and fingerprints, and particulate contaminants, such as dust and lint. If needed, a flame hardening phase follows the pre-treatment one for polypropylene components. The parts are then subjected to finishing.

The goal of customised but sustainable industrial production “The investment in this integrated automatic system for managing the high quality coatings we apply to our bumpers is a part of our company’s ‘green quota’: our group has committed to devote a share of its investments to sustainable projects. Indeed, we relied on Verind also because it has always been attentive to environmental sustainability issues and focussed on the creation of circular economy cycles for modern painting processes,” states Ceppi.

SPECI AL PaintExpo

but also environmental sustainability and energy efficiency policies aimed at meeting the needs of the present without compromising the ability of future generations to meet their own needs. Our technology, integrated in IMR’s already-existing, very high-quality lines, has brought numerous benefits, that is, maximum customisation capacity combined with the generation of less waste and emissions. An actual and innovative industrial result which combines a general production optimisation with integrated circular economy logics.”

From left to right, Alessandro Soba from Verind, Paola Giraldo from ipcm®, Gianluca Ceppi and Paolo Buratto from IMR Industriale Sud Spa, Marco Assorgia from Verind, and Giorgia Ricchiuti from ipcm®.

Sales Manager at Verind. “Nowadays,

to help them integrate sustainable

a company like IMR that operates in

industrial solutions and systems into

the global market can only achieve a

their production cycle as a significant

competitive advantage by adopting

corporate improvement,” says

not only technological innovations

Alessandro Soba, Industry New Business

and Industry 4.0-oriented solutions,

“IMR Industriale Sud asked Verind

Modularity concept of Dürr’s PIG system. On the right a PIG unit during assembly.

118

N. 62 - MARCH/APRIL 2020 - international PAINT&COATING magazine

SAFE

STURDY

SUCCESS STORIES

SPECIAL PaintExpo

Transparent Information for A Simplified Management of The Coating Process 4.0 Transparency of the powder coating process anytime and anywhere. With the COATIFY information and management platform, WAGNER fulfils this wish of a leading contract manufacturer in metalworking. The web-based system continuously provides relevant performance data of the coating system and raises awareness among the workforce for system utilization, cost reduction and highest quality in coating.

precision are manufactured

has led to a doubling of the

Fox Laser Ltd is a leading contract

for renowned suppliers in the

workforce in the last four years.

manufacturer in the metalworking

automotive, transport and switch

The growth required expansion

industry. In Sofia, Bulgaria,

cabinet construction sectors.

of the production facilities to

housing and profile components

The increasing capacity utilisation

increase capacity. This also

of the highest quality and

of the company due to its success

applied to the companyâ&#x20AC;&#x2122;s surface

ÂŠ Wagner Group

The challenge

Transparent information for a simplified management of the coating process 4.0.

120

N. 62 - MARCH/APRIL 2020 - international PAINT&COATING magazine

SUCCESS STORIES

to date at the beginning of 2019. For this purpose, a fully automatic

technology, which was brought up

SPECIAL PaintExpo

WAGNER powder coating system with powder centre, booth and ten automatic guns was installed. The successful company development at Fox Laser requires the continuous hiring of new employees, who have to quickly familiarize themselves with the production facilities. At the same time, costs have to be continually optimized to ensure high production quality and competitiveness. In order to meet these versatile requirements, those responsible at Fox Laser wanted a comprehensive yet easyto-use process control system for powder coating. The aim of the

The WAGNER system with the web-based information and management platform COATIFY represents the latest state of the art in powder coating technology.

production manager was to keep an overview of the system anytime status at all times.

The solution In the planning phase for the new

and anywhere and to know its

powder coating plant at Fox Laser, WAGNER Industrial Solutions launched the COATIFY information and management platform. This system exactly meets Fox Laser’s expectations for modern process monitoring. The web-based Internet of Things platform COATIFY visualizes the powder coating process intelligently and continuously. The system’s performance data can be captured at a glance on the clear user interface with descriptive diagrams and graphics. Relevant production data are easily prepared and logged, providing the user with a perfect overview of the process. The platform can

COATIFY optimally complements the components of the WAGNER powder coating system and makes the coating process even more eﬃcient and economical.

international PAINT&COATING magazine - MARCH/APRIL 2020 - N. 62

121

SPECIAL PaintExpo

With COATIFY, service measures can be planned in good time in order to increase system availability and thus save costs.

be accessed via PC, tablet or smartphone and enables secure access to internal production data from anywhere. “For us, COATIFY came at just the right time. With the continuous provision of important production data on various end devices, we have the possibility to carry out an extremely reliable production monitoring. This improves process reliability and increases productivity,” says Dako Lisichkov, Managing Director at Fox Laser. He is convinced that COATIFY is optimally equipped for the future also with upcoming updates and new developments with regard to Close-up of an exemplary metal workpiece from Fox Laser after powder coating.

122

N. 62 - MARCH/APRIL 2020 - international PAINT&COATING magazine

new coating solutions.

SUCCESS STORIES

The customer experience After a short time COATIFY has already proven itself in operation at Fox Laser. Thanks to the clearly structured and graphically comprehensible system information, seamless monitoring of production is ensured at all times. Timely information on upcoming maintenance, malfunctions or deviations from individually definable limit values increase quality and system availability and thus reduce costs. The system operators at Fox Laser can also access the current operating manuals of the systems at any time via COATIFY. If a question cannot be answered on site, the customer sends a service ticket directly to WAGNER via COATIFY. This ticket provides system data and running times of the components electronically. If required, WAGNER service staff can also carry out remote maintenance. “With COATIFY, we at Fox Laser now have full control over our coating quality and can intervene immediately if a parameter changes. This transparency increases process reliability, which will also have a positive effect on cost accounting,” Dako Lisichkov is convinced. COATIFY optimally complements the coordinated components of the WAGNER powder coating system and thus, makes powder coating even more efficient and economical. With COATIFY, WAGNER has created an industry solution with added value that raises production plants in surface technology to a new level in terms of economy, efficiency and process reliability. For further information: www.wagner-group.com

Innovative solutions

Innovative Lösungen

Eurotherm solves every problem concerning painting processes, creating complete lines for the entire process.

Eurotherm löst alle Probleme in Bezug auf Lackierprozesse und erstellt komplette Linien für den gesamten Prozess.

Our structure is organized and flexible and able to satisfy the most demanding requests.

Unser flexibles und lösungsorientiertes Unternehmen ist darauf ausgelegt die anspruchsvollsten Anforderungen zu erfüllen.

Customers who turn to Eurotherm are customers who, despite knowing the “painting process”, want to improve production by adopting highly customized technical solutions.

Headquarter: based in Turin (IT)

Number of employees: 65

Eine Vielzahl unserer Kunden sind sehr erfahren im Lackierprozess. Zusammen mit ihnen entwickeln wir individuelle technische Lösungen, optimal auf ihre Bedürfnisse abgestimmt.

Plants realized in 2019: 180

Other locations: Stuttgart (DE), Toulouse (FR), Verona (IT)

EU1: 3.500 m² of offices, carpentry and painting departments EU2: 5.300 m² for sheet metal department, assembly, storage and shipment

Eurotherm Lackieranlagen GmbH T +49 711 400 545 13 | M contact@eurotherm.eu Andreas Bisinger Geschäftsführender Gesellschafter T +49 172 749 64 74 | M andreas.bisinger@eurotherm.gmbh

eurotherm.eu

Joe Kaut Vertrieb Süddeutschland/Österreich/Schweiz T +49 172 783 83 22 | M joe.kaut@eurotherm.gmbh

UV clear coatings are well suited as adhesive primers on diﬃcult substrates prior to printing in order to ensure the adhesion of digital print colours.

INNOVATIONS: PRESENT&FUTURE

SPECIAL PaintExpo

Increasing Productivity, Reducing Emissions Oliver Zanner FreiLacke - Emil Frei GmbH & Co. KG, Bräunlingen-Döggingen – Germany

o.zanner@freilacke.de

UV coating systems from FreiLacke are curing particularly quickly and offer outstanding mechanical properties.

Coatings protect surfaces, provide them with

all of their components react with each other

systems, which are the subject of growing

new functions and refine them with special

during the UV curing process, hardly any

regulatory scrutiny.

colours and haptic elements. UV coatings

VOC emissions are produced when they are

UV coatings are applied using a rolling or

with environmentally friendly properties are

processed. That makes them a particularly

spraying process. They are dried using

becoming increasingly popular: since nearly

interesting alternative to solvent-based coating

sources of radiation that emit ultraviolet

124

N. 62 - MARCH/APRIL 2020 - international PAINT&COATING magazine

INNOVATIONS: PRESENT&FUTURE

light and do not require a lot of heat.

coatings in order to minimise solvent

The photo initiators contained in the

emissions in the production process.

High scratch resistance, good elasticity

coating absorb the energy from the

If the surfaces are flat, completely

Thanks to its integrated nano particles,

light and disaggregate, which triggers a

solvent-free UV coatings can be rolled on.

ES1952H in particular boasts a very high

chain reaction – following a short, high-

The coating expert Frei offers a variety

scratch resistance, good elasticity and good

energy radiation, the UV coating systems

of UV coatings that stand out because

chemical resistance, which was tested in

are cured. The advantage: The coated

of their very short curing times and

accordance with DIN 68861, according to the

substrates can immediately be processed

very good mechanical resistance. For

coating expert. In addition, the ES1910 and

further, packaged or stacked. That results

example, immediately after they are fully

ES1913G systems also feature top chemical

in an increase in productivity in the

cured, the ES1910, ES1952 or ES1913 UV

and disinfectant resistance, which customers

manufacturing sector.

coatings feature a surface hardness of

often demanded for interiors.

more than 100 oscillations according to

Over the past decades, UV coatings were

Minimal abrasion

the pendulum hardening method.

primarily used for wooden surfaces. But that

“UV systems are mainly used on flat

“This is also evidenced by the abrasion

has changed: They are now also being used

surfaces,” said FreiLacke’s Dipl.-Ing. (FH)

test according to TaberAbrasor CS10

for substrates like metal or plastic. But UV

Beate Brehmer. “But the development of 3D

2 x 500 gram at 500 revolutions. The

clear coatings from FreiLacke do not just

curing mechanisms is progressing rapidly,

abrasion of the FreiLacke products

protect surfaces: Systems like ES1975HF

which means they can also be used on less

ES1901 and ES1952 is less than

or ES1970 are also well suited as adhesive

even surfaces. As a result, we are seeing an

5 milligrams”, explained Gut. In

primers on difficult substrates prior to printing

increased use of hydro UV coatings”. The

comparison: It is approximately 10 to 15

in order to ensure the adhesion of digital print

formers are usually applied as UV spray

milligrams for conventional UV coatings.

colours.

