ipcm® n. 56 - March/April 2019 by ipcm® International Paint&Coating Magazine

The first international magazine for surface treatments

ISSN 2280-6083

ipcm digital on

® In this issue :

www.myipcm.com

SPECIAL ON ARCHITECTURE & DESIGN

INTERNATIONAL PAINT&COATING MAGAZINE

2019

10th Year - Bimonthly N° 56 - MARCH/APRIL

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CONTENTS MARCH/APRIL

INNOVATIONS: PRESENT&FUTURE

Ecoscreen Equipment Analytics Optimizes Plant Availability and Product Quality

Solid Company Know-How and Flexibility: CM Automazione’s Philosophy

HIGHLIGHT OF THE MONTH

S P ECI AL O N ARCH I TECTURE & D E S I G N

FOCUS ON TECHNOLOGY

luK: Revamping as a Technological A Development Strategy

05 EDITOR’S LETTER 06 ANALISYS BREXIT: Consequences and Possible Solutions for the Surface Treatment Industry

10 14

BRAND-NEW ANALISYS

Challenging Trends for Canada’s Chemical Sector

BRAND-NEW

22 28 36

S P E C I A L O N A R C H I TEC TUR E & D ES I G N

eturn to GLOBAL: The New Industry R 4.0-Oriented Plant for Coating Aluminium Radiators

BRAND-NEW

SUSTAINABILITY

BRAND-NEW

FOCUS ON TECHNOLOGY

A 4.0 Connection Point: Speroni’s Plant Choices Are Projected into the Future, but in the Name of Continuity

FOCUS ON TECHNOLOGY

INNOVATIONS: PRESENT&FUTURE

i4smallparts. The Overall Solution for Micro-Coating

S P E CI A L ON A R C H I T E C T U R E & D E S I G N

Maximum Booth Automation for the Coating of Metal Components and Office Furniture

BRAND-NEW

relevant information about the safety and quality of

your products updated and at hand

A NEW FOCUS ON INNOVATION www.adaptacolor.com

CONTENTS MARCH/APRIL

S P ECI AL O N ARCH I TECTURE & D E S I G N

INNOVATIONS: PRESENT&FUTURE

A Flexible and Modular UV Tunnel Functional to the Development of Formulations in the Laboratory of Paint Manufacturer Arsonsisi © Airprotech Srl

102

Elegance Meets Design: Demand for Flat Matte Finishes on the Rise

HIGHLIGHT OF THE MONTH

S P E C I A L O N A R C H I TEC TUR E & D ES I G N

114 98

FOCUS ON TECHNOLOGY

Saveral: The Innovation-Oriented, Pioneering Company in the Italian Powder Coating Sector

FOCUS ON TECHNOLOGY

In Mexico, a Coating Line Was Updated To Optimise Control on the Quality of Aluminium Door and Windows Frames

108 HIGHLIGHT OF THE MONTH BASF’s Lean Lab Sets New Standards: Fit for the Future

122 FOCUS ON TECHNOLOGY

At Metalux, the Pre-Treatment Process Becomes Decisive for Obtaining the Powder Coating Quality Label

128

132 SUCCESS STORIES

Henkel’s New Bonderite E-CO DMC Digital Multichannel Controller Helps Customers Optimize the Performance and Cost of Metal Pretreatment Processes

134 FOCUS ON TECHNOLOGY MagicCylinder® EquiFlow®: The New Powder Coating System Installed by the Procicchiani Group

INNOVATIONS: PRESENT&FUTURE

Management and Abatement of Emissions Generated by Industrial Coating Processes

140 STANDARD & LEGISLATION

- UCIF INFORMS

Sustainable Growth Fund

142 TRADE FAIRS & CONFERENCES 145 ZOOM ON EVENTS

ROBOTIC SOLUTIONS FOR INDUSTRIAL COATING Articulated and cartesian robots for every painting need! LeBot C5: 5 axis cartesian robot with shape acquisition scanner system.

LeBot A6: 6 axis articulated robot with self-learning, point-to-point and 3D offline programming, available also with overhead crane and carousel configurations.

LeCrob Production Manager STD RFID WEB: production management software with RFID tags and antennas for automatic recognition of production queue

LeBot IA6: articulated 6-axis industrial robots for point-to-point applications, controlled by our LeCRob K-Manager software.

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INNOVATIVE PRE-TREATMENT SOLUTIONS Pre-treatment is changing. You need solutions that meet the real demands of the industry: efficiency, savings, and most of all, safety. You need solutions that are reliable and adaptable to your operations – not someone else’s. That’s why you need Quaker Chemical. Our new heavy metal free solutions can be tailored to your particular requirements to ensure not only excellent corrosion protection but also reliable adhesion to subsequent paint coatings. Because at the heart of the metal surface treatment industry, you’ll find us.

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EDITORâ&#x20AC;&#x2122;S LETTER

This is a moment of great excitement Richiedi la versione in italiano a info@ipcm.it

lthough the media describe the global industrial situation gloomily, with recession forecasts for all major world economic powers, we have found a dynamic and confident atmosphere during our first visits of the year to several surface treatment companies. 90% of them has made significant investments in plant innovation in the last six months. Some chose revamping projects in order to fully or partially update existing plants and bring them to the state-of-the-art level, thus extending their service life and improving their operational quality degree. Others opted for a more radical change and fully replaced their surface finishing lines, sometimes including them in more extensive plant upgrade programs that also involved other production phases. Whether they are new coating booths, sensors and control equipment installed in the pre-treatment phase together with a change in the chemical used, or complete finishing lines, the Industry 4.0 and its digital paradigms have been the main drivers of development and investment. However, they are not the only ones: the improvement of production sustainability (adoption of water-based or powder coatings), the replacement of chromium-based pre-treatment processes (both in the aluminium and coating contracting sectors), and, above all, the automation of production and control processes are all significant trends that translate into production efficiency, consumption and waste reduction, and, above all, quality consistency. Through a virtuous combination of green chemistry and green engineering, companies seem projected to create a future in which it will be possible to produce even very small batches efficiently, sustainably, and with a very high quality degree. Trade fairs are also a gauge of the health of the industry. February and March were two eventful months, e.g. the world-class exhibition for the paint and coating industry European Coatings Show in Nuremberg, the equally important trade fair for the cosmetic packaging sector Cosmopack in Bologna, and national trade fairs such as Scandinavian Coatings in Copenhagen, Middle East Coatings Show in Dubai, Pakistan Coatings Show in Lahore, Industrie - Midest in Lyon, and MadeExpo in Milano. None of them saw any decrease in the participation and number of visitors. So what is the real situation? Surely, European data on the scale of the industrial slowdown are far from comforting. The Purchasing Managersâ&#x20AC;&#x2122; Index (PMI), an indicator of the manufacturing activity, ended 2018 with the lowest growth rate of the last four years in the euro area, whereas uncertainty on the Brexit deal is a further source of concern. In China, the industrial production rate is the lowest of the last three years and in the United States the beneficial effects of the tax cut are running out. Yet companies continue to believe, invest, and look for new solutions and new tools to be more efficient, competitive, and prosperous.

Alessia Venturi Editor-in-chief Direttore Responsabile

The disconnect between the political-financial and industrial reality is well known. The spirit of initiative and the courage of entrepreneurs