SPECI AL PaintExpo

Practical example: UV coatings at Stengel GmbH

using special UV lamps and then

radical polymerisation. Fillers and

receive an overcoat of protective clear

pigments can be used for providing

The demand for digitally printed

coating that is sprayed on. Another

colour and matting as well as to keep

surfaces with UV materials is also

production process is not worth

prices low. Classic additives improve

on the rise – for example for plastic

considering, according to Sendner,

defoaming, flow, wetting and light

substrates in construction, walling

because the quality is just right and

protection.

elements for interiors and sanitary

the workflow has been perfected.

Depending on the applications

facilities as well as for printed

Stengel and FreiLacke are currently

process, the layer thicknesses

outdoor industrial surfaces. That is

jointly researching an anti-slip coating

of the UV systems of the coating

also the case at Stengel GmbH from

for ships.

manufacturer from the Black Forest vary from 10 to more than

Ellwangen: The company specialises

80 micrometres. That allows

shipbuilding sector – in particular for

Background information Focus on UV coatings

wet rooms. Stengel has been relying

UV-curable coating systems largely

gloss levels from high gloss

on UV systems from FreiLacke since

consist of oligomers (binding agents)

(angle < 20°:70-90GE) to matt

2013. “First, we prime our metal tiles

and monomers (reactive thinners).

(<60°: 15GE). Following 1,000 hours

with a white UV basecoat using a

They are primarily responsible for film

of WOM weathering, the products

spraying application. Following the

formation and give the coating system

ES 1901, ES1970 and ES1952 feature

partial gelling, the tiles are placed

its basic properties.

a residual gloss of >90 percent

in large flatbed printers, where the

The monomers are also tasked with

and a dE value of <1.5. In addition,

decorative UV coating is applied”,

reducing the viscosity. It is essential

FreiLacke has developed some highly

explained Uwe Sendner, the head

that the formulation contains

matt systems in recent years that

of production. Both layers are dried

photo-initiators in order to initiate

were well received by customers.

in the production of metal tiles for the

UV coating systems feature top chemical and disinfectant resistance, which customers often demanded for interiors.

126

An application example of UV coatings.

N. 62 - MARCH/APRIL 2020 - international PAINT&COATING magazine

them to meet a wide range of

Six-axis KUKA robot.

FOCUS ON TECHNOLOGY

SPECIAL PaintExpo

Hannex Increases Painting Efficiency and Quality with ProMix PD2K Philippe Godbil Graco, Maasmechelen - Belgium

philippe.godbil@graco.com

Polish paint sprayer Hannex has a mission to provide ultimate painting performance, and Graco’s latest 2K proportioner helps them meet their goals.

128

N. 62 - MARCH/APRIL 2020 - international PAINT&COATING magazine

The Hannex Painting Company is a young but fast growing

FOCUS ON TECHNOLOGY

company dedicated to high-quality painting services. Based in west Poland in the town of Obrzycko, about 50 km north of Poznań, the company started operations in 1996 as a specialist painter of plastic household goods. Over the years it has expanded its partnerships with the automotive industry with clients such as Man, Volvo, Ster and Kiel. The Hannex strategy is based on using the most modern technologies and innovative solutions offered by reputable companies. New automated varnishing lines were commissioned in 2013 and 2016, equipped with six-axis KUKA robots and state-of-the-art computer-controlled paint application systems. Recent investments include a double heat recuperation system, a constant humidity system, a fully automated drying plant, and the implementation of a 3D system for marking details. The company is certified to ISO 9001:2015 and ISO 14001:2015 quality management systems, confirmed by the TÜV Rheinland quality certificate. Moreover, their production processes and procedures comply with the VDA 6.3 standard. This is an extension of ISO 9001:2015 and aims to help automotive companies meet growth, innovation and compliance goals.

Responding to a more challenging market situation Recently, market challenges have driven Hannex to increase the efficiency of their production lines and further improve their already high production quality levels. New orders brought the necessity to achieve very low paint flows for the painting of small details. Together with new combinations of paint viscosities and mix ratios, their existing painting equipment was not able to provide the flexibility and efficiency they were looking for. Faced with these various

ProMix PD2K: Graco’s latest 2K proportioner.

had to make key decisions regarding the future direction of the company.

challenges, Krzysztof Iwanicki, owner and CEO of Hannex,

“We have been partnering with Graco and its authorized distributor Arkus for a number of years, especially for the application of two-component paints and coatings,” explains Iwanicki. “Discussions over the changing direction of Hannex came at the same time as the market release of an interesting new generation of Graco’s 2K proportioner ProMix PD2K.” The ProMix PD2K is based on unique technology of electrically powered and controlled positive displacement dosing pumps. The use of 100% positive displacement technology allows accurate mix ratios and consistent performance. It’s particularly ideal for short pot life materials,

KUKA robot for application and control of the process.

international PAINT&COATING magazine - MARCH/APRIL 2020 - N. 62

129

SPECI AL PaintExpo

as the ProMix PD2K mixes the material close to the gun so the flush zone is significantly smaller. This allows for faster colour changes, less material usage, and reduced disposal costs. In fact, up to 80% reduction in flushing waste is possible compared to the most efficient traditional proportioning systems. It also stalls under pressure for consistent, on-ratio results (within 1% accuracy), and is field serviceable in less than 20 minutes, which means there’s no need for costly factory rebuilds like gear pumps.

Upgrading with new Graco proportioners As Hannex was looking for a flexible solution that would allow the application of both water- and solvent-based coatings, instead of separate systems based on gear pumps, the ProMix PD2K Dual Panel was the perfect choice. This single unit allows the creation of two independent systems to supply two distinct robots equipped with automatic low-pressure guns. “This would enable us to dedicate one system to water-borne paints and the second system to solvent-borne paints, each for three colours and two hardeners,” adds Iwanicki. Hannex therefore requested Arkus to install the Graco ProMix PD2K Dual Panel. In addition, the paint kitchen was equipped with Graco’s proven low-pressure membrane Triton 308 pumps, which were installed in a separate room. The complete system was connected to the PLCs of the KUKA robots for application and control of the entire process. Air operated double diaphragm pumps.

Achieving higher eﬃciency and quality Hannex was completely satisfied with the new

installation. ProMix PD2K has enabled them to paint simultaneously with two independently operating robots, each with different colours for different details. At the same time, control of the overall process was consolidated in only one unit for easy operation. ProMix PD2K also allows the painting of small components with a high degree of flexibility, using between <3 and 50> cc/min. “The implementation of the Graco ProMix PD2K has helped us to improve the finish quality of our paint jobs and reduce the amount of improperly painted parts to less than 3%,” remarks Krzysztof Iwanicki. “This increase in efficiency played a key part in us achieving a very fast return on investment. In addition, the new installation proved to be almost Triton 1:1 150 Series Pump.

130

N. 62 - MARCH/APRIL 2020 - international PAINT&COATING magazine

failure-free.”

The PVD process can be applied to several sectors, from automotive to packaging, and it oﬀers clean but equally functional chrome plating results in terms of both resistance and quality.

INNOVATIONS: PRESENT&FUTURE

SPECIAL PaintExpo

UV Coatings and PVD Process, an Innovative Combination that Opens New Frontiers for Surface Finishing From an interview with Tristan Rodriguez GI EMEAI Specialty Plastics & PVD Segment Manager at Sherwin-Williams

The Specialty Plastics & PVD Segment, created in 2019 to bring together all the experiences developed over many years within the entire company Sherwin-Williams to accelerate its growth strategy in this particular sector, has developed a range of high solid UV coatings that are complementary to the PVD technology. In order to test these paints and offer its customers a demonstration of their application, Sherwin-Williams installed a Kolzer PVD machine in its laboratory in Mariano Comense (Como, Italy).

132

N. 62 - MARCH/APRIL 2020 - international PAINT&COATING magazine

INNOVATIONS: PRESENT&FUTURE

The issue of sustainability is playing a primary role in our global society, now more than ever. It does not only guide daily personal choices, but it is often also the reason behind corporate strategic decisions. Sustainability has increasingly turned from a simple (so to speak) practice to a real competitive advantage by intertwining with technological innovations, which are its true drivers. An example of this is the PVD technology. The Physical Vapour Deposition (PVD) process can be applied to several sectors, from automotive to packaging, and it offers clean but equally functional chrome plating results in terms of both resistance and quality. PVD has carved out more and more space in the surface treatment industry as a replacement for galvanic processes, which are far more polluting. Paint

The KOLZER DGK24 PVD system installed in Sherwin-Williams’ laboratory in Mariano Comense.

manufacturers have also recognised the potential of these process, thus

Industrial application conditions in the laboratory

solutions and specific products for each

to PVD that offer additional metal protection properties and the ability to

“Sherwin-Williams pays great attention

machine supplied by Kolzer, a company

customise finishes with different effects.

to the needs of the market, which is

we have known for a long time, as it

Sherwin-Williams was among the first

increasingly requiring solutions that

has already served several firms in the

multinational companies to devote a

ensure a high quality level in terms of

cosmetic, home appliance, design, and

business segment to plastics and PVD,

both resistance and aesthetics, but that

automotive industries.”

in order to develop UV coatings capable

are also sustainable and environmentally

“We equipped the Mariano Comense

of increasing process performance.

friendly. This is also due to more and

laboratory with a KOLZER DGK24 type

In its laboratory in Mariano Comense

more stringent chemical regulations, such

machine. We opted for a medium-sized

(Como, Italy), Sherwin-Williams has

as REACH, the European regulation on

plant instead of a laboratory version

recently started a research and

the use of these products, which provides

in order to enable Sherwin-Williams to

development project for a range of

for the elimination of Chromium VI from

perform treatments on ‘real’ parts,

UV coatings to be applied in market

any industrial process by 2023,” explains

with processes that are as close

sectors where PVD processes are

Tristan Rodriguez, the GI EMEAI Specialty

as possible to actual industrial

widespread, such as the cosmetics and

Plastics & PVD Segment Manager of

applications,” explains Kolzer owner

car interior ones. In order to give added

Sherwin-Williams. “All these factors, as

Antonio D’Esposito.

value to this development process and

well as the intent to follow the growth

“We chose this model to operate in

guarantee the full functionality of its

trend of PVD and its related paints,

the same process conditions of our

coatings, Sherwin-Williams installed a

led us to the creation of our Specialty

customers. Performing operations

PVD machine in its lab. It was supplied

Plastics & PVD division, devoted to the

as similar as possible to real-world

by Kolzer Srl (Cologno Monzese, Milan,

development of a range of UV coatings

applications is a factor of fundamental

Italy), which has been designing and

capable of increasing the performance

importance for us, because in this

developing PVD chrome plating systems

degree of PVD processes. In order to

way we are able to coat workpieces

since 1952.

provide our customers with tested

and send them to our customers

developing complementary products

application, we also installed a PVD

international PAINT&COATING magazine - MARCH/APRIL 2020 - N. 62

133

SPECI AL PaintExpo

and paint adhesion; PVD stage; and top coat application to improve aesthetic and resistance characteristics.

The future of the automotive industry? “Thanks to our collaboration with Kolzer and to Sherwin-Williams’ commitment to implement increasingly more sustainable technologies, we have managed to develop base coats and top coats for the cosmetic packaging industry and we are now working on other products to meet the needs of several other sectors. We will soon install a second Kolzer PVD machine in one of our laboratories in France, with the aim of further expanding this segment in Europe, and The Kolzer system enables Sherwin-Williams to perform demonstrations and to develop the most eﬀective cycle directly on the customers' products.

subsequently in the rest of the world,” states Tristan Rodriguez. “One of the most promising markets for this technology is the automotive sector, that has always sought and required

for technical approval, so that they can

on, without any dimensional and structural

high performance levels in terms of impact,

directly assess our products and their

limitation,” states Antonio D’Esposito.

scratch, humidity, and chemical resistance.

effectiveness. In addition to supporting us in

“Research on colours and aesthetic finishes

Indeed, we expect strong growth in this field

the development phase, our Kolzer system

is very important for Sherwin-Williams. This

and the tests carried out so far have obtained

enables us to perform demonstrations and

is why we organise workshops in which our

promising results.”

to develop the most effective cycle directly

customers have the opportunity to meet our

“Sherwin-Williams and Kolzer are at the

on the customers’ products,” indicates

designers, test the finishes obtained with

forefront of promoting the use of more

Tristan Rodriguez. “Thanks to this Kolzer

PVD processes, and learn about new colour

sustainable products and processes, able to

machine, we were also able to test and

trends,” confirms Tristan Rodriguez. The

meet the specific needs of the market in terms

develop a base coat and top coat range for

ideal process includes as follows: base coat

of quality, customisation, and production

the cosmetic packaging industry. These are

application to increase substrate hardness

efficiency,” he says.

low VOC content, able to meet the needs of the cosmetic industry and to offer excellent chemical and mechanical resistance when combined with a PVD process.” “The combination of UV coatings and PVD technology results in a safer and more environmentally friendly cold process, with no water consumption or harmful emissions. The cycle speed also guarantees economic savings on process and material costs, as well as a high production yield. Thanks to the use of UV paints, this process creates an ideal coating to give products high performance and excellent aesthetic properties. This increases their perceived value and enables designers to freely select base materials, that is, plastics, metal, glass, wood, leather, and so

134

One of the most promising markets for the PVD technology is the automotive sector.

N. 62 - MARCH/APRIL 2020 - international PAINT&COATING magazine

booths

ovens

cataphoresis

tunnels

complete plants

eosmarketing.it

conveyors

IDEAS NEED TALENT C.M.V. srl - Via dellâ&#x20AC;&#x2122;industria, 2 - 61036 Tavernelle di Colli al Metauro, PU - Italy - T +39 0721 892274 - info.cmv@cmvimpianti.it - www.cmvimpianti.it

PhoenixTM has strengthened the FIS04 system with an intrinsically safe data logger.

INNOVATIONS: PRESENT&FUTURE

SPECIAL PaintExpo

PhoenixTM Company History Carola Konitzer PhoenixTM GmbH, Bad Oeynhausen – Germany

carola.konitzer@phoenixtm.de

PhoenixTM was founded in 2010 by Michael Taake, Ian Budden and Dave Plester. Two company headquarters were established, PhoenixTM GmbH in Bad Oeynhausen and PhoenixTM Ltd. UK based in Earith near Cambridge.

136

N. 62 - MARCH/APRIL 2020 - international PAINT&COATING magazine

INNOVATIONS: PRESENT&FUTURE

The three company founders before creating PhoenixTM had worked very closely together in the Industrial Temperature Profiling industry, in the specification, design, promotion and support of temperature monitoring solutions. Together they accumulated over sixty years of experience. Michael Taake knows the heat treatment market and customer requirements very well through his time in sales. Ian Budden was involved in development and has very precise knowledge of the requirements for the system components in the heat treatment area. Dave Plester, on the other hand, was an industry expert of high temperature applications such as steel and aluminum processes and brought valuable knowledge and further developments into the companyâ&#x20AC;&#x2122;s knowhow. Sadly, Dave passed away in 2017. The two companiesâ&#x20AC;&#x2122; headquarters in Germany and Great Britain have grown continuously in recent years, so that PhoenixTM GmbH moved to larger premises at its current location in Bad Oeynhausen in October 2017. PhoenixTM Ltd in the UK also moved in 2015 from Ely to Earith and larger premises with improved production and services facilities. PhoenixTM GmbH with now nine employees, the sales areas Europe, Mediterranean countries, Middle East and Russia as well as their former republics are served from here. In many of these countries, PhoenixTM GmbH has cooperation partners who have been involved to a large extent from the very beginning and are very familiar with the products and possible applications. This guarantees competent and always available customer support on site. In addition to sales, customer service is a major component of the company philosophy. At the location in Bad Oeynhausen, the data loggers are calibrated and repairs are carried out. Calibrations according to UKAS guidelines are carried out in England. The next milestone is the targeted DAkkS certification of the German location in order to further expand the service for customers. PhoenixTM started with temperature measurement systems for the high temperature range. This is still one of the core competencies today. Gradually, more and more areas of application were added, driven by close collaboration with an increasing customer base. Thanks to the many years of intensive cooperation with many customers, PhoenixTM has successfully brought many innovate unique new technology break throughs in the heat treatment monitoring onto the market. For example, the Oil Quench TS12 system, which

visit us at Messe Karlsruhe October 12-15, 2020 hall 1, booth 1541

ÂŠ PhoenixTM

SPECI AL PaintExpo

A glimpse of the company.

was developed in close cooperation

short decision-making processes

depending on the recipe, can

with the IWT. This system made it

and close cooperation with

produce explosive gases.

possible for the first time to measure

development and production in

Temperature monitoring is and

a complete carburizing process

England, such projects can be

remains an important part of

including an oil quench bath. Not

implemented quickly and easily.

production, in the high temperature

only the furnace temperatures are

The latest development is a

sector (steel and aluminium

measured, but also the heat transfer

system that was continued from

applications), in coating, but also

in the quenching bath is also made

the FIS04 coating system to meet

in the ceramic industry and in the

visible. Vapor formation or insufficient

the requirements of the ATEX

food sector. Due to the constantly

flow can be optimized easily based on

regulations (ATmosphere EXplosive

increasing demands on quality

the measured data.

= explosive atmospheres). Since

and product safety, but also new

Another example for a new product

the last change in 2014, these

market developments, such as

development is the TS27 thermal

have passed from the BetrSichV

the advancing conversion of the

barrier series, which, depending on

(Industrial Safety Ordinance) to the

automotive industry to electric

the specific needs, can be individually

GefStoffV (Hazardous Substances

cars, it is becoming increasingly

adapted to the respective customer

Ordinance). In the course of this

important to gain safe and precise

requirements. For example, in the

transfer, various new requirements

knowledge of the applications and

robot assembly of heat treatment

for the regulations were added,

processes. Process reliability and

furnaces, this is an important aspect

which must now be taken into

product quality are not the only

in order to enable smooth loading

account. In order to be able to offer

important factors. The efficiency of

and unloading of the furnaces. The

legal security to those responsible

the furnace and the optimization

containers are designed to fit into

for security in the company,

an engine block, for example, and, if

PhoenixTM has strengthened the

emissions are equally important.

necessary, can be inserted into the

FIS04 system with an Intrinsically

All of this is directly related to the

production line at any time without

safe data logger to comply with the

correct setting of the ovens. The

interrupting production. The gripper

valid ATEX approvals according to

aim of every oven measurement is

of the robot can handle the complete

Directive 99/92 / EC (or ATEX 137).

to balance the energy input and the

measuring system as easy as a normal

It has been certified accordingly

quality of the products in such a way

work piece. Other collaborations

and is approved for Ex Zone 2.

that the two are optimally balanced.

take place in the area of software

This is particularly important for

This is exactly what the PhoenixTM

development and integration in, for

wet painting systems, as the paints

temperature measuring systems

example, the furnace controls. With

are outgassed while curing and,

offer.

138

N. 62 - MARCH/APRIL 2020 - international PAINT&COATING magazine

of operating costs and CO2(g)

Aerial view of the plant.

FOCUS ON TECHNOLOGY

SPECIAL PaintExpo

SLA Industrie: A Last Generation Vertical System to Increase the Productivity of a Service Company in the Aluminium Profile Sector Alessia Venturi ipcm®

SLA Industrie, a service company for the procurement, processing, finishing and assembly of aluminium profiles for the French ATRYA Group, has invested in a vertical coating plant for profiles with a maximum length of 7 meters, designed and installed by SAT (Verona, Italy), to replace the previous saturated horizontal plant. The new line presents two highly productive V-shaped coating booths featuring dense phase application devices and numerous technical characteristics aimed at improving sustainability and product quality.

140

N. 62 - MARCH/APRIL 2020 - international PAINT&COATING magazine

FOCUS ON TECHNOLOGY

(Fougerolles-Saint-Valbert, France), specialising in the processing and coating of aluminium profiles for door and window frames. The boom occurred over the previous ten years in the aluminium frame market had completely saturated the horizontal coating line of the company. In order to make up for its lack of production capacity, SLA Industrie chose to make a major investment in a vertical coating plant for profiles with a maximum length of 7 metres. SAT (Verona, Italy) designed and installed it, supplying a last generation, high productivity line with two V-shaped coating booths featuring dense phase application devices and numerous technical characteristics aimed at improving sustainability and product quality.

Sectional view of the profiles assembled with the thermal bridge.

Company history SLA Industrie operates as the procurement, processing, finishing, and assembly service provider of the ATRYA group, a French plant engineering business in the sector

with finished products, or semi-finished products that

of architectural profiles. Johannes Tryba, a carpenter of

have reached the required process stage, as quickly as

German origin, established it in 1980 in the French region

possible. In order to do so, it is essential to have systems

of Alsace by launching the production of PVC windows with

and machines that enable a lean production flow and

fifteen employees and a production capacity of twenty

can compensate for any production peaks or structural

windows per day, sold in the French market. Indeed, the

increases in demand – including the demand for small

ATRYA group’s history is the story of a passion that became

batches - without the need to rely on contractors.

a job and of a job that proved a very successful endeavour.

This was also the issue faced in 2018 by SLA Industrie

In 1984, TRYBA designed its first range of profiles.

The mission of a service company is to provide its customers

Detail of the vertical coating installations

international PAINT&COATING magazine - MARCH/APRIL 2020 - N. 62

141

SPECI AL PaintExpo

recyclability even when painted. The ATRYA group was officially created in 2004 by including various brands, operating in both the BtoB and BtoC markets and in the public building sector. Since 2004, the ATRYA group has continued to expand in France, Germany, Switzerland, and Belgium by incorporating new sectors, such as that of profiles for verandas, pergolas, and garage doors. It thus became a benchmark company in the market of high quality architectural structures. Its strong focus on the protection of our planet has led it to adopt a responsible development philosophy, based on continuous

innovation that is also respectful of humankind and the

Pascal Fischer, SLA Industrie general manager.

Its success was such that in 1988 it completely automated its production process. TRYBA managed to consolidate its presence in all market segments, thanks to both targeted acquisitions and the establishment of various production units in France, Switzerland, and Germany, thus laying the foundations for the creation of a European-level group. PVC door and window frames were joined by wood and, above all, aluminium ones. Indeed, since the 2000s aluminium has become more and more appreciated thanks to its characteristics of sustainability, lightness, and

The loading.

The warehouse with the pre-load zone.

142

N. 62 - MARCH/APRIL 2020 - international PAINT&COATING magazine

Internal view of the pre-treatment tunnel.

FOCUS ON TECHNOLOGY

environment: this approach is well summarised by its motto, “ATRYA, Making the best of WE (World’s Energy)”.

SUPER DURABLE POWDER COATING SOLUTIONS FOR

The ATRYA group is now among the major European door and window manufacturers, with 1450 employees, 15 production sites in Europe, an annual turnover of 265 million Euros, and a commitment to always invest in the excellence of its product.

The transition from the horizontal to the vertical system Established in 2008, SLA Industrie is the ATRYA’s group service company. It deals with all the operations needed to transform a profile into a window or door, from machining, thermal bridge assembly, and accessory

AGRICULTURAL, CONSTRUCTION & EARTHMOVING EQUIPMENT

and small part integration to coating, wood-effect sublimation (carried out in-house), and anodising (currently outsourced). In addition to these services, SLA Industrie also manages the procurement of the aluminium extrusions used by all the companies of the group to produce their aluminium, wood/aluminium, and PVC/aluminium doors and windows. in the last few years, thanks to the sustainability characteristics of this material, whose properties perfectly meet the requirements of recyclability, low environmental impact, and lightness of structures. Aluminium frames have gained more and more ground

POWDE

“The demand for aluminium has grown exponentially

Visit us in Hall 2, Booth 2128 R

within our group, to the point of pushing us to invest in a new coating plant to adapt our productivity to the boom in market demands. In 2018, our production volume had reached 400,000 coated square metres per year: despite working on three shifts, our horizontal line had reached full capacity. We therefore chose a vertical system supplied by Italian company SAT. We definitely broke with the past, since our already-existing plant was a horizontal machine,” says SLA Industrie general manager Pascal Fischer. “At the end of 2019, the vertical line was ready for the ramp-up phase and we started gradually reducing the use of the previous plant – a phase that is still underway. The vertical line is also supported by a small horizontal line, which we installed in 2015 to coat the accessories and sheets necessary to complete our profiles.” “We deliberately chose a vertical plant that was oversized with respect to our current production needs because we knew we had to take an important step for the development of our company,” states Pascal Fischer. SLA Industrie also coats parts for some firms outside the ATRYA group, which it provides with an integral profile

EcoPoliﬁx Srl − Socio unico T: +39 (0) 424/848555 E: info@ecopoliﬁx.it Member of HELIOS. Part of KANSAI PAINT.

www.ecopoliﬁx.it www.helios-powdercoatings.com

SPECI AL PaintExpo

The vacuum evaporator of the water treatment plant.

production according to both colours and delivery deadlines, and dropped off in a few storage buffers in front of the vertical system’s loading station: each buffer corresponds to a different customer or colour batch. SAT’s plant includes a pre-treatment station with a Qualimarine-level cycle with alkaline attack, acid attack, conversion, and rinsing phases. “We chose to obtain the Qualimarine certification: it is the quality mark of French association Adal and it differs from the Qualicoat Seaside one because it has lower tolerances in terms of raw material quality and especially of copper content in alloys, as it is a corrosion factor,” explains Pascal Fischer. “Pre-treatment waste water is handled with a zero-discharge purification

system with a vacuum evaporator.”

The pre-treatment tunnel.

management service based on their production schedules, so that they can directly manufacture the window frames with the profiles of each batch.

Features of the vertical line: energy eﬃciency, safety, and excellent coating quality SLA Industrie stores its profiles, mostly coming from European extruding firms, in an advanced automatic warehouse with 2,200 slots. These are then picked up according to production orders, aimed at optimising

144

N. 62 - MARCH/APRIL 2020 - international PAINT&COATING magazine

Pascal Fischer from SLA Industrie, on the left, with Stéphane Sénéchal from SAT.

FOCUS ON TECHNOLOGY

temperature rises. In this area of France, it can be very hot in summer: the coolers prevent the baths from accumulating too much heat. Finally, the pre-treatment station features a scrubber system to purify the tanks’ vapours before air is released.” The powder application area consists of two V-shaped booths, each equipped with 16 spray guns fed through GEMA dense phase pumps. “In the V-shaped booths, the suction ducts are located behind the guns and, therefore, overspray suction also contributes to paint the profiles,” says Pascal Fischer from SLA Industrie. “Thanks to their rotating walls, the booths are constantly cleaned during

The booth 1.

The booth 2.

“The drying oven following the pre-treatment station was separated from the curing oven already during the design stage, at the specific request of SLA Industrie,” says Stéphane Sénéchal, project manager at SAT, “because they required a process enabling to fine-tune operating temperatures. This is why we installed two independent ovens, each with its own burner. With the aim of better managing energy efficiency, we have also equipped the pre-treatment tunnel with two cooling unis in correspondence with the conversion tank, which keep the baths’ temperature constant when the environment’s

Touch screen for booth and guns setting up.

international PAINT&COATING magazine - MARCH/APRIL 2020 - N. 62

145

SPECI AL PaintExpo

The V Shape configuration with opposing guns.

spraying, so that the colour change operations are very quick. The two booths work simultaneously, not based on the typical distinction between light and dark colours, but rather on production batches. Of course, we try to optimise production orders by tint, but our main goal is to meet our customers’ deadlines and only rarely is it

possible to devote one booth to dark colours and the

The powder centre.

other to light ones. We currently perform five to twenty colour change operations per shift. We carry out powder recovery operations or not depending on each batch size. The speed of the chain is 1 metre/minute and during loading we leave 5 metres between one batch and another: if the batch to be processed is smaller than 5 metres of chain, we do not recover the powder used.” “The latest type of GEMA dense phase powder management unit is equipped with a gap control system, The fans are positioned at floor level of the oven.

146

N. 62 - MARCH/APRIL 2020 - international PAINT&COATING magazine

which automatically detects the lack of profiles on the

FOCUS ON TECHNOLOGY

are normally managed by individual control modules,” says

Coating eﬃciency with reduced powder consumption and improved quality

Stéphane Sénéchal from SAT. “This enables the operator

“Last year, we decided to standardise the use of Qualicoat

to save time and prepare for the subsequent coating

Class 2 powders in order to guarantee excellent quality

program while the system performs the booth and gun

and position ourselves in the high-end market. This led to

cleaning operations.”

a natural selection of our paint suppliers. We have now

“Another peculiar characteristic of this plant is its curing

three main ones: Tiger Coatings, Axalta, and IGP,” explains

oven. It has excellent insulation and softer, more fluid,

Pascal Fischer from SLA Industrie. “With the installation of

and uniform air distribution, since this comes out from

the new plant and, above all, thanks to GEMA dense phase

numerous bottom holes with the same speed. In this

technology, we have already found that we consume much

way, air comes out fragmented and with a constant flow:

less powder than we did on the horizontal line. We already

this avoids any collisions between the profiles and the

had some experience in the use of dense phase pumps on

dispersion of impurities, which may cause inclusions

our horizontal line for coating some accessories, and we

on the profiles’ finished surfaces,” indicates Sénéchal.

chose to also install them on our vertical line because the

“Moreover, gas consumption is limited and fans are

application quality degree is higher.”

positioned at floor level to facilitate maintenance. Finally,

“While designing this plant, we focused on the

its most important construction characteristic, which has

environmental issues related to energy efficiency, which

become the trademark of SAT plants’ curing ovens, are

is a very important aspect for those who choose such a

revolving doors. These are an excellent solution, because

sustainable material as aluminium,” states Fischer. “We

they give the profiles time to gel, with very positive effects

opted for SAT as our plant supplier because its offer best

on coating quality, the reduction of any inclusions, and

suited our technical needs. I especially appreciated the

energy savings.”

oven’s revolving doors, which reduce consumption while

chain and allows simultaneously turning off all guns, which

SPECI AL PaintExpo

AP01 dense phase pumps.

eliminating the inclusion problem on profiles, which is due to the contamination that normally occurs at the entrance of curing ovens. The V-shaped booth concept is also very interesting: we are obtaining excellent finishing results even on very complex profiles: although we still need to optimise a few parameters, the difference with the coating results of the horizontal line is already clearly visible. Therefore, I can say I am pleased with our switch to a vertical plant concept. Obviously, this phase is not easy to manage because our operators must get used to a completely different coating process, but for now things are going very well, exactly as we expected.”

The oven’s revolving doors.

The unloading.

148

N. 62 - MARCH/APRIL 2020 - international PAINT&COATING magazine

LED-UV technology oﬀers various technical and economic advantages – it can be used in a significantly broader range of applications thanks to new paint developments.

INNOVATIONS: PRESENT&FUTURE

SPECIAL PaintExpo

Optimising Painting of Plastic Workpieces: Economically Fulfilling Stricter Requirements for Quality and Sustainability Doris Schulz SCHULZ. PRESSE. TEXT, Korntal – Germany

ds@pressetextschulz.de

The number of plastic parts being coated is rising inexorably – in a nearly unlimited range of diversity. Demands placed on the quality and individuality of painted surfaces are increasing continuously as well. At the same time, less and less expensive and increasingly sustainable coating processes are required. These requirements can only be fulfilled by means of consistent process optimisation. Attention will be focused on corresponding solutions at this year’s PaintExpo.

150

N. 62 - MARCH/APRIL 2020 - international PAINT&COATING magazine

INNOVATIONS: PRESENT&FUTURE

Whether cosmetics packaging, housings or

goals with regard to energy-efficiency and

chemicals, water nor drying are required

automobile parts are involved â&#x20AC;&#x201C; products

climate protection. The situation is further

for either of these processes, they also

made of plastic can be found in practically

complicated by cost aspects. All of this

make good sense where environmental

all industries and all spheres of life.

results in the need for high quality painting

and energy-saving aspects are concerned.

With the help of coatings, these products

processes which are more efficient, flexible

Beyond this, no heat is transferred to the

are frequently provided with appealing

and resource-conserving. Numerous

component which could cause substances

optics and haptics, an individualised

appropriate options will be presented by

used in the plastic such as release agents,

appearance, resistance to mechanical,

the exhibitors at PaintExpo 2020 (from 12

additives or filler materials to subsequently

chemical and physical stressing, as well as

to 15 October, in Karlsruhe, Germany).

migrate to the surface from deeper layers, thus resulting in adhesion problems.

special functional characteristics.

From Pre-Treatment to Quality Control

Electrostatic charging of the plastic

operations and coating job-shops are facing new challenges due to current trends and

Pre-treatment is taken into consideration

ionisation.

changes in numerous industry sectors.

first of all: alternatives to conventional

Where the paints themselves are

These include the use of new and modified

power washing such as plasma and

concerned, new developments resulting

materials and material combinations, the

from so-called single-coat systems are

realignment of entire industry sectors,

CO2 snow-jet technology often make

it possible to reduce cleaning process

making it possible to reduce the number of

shortened product lifecycles and smaller lot

costs and footprint, and to integrate fully

required painting steps, at the same time

quantities, personalisation of products, the

automated cleaning processes into the

achieving strong resistance to external

digital transformation and more rigorous

painting line. Due to the fact that neither

influences on painted surfaces. One of

surfaces can be counteracted by means of

ÂŠ acp systems

And thus companies with in-house painting

Alternative cleaning methods such as snow-jet technology make it possible to reduce cleaning process costs and footprint, and to integrate fully automated cleaning processes into the painting line. Beyond this, cold cleaning can eliminate adhesion problems.

international PAINT&COATING magazine - MARCH/APRIL 2020 - N. 62

151

SPECI AL PaintExpo

Whether manual or automated application is involved – the use of modern, electrostatic spray guns increases application eﬃciency and reduces overspray, thus minimising material consumption.

Plasma-vacuum coating in combination with UV paint is an eﬀective alternative for metallizing plastic parts.

the issues being dealt with in many

The trend towards automation is

of process parameters such as paint

industry sectors with regard to increased

advancing relentlessly – at small and

quantities, temperature, process air

sustainability involves alternatives to

mid-sized companies as well. Reasons for

and the spray jet, as well as logging

galvanising with chrome(VI). The paint

this include increased process reliability

and evaluating the resultant data, are

manufacturers have developed various

and reproducibility, as well as the minimal

also available. Furthermore, innovative

solutions to this problem. Depending

scrap rates which result therefrom

developments permit process-integrated

on the application and the requirement,

in combination with the respective

quality control of the coated surfaces –

these include three-coat paint systems

savings. Painting equipment and robot

for example non-destructive, contactless

or economically efficient single-coat

manufacturers are responding to this

coating thickness measurement on still

solutions. With their diverse colour

need with multi-axis robots specially

wet as well as already cured paint layers.

variants and effects, these paints are

designed for the coating industry, as well

Selecting the right process is a

more than just an alternative to a

as so-called robot painting cells.

prerequisite for a resource-efficient,

galvanically applied chromium coating.

The paint application technology required

sustainable, high-quality coating process:

Plasma-vacuum coating in combination

to this end is specifically adapted to the

whether liquid painting, powder coating,

with UV paint is a further option. And

respective customer project. New spray

a UV painting process or a combination

significantly more painting solutions are

gun controllers permit highly accurate

is best depends on, amongst other

available in the meantime, which are laid

application. All painting parameters

factors, the product to be painted, the

out for polymerisation with

can be easily accessed and adjusted

required quality and the necessary

LED-UV technology. UV paints which

extremely precisely. This leads to

degree of flexibility. And it pays off to

make it possible to exploit the advantages

outstanding reproducibility, uniform

closely scrutinise processes which have

offered by LED-UV curing – amongst

painting results and reduced material

been in use for years or even decades,

others the curing of heat-sensitive

consumption. In addition to the classic

and to compare them with alternatives.

substrates, energy-efficiency and

teach-in process, robot motion sequences

Thanks to the fact that all technologies

immediate readiness for use after being

can also be programmed offline at a

throughout the entire process sequence

switched on – are not only available for

PC with the corresponding software.

are exhibited at PaintExpo, and because

the metallization of plastic surfaces, but

Other automation issues for which new

all relevant suppliers are represented

rather for conventional painting tasks

developments will be presented include

at the event, this comparison can be

as well. Innovations for powder coatings

paint preparation, paint supply, dosing

conducted very efficiently at the world’s

on components made of plastic

and colour changeovers.

leading trade fair in a targeted fashion.

will also be unveiled.

New solutions for automated monitoring

152

N. 62 - MARCH/APRIL 2020 - international PAINT&COATING magazine

ITALY

BRAZIL

SPAIN

GERMANY

USA

Products coated by CMC Verniciatura Industriale.

FOCUS ON TECHNOLOGY

SPECIAL PaintExpo

From Railways to Architecture, up to the General Industry: A Nano-Technology Pre-treatment Process Becomes Strategic for Product Resistance and Appearance Monica Fumagalli ipcm®

The development of pre-treatment nanotechnologies, implemented in industrial production processes about twenty-five years ago, has reached optimal performance levels in terms of corrosion resistance and paint adhesion. CMC Verniciatura Industriale chose to optimise its coating process with a 5-stage multi-metal pre-treatment cycle that ends with a nanotechnology passivation step using the Soft Rain nebulisation system. The chemical products used are supplied by DN Chemicals: their development with powder application operations in mind has enabled CMC to gain important orders from several high-end customers, including major railway vehicle manufacturers.

154

N. 62 - MARCH/APRIL 2020 - international PAINT&COATING magazine

FOCUS ON TECHNOLOGY

The use of nanotechnology for pre-

Now, the revolution of nanotechnology

CMC Verniciatura Industriale

treating metals is now an established

applied to industrial processes is complete,

“The CMC division devoted to industrial

practice: spread around the mid-1990s, it

even though research on possible future

coating,” states CMC Group CEO Stefano

gained popularity in the 2000s, confirming

developments in terms of both technologies

Cicali, “started its business by treating

the validity of its results in the 2010s. In

and products will not stop. The case

bodywork and industrial vehicles. We then

the preface of the study “Nanotechnology

study described below explores possible

specialised in contracting surface treatments.

– Innovation for tomorrow’s world”1,

applications in the preparation of parts

We started with liquid coating and we then

published by the European Commission

intended for the railway, general industry,

integrated powder application processes in a

in 2004, author Ezio Andreta writes:

and architectural sectors.

new 1500 m2-wide factory during the 2000s.”

“Nanotechnology is often described as

Here, CMC received its first orders from

having a ‘disruptive’ or ‘revolutionary’

CMC Group (Monteriggioni, Siena, Italy) has

the mechanical industry in general and the

potential in terms of its possible

offered high quality products and services

railway sector in particular. “We were already

impact on industrial production routes.

for the industry, commercial structures,

dealing with any type of metal,” adds Cicali.

Nanotechnology offers possible solutions

and the furniture sector since 1975. It has

“However, upon entering the railway industry,

to many current problems by means

three divisions, i.e.: Chedin (Chimica Edilizia

we specialised in painting aluminium alloys,

of smaller, lighter, faster and better

Industria, or “Chemistry, Building, Industry”),

which are used for train car boxes, that is,

performing materials, components and

which supplies materials and resin-based

the metal structures formed by walls and

systems. This opens up new opportunities

continuous coatings for shopping centres,

ceilings.”

for wealth creation and employment.

production and storage areas of the food

Following the excellent results obtained,

Nanotechnology is also expected to make

and pharmaceutical industries, shops, and

in 2013 CMC decided to expand its

some essential contributions to solving

private homes; CMC Applicazioni in Resina

business and acquire a new building for

global and environmental challenges by

(or “Resin Applications”), which creates resin

housing a higher performance coating

realising more specific-to-use products

flooring, waterproofing systems, street

plant, able to guarantee the durability

and processes, save resources and lower

furniture, walls, and furnishing accessories;

and salt spray resistance characteristics

waste and emissions.”

and CMC Verniciatura Industriale (or

included in the specifications of the most

“Industrial Coating”), which has offered

important manufacturers of railway vehicles.

various types of liquid and powder coating

Euroimpianti (Valeggio sul Mincio, Verona,

processes even on large parts since 1985.

Italy), a company specialising in the design

1 https://www.nanowerk.com/nanotechnology/reports/ reportpdf/report1.pdf (last visited: 12/03/2020)

The new factory housing the powder coating plant.

international PAINT&COATING magazine - MARCH/APRIL 2020 - N. 62

155

SPECI AL PaintExpo

and construction of aluminium coating systems, installed this plant. It is equipped with a Wagner booth and it uses a pre-treatment system developed by DN Chemicals, an Italian company established in 2018 as a joint venture between Dollmar Spa, located in Caleppio di Settala (Milan, Italy), NoxorSokem Group Srl and Kemmex, located in Cusano di Zoppola (Pordenone, Italy). “Thanks to the know-how acquired to penetrate the railway market, we are currently able to meet even the most challenging powder coating requirements, including the treatment of aluminium profiles for architecture: for this sector, we coat bars up to 3.20 m in length and already-assembled door and window frames.” The metal products treated by CMC belong to three macro-areas: railway industry products and camper components (door hinges) account for 40% of its activity; general industry products, especially The outside of the pre-treatment tunnel.

engine-generator of various sizes and handling machines, also account for 40%; and the furniture and door and window frame

sectors account for the remaining 20%.

An optimised application cycle The line installed in 2013 replaced the old Euro90 plant, also built by Euroimpianti, whose three pre-treatment stages were no longer adequate for the new processing needs. “We attempted to add a rinse with demineralised water as a fourth stage,” says Cicali, “but we did not achieve the required results due to the limited space allocated to each phase, which resulted in a high level of tank pollution. The acquisition of a new building to house an adequate pre-treatment and coating line was therefore a mandatory choice.” The current application cycle includes a 5-stage multi-metal pretreatment process: - acid degreasing and phosphate conversion to remove any grease and oil residues left on surfaces; with aluminium alloys, The Soft Rain management unit.

the degreasing solution is integrated with a pickling-deoxidising powder to favour paint adhesion;

- two rinses with mains water to remove any acid residues from the previous phase; - final rinse with demineralised water, for the elimination of any limestone deposits; - nanotechnology passivation with the Soft Rain nebulisation system. “The latter stage is the added value of this cycle,” notes Cicali, “because it makes the parts’ surfaces chemically inert, thus increasing the adhesion strength of the coatings applied afterwards. Before implementing the Soft Rain nebulisation system, we performed a passivation stage in the tank. However, product concentration was not stable and the process was difficult to control, with the constant risk of non-compliance with parameters. Nebulisation, on the other hand, allows homogeneously applying the exact amount of product required, that is, between 30 and 50 Parts exiting the machine after passivation.

156

N. 62 - MARCH/APRIL 2020 - international PAINT&COATING magazine

nanometres.”

FOCUS ON TECHNOLOGY

The inside of the coating booth.

The parts then remain in the drying oven at 120÷140 °C for 15 minutes,

SIMPLIFY COATING.

Your information and management platform for simpliﬁed coating 4.0.

in order to eliminate any trace of moisture. This is followed by the coating process, with the application of polyester thermosetting powders by electrodeposition in the Wagner booth installed in August 2018. It features a double column of automatic dispensers onto reciprocators. The system is managed from a single point, i.e. the touch screen of the latest-generation SUPERCENTER EVO powder centre, which complies the Industry 4.0 parameters, thanks to its management software of the powder consumption and industrial diagnostics. Curing then occurs in a dedicated oven at a temperature of 190÷200 °C, for at least 20 minutes.

Nanotechnological products functional to anti-graﬃti coatings In order to select the products to be used to improve its pre-treatment operations, CMC carried out numerous tests. “With such high-end customers, nothing could be left to chance,” states Cicali. “Therefore, we performed several deep drawing and cross-hatch tests. The Dollcoat SA115 passivation product achieved excellent results on aluminium, especially with the application of polyurethane anti-graffiti powders, included in the specifications of one of our main customers from the railway sector.” “Dollcoat SA115,” indicates DN Chemicals Sales Manager André Bernasconi, “is the most versatile product that our company has been offering on the market for over ten years. It can be applied on any type of metal and for any type of process. When we performed these deep drawing tests on components coated with anti-graffiti paints, the difference between treated and untreated plates was significant. Anti-graffiti coatings are particularly rigid: after bending with a conical mandrel, the untreated samples’ films were cracked, resulting in the complete loss of paint adhesion, whereas the treated plates were perfect.”

wagner-group.com

SPECI AL PaintExpo

The powder management unit.

A finished large-sized workpiece.

“Dollcoat SA115,” explains DN Chemicals

This would be an advantage not only in terms

we are industrially testing Sol-Gel based

Sales Representative Stefano Baglioni, “is

of eco friendliness, but also of machine

nanotechnology products added with carbon

not only a very effective corrosion inhibitor,

maintenance.”

nanotubes, which are giving amazing results.

but also an excellent adhesion promoter.

DN Chemicals will also continue to

The goal is to refine their formulation and

The former characteristic is fundamental

develop new products and processes.

then extend their application to powder

when treating workpieces in aluminium or

“For years we are implementing the use of

coating systems, which would gain corrosion

iron, the latter when applying anti-graffiti

our nanotechnology products in surface

resistance and film homogeneity properties,

coatings for which specifications impose

preparation processes prior to cataphoresis,”

thanks to their effectiveness in critical areas

a 1000 salt spray hour resistance value –

- reveals Bernasconi. "In the latest months

such as edges.”

pre-treatment system chosen by CMC.” “Indeed, it was our process, optimised with

which is now even exceeded thanks to the

DN Chemicals’ products,” says Cicali, “that convinced our customer, which was in doubt between liquid and powder coatings, that the pre-treatment + powder coating system we offered was highly effective, enough to lead it to include the DN Chemicals process in its specifications.”

Next projects CMC’s research activity for the optimisation of its pre-treatment and coating processes will not stop. “We intend to replace phosphodegreasing with an alkaline stage,” says Cicali. “Together with the passivation stage we perform, it would give excellent results on aluminium and it would allow keeping the first station of our plant clean by eliminating the presence of sludge due to phosphating.

158

Coated architectural components.

N. 62 - MARCH/APRIL 2020 - international PAINT&COATING magazine

eosmarketing.it

do you need a CHAIN CONVEYOR?

BRAND NEW HOOK! loading capacity > 1,500 kg, it allows the rotation with an integrated lock system

TRAS-MEC iW XLI Ç»VWX GSQTER] to safeguard your system and contractually guarantee a downtime free production.

visit us at Messe Karlsruhe October 12-15, 2020

hall 1, booth 1152

www.tras-mec.it

©Avin

FOCUS ON TECHNOLOGY

Higher Productivity for a Contracting Coating Line Thanks to the Integration of a High Temperature Infrared Gas Oven Monica Fumagalli ipcm®

Coating contractors’ needs are known: high finishing quality, energy saving, and improved production capacity. These can be met through flexible, specially designed plants that are often able to achieve excellent performance despite the limited space available. These are also the characteristics of the project developed to enhance an Italian coating contractor’s powder coating line by Avin Srl, a company from the Imel Spa group, in collaboration with Infragas Srl, a firm designing and building infrared gas radiant systems. The addition of an infrared oven proved to be the key choice for the success of the project. Coating contractors demand highly flexible systems and equipment in order to meet their diverse production requirements, arising from the need to quickly coat components with different materials and sizes. Another challenge they often face is the reduced space available for machinery in their factories. Here below, we will analyse the solution developed for a powder coating contractor that is among its region’s leaders in terms of delivery speed, customer portfolio, and performance by Avin (San Martino al Tagliamento, Pordenone, Italy) and Infragas Srl (Mappano, Turin, Italy). The former belongs to the Imel Spa group and it designs and manufactures coating, industrial cleaning, and air treatment systems; the latter specialises in catalytic infrared panels and infrared gas radiant systems. The infrared gas oven installed at the coating contractor’s premises.

160

N. 62 - MARCH/APRIL 2020 - international PAINT&COATING magazine

SPECIAL PaintExpo

©Avin

FOCUS ON TECHNOLOGY

heating) or rapid treatment times (for example, powder gelling). In the case of the plant supplied by Avin to this Italian coating contractor, we decided that the RHT heater was the best option to meet its need for higher production speed.”

Features of the infrared high temperature radiant system “This infrared oven type,” adds Francesca Marabotti, “operates with short wavelengths and, therefore, very high power density. The infrared spectrum includes long, medium, and short wavelengths. The longer the waves, the lower the beam’s

The outside of the infrared oven integrated into the coating line.

penetration capability; the shorter the waves, the stronger the penetration capability. Catalytic panels can cover the medium and long wave infrared spectrum, which can reach a curing

In 2019, the Italian coating contractor started a project for the

temperature of 200-240°C on organic materials such as powder

development and innovation of its coating plant. The aim was

coatings. Therefore, Infragas developed a product capable of

increasing its production capacity and flexibility in order to meet

covering the short wave spectrum, intended for applications

the needs of its customers, which operate in different sectors and

calling for higher temperature and power density values, as

handle parts with a very wide range of shapes, up to 1000 mm in

in the case of this project: the RHT burner can reach surface

width, 3000 mm in length, and 1800 mm in height. Its coating line

temperatures of 950°C, thanks to the surface micro-flame.

consists of a pre-treatment tunnel, a combined drying and curing

These special heaters are intended for thermal processes that

oven, and two powder application booths.

require high temperatures or rapid treatment times and they

“A bottleneck,” explains Avin Sales Manager Matteo Macor, “was

are ready for installation: they are already equipped with a

found at the curing oven level: frequent downtimes occurred

radiant device linked via a connection hose to a control unit,

due to its inability to cure parts with high coating thicknesses on

which guarantees it is fed with the correct air-gas mixing ratio.

schedule and while keeping up with the line speed, equal to 2.7

The Radiant High Temperature (RHT) – made up by radiant

m/min.” A gelling phase before curing could be the ideal solution.

modules, connection hose, and pre-mix control unit – is

Therefore, Avin’s team, in collaboration with Infragas, designed

CE certified.”

and constructed a tailor-made high temperature infrared oven. “We thought that the integration of an infrared oven would have

©Avin

The enhancement of the coating system

sped up operations thanks to its gelling phase, that could bring the parts at the required temperature of about 90-100°C before curing,” adds Macor. “The challenge for the technical teams of our two companies was coping with the very limited space available to place such ideal system. This is why we devised an oven of about 3 metres that met all our client’s needs.”

Choosing the right emission source for eﬀective and fast processes Infragas’ radiant panels emit a range of electromagnetic waves whose length is quickly absorbed by most organic products. “With powder coatings, for instance, catalytic infrared energy is perfectly absorbed until curing,” indicates Infragas Marketing Manager Francesca Marabotti. “With liquid coatings, on the other hand, the wavelength of our radiant burners guarantees rapid water and solvent evaporation as well as consistent, high-quality finishes without generating any thermal stress on substrates. Finally, short wave infrared RHT burners are particularly suitable for thermal processes requiring high temperatures (for example, mould

Gelled parts in the infrared oven.

international PAINT&COATING magazine - MARCH/APRIL 2020 - N. 62

161

©Avin

SPECI AL PaintExpo

contain heat: the pre-chamber’s hood conveys the 300°C-hot air from the infrared oven towards the post-chamber, remaining at a temperature of 180°C and directly connected to the curing oven, thus keeping both the air and workpiece surfaces’ temperature constant, and achieving a thermal recovery. “The automatic management system,” says Macor, “consists of a control panel and an electrical panel entirely made and supplied by Avin. It is however possible to intervene manually where and when necessary.”

Benefits “The main advantage,” states Macor, “is the higher curing speed guaranteed. Previously, the workpieces entered the curing oven at 20-30°C and, therefore, the process started after several The Infragas RHT control group.

minutes: now, after passing through the infrared oven, the components reach the curing one at 90-100°C and, in just 3 minutes, their surfaces reach a temperature of 170°C.”

The right solution for the coating contractor

“Finally” adds Marabotti, “the number of radiant heaters in the

“In the solution provided to this coating contractor,” explains

oven is limited regarding the high powder density required: there

Macor, “the oven has movable walls that enable to maintain a

are 6 RHT 6c heaters arranged on the two walls, which move

distance between the oven structure and the workpieces of about

alternately. This alternation results in a further saving of energy

300 mm per side through the automatic management system,

resources, which is highly appreciated by our customer”.

thanks to the upstream detection of the products’ dimensions

“The improvement of its coating line will continue with the

and shapes. Such movable walls’ clear opening width ranges

update or integration of a few devices; however, it is already

from 700 to 1600 mm. In this way, users can even hang the

pleased with the greater coating speed and productivity

components randomly, for example in the case of any urgencies,

achieved” ends Macor.

the walls can move both symmetrically and asymmetrically, in order to adapt to the different shape of the products to be coated, such as, for instance, chairs.”

©Avin

A pre- and post-chamber precede and follow the infrared oven to

The touch-screen monitor for process management.

162

N. 62 - MARCH/APRIL 2020 - international PAINT&COATING magazine

Components entering the infrared oven.

SPECIALISTS IN PLASMA PVD COATINGS

visit us at

ENJOY PVD TECHNOLOGY

Messe Karlsruhe - October 12-15, 2020 - Hall 1, booth 1346

Kolzer machines guarantee versatility in Metallization and PVD Sputtering treatments as well as repeatability in production. Kolzer systems perform well in all conditions, with all materials and for processing on each substrate. PVD is totally eco-friendly process with low environmental impact.

www.kolzer.com

The HangOn award ceremony at the Stockholm City Hall.

HIGHLIGHT OF THE MONTH

SPECIAL PaintExpo

HangOn Wins SEB Award for Best International Growth 2019 Marta Fumagalli ipcm®

Swedish company HangOn, a manufacturer of workpiece hanging systems and coating masks, received Ernst&Young’s “Entrepreneur of the Year” award for “Best International Growth 2019” on January 30, 2020, during a ceremony at the Stockholm City Hall.

Ernst&Young is a global leader in insurance,

a better world of work. For over thirty years,

award programs in the world. Aimed at

tax, transaction, and consultancy services.

it has been cooperating with entrepreneurs

encouraging entrepreneurial activity among

The quality services it offers help build trust

and companies in the fastest growing global

people with great potential, it honours the

in capital markets and economies around the

markets through EY Entrepreneur Of The

contribution of those who inspire others

world. EY plays a fundamental role in building

Year™, one of the most prestigious business

with their vision, leadership, and results.

164

N. 62 - MARCH/APRIL 2020 - international PAINT&COATING magazine

HIGHLIGHT OF THE MONTH

The EY prize “Entrepreneur of the Year.

The Törefors family.

As the first and only truly global award

confirmation that we are working properly.

program of its kind, Entrepreneur Of The

We are so pleased to know that many people

Year™ celebrates those who are building and

appreciate our work. Even a niche company

ipcm®: How important is teamwork in HangOn’s achievement?

running successful, growing, and dynamic

like ours, if well positioned on the market,

PT: Our team was crucial. As we explained

businesses through regional, national, and

can obtain an award of such importance.

to the jury, although this is a prize for

global awards in over 145 cities and more

Finally, this also favours the sector for which

entrepreneurs, special attention should be

than 60 countries.

we operate, that of surface treatments. We

paid to our employees and collaborators.

In addition to the main “Entrepreneur Of

only produce one type of accessory out of

We would have never won without them:

The Year” award, other prizes are also

entire treatment lines, which however is

this is why we intend to celebrate together

assigned, such as the one won by HangOn

crucial for the quality of their results thanks

with them, throughout all our branches.

(Hillerstorp, Sweden), a European leader in

to its efficiency, ergonomics, and economy.

This is something we want to share with the

the production and marketing of masks and

We are currently trying to make coating

whole organisation.

hanging hooks and frames for the coating

lines even more efficient by minimising

sector. The company was nominated for the

their environmental impact. One of the

EY Entrepreneur Of The Year 2019 award

key elements on which we are focussing is

and it actually won the SEB award for “Best

precisely sustainability.

ipcm®: What is HangOn’s next goal as an international company?

International Growth”. The ceremony took

In 2019, we experienced constant growth; we

PT: We are hiring staff in Germany, Holland,

place on January 30, 2020 at the Stockholm

acquired Dutch firm MBS, which has enabled

and Great Britain. We also opened a new

City Hall. The jury chose HangOn based on its

us to expand our HangOn BV distribution

factory in India. I think I can say that our

innovative drive, from product development

hub by about 3000 m . We will also soon

main goal is to continue gradually growing

to technical knowledge. “We are honoured

launch a software package to track our

at the international level and continue

to have been rewarded in this way,” says

production flow, which will help us improve

accepting the challenges with which we are

HangOn CEO Petter Törefors, interviewed by

our manufacturing processes. As already

faced every day.

ipcm®.

mentioned last September during the

HangOn Sales Conference, we are striving

Petter Törefors concluded this interview by

ipcm®: How would you describe HangOn’s path to winning this award? What is its meaning for you and your company?

to further implement process automation

announcing his company’s participation in

solutions and achieve maximum productivity

PaintExpo, the world’s leading trade fair for

with our equipment. I think this was one of

industrial coating technologies, to be held

one of our strong suits, as far as this award

from October 12 to 15, 2020 (Hall 2, Booth

PT: The journey was not an easy one. Over

is concerned. In fact, the jury focussed a

2120).

a year and a half, we have faced numerous

lot on issues such as sustainability and

interviews and we have prepared ourselves

digitalisation.

for the competition with the other finalists, which took place in front of a jury that we did not know. This award was a great

A. Venturi, “HangOn Sales Conference 2019: the smart way for hanging and masking”, ipcm®, year 2019, no. 60, November–December, pages 122-126

international PAINT&COATING magazine - MARCH/APRIL 2020 - N. 62

165

SUCCESS STORIES

Paint Shop of the Future: Away from the Line, Towards the Box Growing model diversity, different drive technologies, and greater personalization are pushing conventional line manufacturing to its limits in the automotive industry. Whether major high-volume manufacturers or small e-car startups, manufacturing has to make the switch from rigid to flexible to be able to respond more quickly to customer and market requirements. Dürr’s new “Paint shop of the future” concept breaks away from the traditional line layout, splitting up industrial automotive painting into boxes or short process sections for the first time. This allows the automotive industry to paint much more flexible. In addition, the “Paint shop of the future” saves time and material, increases availability and makes painting more sustainable. Dürr to have a rethink and develop a radical new layout for future

diverse. But the greater the variety of models painted on a line, the

requirements.

more inefficient the process. This is due to the fixed cycle times,

“With the “Paint shop of the future”, Dürr is reimagining the painting

which are based on the biggest model and the paint with the

process and moving beyond the boundaries of the production

longest application time. If smaller car bodies could be transported

line,” explains Bruno Welsch, member of the Board of Management

faster and some colours could be applied more quickly, this would

of Dürr Systems AG. “The new approach adapts to the needs

save time and increase output. However, the fixed cycle does

of manufacturers, and enables an efficient and flexible painting

not allow this. This was one of the many reasons that prompted

process in every production scenario.”

Model ranges and application processes are becoming more

The paint shop of the future is a modular concept that enables easy adaptation of production capacity to all scenarios.

166

N. 62 - MARCH/APRIL 2020 - international PAINT&COATING magazine

On-demand cycle times The general idea of the “Paint shop of the future” is based on splitting up the 120 work steps involved in a painting process into boxes and smaller sections. Instead of a fixed cycle, the process times in each box are precisely adapted to the needs of the individual body. This is made possible by processes running in parallel in the boxes and the interaction with a central highbay storage system and the automated guided vehicle system EcoProFleet. The fleet of AGVs is controlled by the software DXQcontrol. It guides the AGVs with the car bodies intelligently to the next processes, and in this way

www.cmautomazione.it

hi-tech

SUCCESS STORIES

conveyors

ensures efficient utilization of all the boxes. It enables the bodies to be sorted in anticipation of future processes, brought to and collected from the right workstation with pinpoint accuracy, and passed off to final assembly at the end in the sequence planned by the manufacturer. The concept also enables easy expansion of capacities or smooth integration of new models. The revolutionary box concept can be applied to the entire top coat and workstation area, or just to selected process steps.

Fewer resources, greater eﬃciency In terms of the concrete implementation, the box concept means that three painting processes – the interior and the two exterior applications – can be combined in just one booth. This patent-pending concept, the EcoProBooth, thus helps to save process time, since two of the previously usual three conveying processes are eliminated. The paint-loss during the colour change process can even be reduced by up to ten percent if just one paint is applied in a box, for instance the current top seller white. Splitting up the painting process into boxes shortens the overall process by tailoring the application time to the individual vehicle. These properties combine to reduce CO2 and VOC emissions. The overall equipment availability also increases, since any malfunction only has an impact on the box section in question and does affect the entire production line, in contrast to the classic line manufacturing model. The variable layout also makes integrating special processes such as a special paint supply or overspray-free two-tone painting easier and more cost efficient. Adaptable to both large and small production

CM AUTOMAZIONE srl - FA Ganci

Ufﬁci e produzione: Via Monte Bianco 20 - 20833 Giussano (MB) - IT p. +39.0362.314075 - f. +39.0362.861222 - info@cmautomazione.it

The concept of the “Paint shop of the future” is geared

SUCCESS STORIES

towards the specific requirements of various OEMs. It offers major high-volume manufacturers with a high hourly capacity the opportunity to integrate new models and technologies with greater ease. It enables companies that want to avoid investment risks to predictably expand from 24 units per hour to 48 and 72 units in two steps. Newcomers to electric mobility can start their manufacturing with minimal quantities and gradually expand as demand increases. The modular concept is also Industry 4.0 capable and can be combined with the intelligent software products from Dürr’s DXQ family for various scenarios. In this way, Dürr analysis tools make painting processes more transparent and help to further increase the first run rate. For further information:

The AGV EcoProFleet is used as a flexible conveyor system in the paint shop of the future.

www.durr.com

The variable layout makes integrating special processes such as overspray-free two-tone painting easier and more cost eﬃcient.

168

N. 62 - MARCH/APRIL 2020 - international PAINT&COATING magazine

visit us at Messe Karlsruhe - October 12-15, 2020

hall 2, booth 2426

Your Aluminium Powder

Coating Partner sataluminium.com Âˇ gemapowdercoating.com

Ta ke a l o o k a t o u r t e ch n o l o g i e s i n a c t i o n !

HUBO Automation’s headquarters in Civate (Lecco), an example of bio architecture.

HIGHLIGHT OF THE MONTH

HUBO Automation: Innovation and Sustainability in Coating Automation Edited by ipcm®

HUBO Automation, a company specialising in the production of complex automation systems and automatic lines with robots, told ipcm® about the secrets of its success, from the design of simple machines to the care of its staff.

HUBO Automation was established over

of Northern Italy, HUBO has been able to

systems such as Cartesian robots with three or

thirty years ago based on an idea of Antonio

develop technologically advanced, reliable,

more controlled axes and efficiently program

Castagna, forerunner of the thermo-setting

and efficient solutions in the coating, welding,

the robots of the world’s major manufacturers.

powder coating technology and the father

and assembly sectors for a wide variety of

It also supports management operations with

of Sergio and Luigi, who later took over the

industries; these include automotive, railway,

its RFID® detection technology.

company and became its current owners.

packaging, mechanics, and medical. Thanks to

“With the emergence of the need to switch from

Based in Civate, near Milan (Italy), in the

the considerable experience gained over the

manual to automated processes also in the

middle of one of the major industrial hubs

years, HUBO can now supply special handling

coating sector, HUBO started manufacturing

170

N. 62 - MARCH/APRIL 2020 - international PAINT&COATING magazine

HIGHLIGHT OF THE MONTH

and a second one for coating plant engineering firms, where HUBO intervenes right into the system design phase. Currently, we are working with several major plant engineering and equipment manufacturing companies in the world, not only in the paint application field but also in the loading and unloading one. We are also an official integrator of the most widespread antropomorphic robots.” The experience gained in the most diverse markets has created a knowledge background that enables HUBO to designing unique, customised machines and systems, almost as if they were prototypes every time. “We deal with much more complex automation issues than those arising, for example, from the needs of a coating contractor,” states Luigi Castagna while telling us about a recent project carried out for the Russian market. “This company wanted to automatise its coating process for wind turbines,

Sergio Castagna (left) and his brother Luigi, the current managers of HUBO Automation.

components 12 metre long. Standard reciprocators were inadequate: the complex geometries in use called for a custom designed system. In these cases, in fact, it is also crucial to analyse the structure of the product

reciprocators for automatic booths, thus gaining a highly loyal customer

to be coated. For this type of projects, HUBO has an amazing technical

base,” says Luigi Castagna. “The success of our first automation systems,

department that accounts for almost half of the company staff, that is,

the growing demand, and the increasingly challenging requests which

twelve employees out of twenty-eight.”

we have been able to meet have led our firm to grow and establish itself

“We have a very young team with a strong corporate spirit,” adds Sergio

as a leader in the industrial coating automation field.

Castagna. He then mentions another project that HUBO has completed

“We have always used two sales channels: a direct one for end users

over the last few months: the supply of a plant for LNG ships in America,

27-29 October 2020

HUBO’s technical department is one of its strengths.

A technician working on a robot that will be integrated into a complex automation system.

which required an advanced automation

applications also in the eyewear sector,”

our working environment comfortable for

system to apply glue on the insulating panels

indicates Luigi Castagna. “Our first experience

employees.”

of the gas storage area of the ships.

in this field was with an Italian company,

“Another issue that is close to our hearts is

“HUBO is also active in South America.

world-leader in the eyewear industry. Here,

that of young people,” says Luigi Castagna.

Here, we cooperate with large multinational

HUBO developed an automation that, through

“There are many professional schools in the

groups in the field of powder coil coating,

robot, supported the automatic loading and

city of Lecco and HUBO makes itself available

which is an application that requires complex

unloading of the piece-carrying jigs on the

to offer internships to students, who also have

automatic systems for the colour change-

coating line."

a chance to be hired by the company itself.

over operations,” says Sergio Castagna.

HUBO’s activity was strongly boosted by the

We have a very young team. A few people who

“These coil coating lines are equipped with

emergence of anthropomorphic robots, a

started working with us as workers are now

units featuring up to twenty-four guns: in the

technology for which a very large market has

expert technicians.”

colour change-over phase, these rotate by

opened up. Able to replace humans, robots

One of HUBO’s future projects is to build

180 degrees outwards in order to ensure that

are widely used in the liquid painting sector,

Automatic Guided Vehicles (AGV), i.e.

during the cleaning stage paint residues do

but they are now more and more common in

machines capable of moving without the direct

not fall over the coils. We have automated

the powder coating sector, too.

involvement of a driver on board, equipped

several coil coating lines up to 150 metres in

One of HUBO’s strengths is the care for its

with smart software to optimise pick up

length, equipped with different spray paint

staff. The structure of its Civate headquarters,

operations and routes. “HUBO has already

booths working simultaneously: thanks to our

manufactured three vehicles of this kind,

devices, which allow adjusting the movement

this approach. “We have adopted all the

which are enjoying widespread success. This

of the guns that approach or move away from

necessary systems to limit the environmental

means that our company continues to develop

the metal surface with a continuous flow and

impact of our activities. We paid special

new areas of interest. We believe that we don't

at high speeds, the production flow is never

attention to the liveability of our company.

have to rest on our laurels."

interrupted.”

Our spaces feature many windows and glued

“We have worked on several important

laminated timber ceilings, in order to make

172

N. 62 - MARCH/APRIL 2020 - international PAINT&COATING magazine

Accessories for the famous scooter Piaggio Vespa.

FOCUS ON TECHNOLOGY

A New Shot Blasting Machine Devoted to Stainless Steel Gives Viganò Accessori Srl Full Control over the Quality of its Products Marta Fumagalli ipcm®

Viganò Accessori Srl, a well-established company in the production of accessories for the automotive and motorcycle industries, installed a Tosca shot blasting system exclusively devoted to the treatment of stainless steel in order to have full control on the quality of its production flow.

174

N. 62 - MARCH/APRIL 2020 - international PAINT&COATING magazine

FOCUS ON TECHNOLOGY

manufacturers of original accessories

major motorcycle manufacturers,

Como, Italy) is a well-established

and parts for OEMs,” says Roberto

whereas the metals division produces

company founded in 1953 and

Viganò. “We work for the major

all the other accessories,” explains

specialising in the production of

motorcycle manufacturers in the

Viganò.

accessories for the automotive

world, such as Honda, Yamaha and

The company currently has one

and motorcycle industries. It

Peugeot, which we provide with

production site, but that does

achieved success in the 1950s by

accessories both in metal and other

not stop it from being the largest

manufacturing accessories for the

materials, that is, components such

manufacturer of polycarbonate

famous scooter Piaggio Vespa, an

as windscreens or polycarbonate

screens in Europe, with an annual

Italian style icon. In 2009, under the

screens, luggage racks, skid plates

production of hundreds of

management of Roberto Viganò,

and bag racks. We have two divisions

thousands of windshields. It does

Viganò Accessori left the aftermarket

handling their processing, one for

not have a paintshop and it does

sector to become a leading

the treatment of metal and the other

not perform any chemical treatment

supplier of all major motorcycle

for screens production. Our screens

in-house: the workpieces requiring

manufacturers, also thanks to a

division produces wind-screens,

one, e.g. galvanising or anodising,

highly automated production cycle.

mainly made of polycarbonate for

are entrusted to external suppliers

“We are among the leading

safety reasons as required by all

certified by its customers. However,

Viganò Accessori Srl (Lurago d’Erba,

The TS500 shot blasting plant installed by Tosca Srl.

international PAINT&COATING magazine - MARCH/APRIL 2020 - N. 62

175

system exclusively for steel. “We used to

Accessori must have an excellent

outsource our shot blasting operations,

knowledge of finishing technologies.

but we relied on suppliers that treated

Technical characteristics of the shot blasting machine supplied by Tosca

In this way, we can guarantee optimal

different types of materials in the same

The machine supplied by Tosca

quality, which is only possible by

machine, thus causing major pollution

(Canegrate, Milan, Italy) is a TS500 shot

following the production flow of all

problems on our stainless steel parts.

blasting plant. This suspended load

parts from A to Z.”

That is why we decided to insource

system has a Y-shaped conveyor with

Viganò Accessori’s metal division is

this process to have full control over its

two hooks with a size of ø 1000x1500

further divided into two units for the

quality. We chose Tosca as our partner

(H) mm and a flow rate of 500 Kg. It

treatment of steel and stainless steel,

for this project.”

is also equipped with three turbines

as decided by the owner in order to achieve the highest quality degree. “Each

“as it acts as a prime contractor, Viganò

material calls for dedicated machines and plants and special abrasives, simply because, if only one machine is used for both metals, the residues from the steel processing operations contaminate the stainless steel processing phase and vice versa; this can create problems in the subsequent finishing treatments,” notes Viganò. Therefore, Viganò Accessori decided to install a shot blasting machine only devoted to stainless steel and its future projects already include

another investment for a second

The treatment chamber for the shot blasting.

176

Connection options with the electrical panel.

N. 62 - MARCH/APRIL 2020 - international PAINT&COATING magazine

FOCUS ON TECHNOLOGY

featuring a 7.5 kW motor each. The

separately regulate launch speed and

and receiving production data: the

conveyor has a semi-automatic hook

abrasive flow rate. On the other hand,

company sends its treatment programs,

handling technology: the operator

Tosca’s shot blasting system is equipped

containing all the necessary data, to

pushes a hook towards the entrance of

with a special software package,

the Tosca shot blasting plant, and then

the shot blasting chamber, where the

developed in collaboration with its

processes each cycle’s results,” adds

system anchors it and drags it inside

customers over the years, which allows

Tosca’s team.

for the various shot blasting phases.

simultaneously managing these two

Relatively small stainless steel abrasives

values via a simple PLC interface. This

are used, with a diameter of 0.3-0.4 mm.

guarantees surface finishing results that

Viganò Accessori’s production flow

“We have supplied Viganò Accessori

are definitely above average.

Viganò Accessori currently has all

with one the latest machine types we

“Moreover, this last generation machine

the technologies needed to entirely

have designed. It was conceived for

features different Industry 4.0-oriented

manufacture its products, apart from

shot blasting steel and stainless steel

interfacing accessories. For instance,

the coating and galvanising treatments

parts and, therefore, it is equipped

it has multiple modules for interfacing

that are entrusted to qualified firms. The

with a suitable filter to handle the

with the electrical panel via the IO-Link

process starts with laser-cut stainless

powders generated from their

network and a modem enabling Tosca

steel pipes that are bent in-house with a

treatment,” explains Tosca Srl’s team.

to remotely connect with the system

pipe bending machine and then welded

“The peculiarities of this system are its

for analysing any anomalies, solving any

through robots. After machining, the

versatility and modularity, especially in

technical problems, and modifying the

parts are subjected to controls and then

the adjustment of turbine performance.

PLC software package. The PROFINET

sent to the shot blasting plant. A further

Conventionally, the inverters and servo

connection with Viganò Accessori’s

control is then performed to check the

drives linked to turbines are used to

management system allows sending

aesthetic quality of the workpieces. If

UCIMU-SISTEMI PER PRODURRE

075/2018 BMXX18R

the products are approved, they are sent to the assembly, packaging, and shipping department. If they need a coating or galvanising treatment, they are sent to the supplier after shot blasting. “The shot blasting process is very important for our production cycle. Without it, it would not be possible to carry out the subsequent finishing treatment,” states Viganò. “Thanks to our new system, our customers have noticed a significant difference in terms of quality, compared with our previous products. First of all, we have eliminated the need to handle our parts, thus no longer risking to damage their surfaces; secondly, we also avoid aesthetic imperfections, as we take care of the whole process personally,” says Viganò.

The partnership with Tosca Srl During his interview with ipcm®, Roberto Viganò revealed that he chose Tosca as his shot blasting partner because of the attention to detail shown in each of their machines. “One of the reasons why we selected Tosca as a supplier was the timeliness and quality level of its service. Moreover, their systems are custom-built based on individual needs,” indicates Viganò. “The shot blasting machine provided to Viganò Accessori was custom-made based on an Industry 4.0-oriented, wellaccessorised standard system,” explains Tosca Srl’s team. “It was installed at the end of July 2019. I am

The three fixed turbines of the shot blasting machine.

that I intend to buy another one in the near future, to be exclusively devoted to the

very pleased with my choice, so much so

treatment of steel,” states Viganò. Indeed, an unusual feature of Viganò Accessories is that it is a single-vendor company. “Our business philosophy is to “espouse” a provider and its product and corporate approach: once I have chosen a partner who can meet all my requirements, I have no reason to change.”

The bag racks manufactured by Viganò Accessori.

178

N. 62 - MARCH/APRIL 2020 - international PAINT&COATING magazine

Â®

Daccordi Cicli has crafted custom frames for road and racing bikes since 1937.

FOCUS ON TECHNOLOGY

Daccordi Cicli: The Perfect Combination of Craftsmanship and Innovation Ilaria Paolomelo ipcm®

Thanks to its valuable twenty-year collaboration with Colorificio Giuntini, a distributor of Salcomix coatings, Daccordi Cicli can meet the finishing needs of every customer. This company has made the customisation of its bicycle frames its main strength, thus becoming a leader of the Italian bike frame market, a sector with a long-standing tradition.

“A bicycle is like a suit. You can buy a

thus becoming a leader of the Italian bike

bicycle frames. “Back then,” says Sena

beautiful standard suit, or order one made

frame market, a sector with a long-standing

Daccordi, from the third generation of the

to measure from a tailor.”

tradition. Daccordi Cicli’s history began

company’s owning family, “bicycles were the

This is the mantra of Daccordi Cicli, a

way back in 1937, when bike enthusiast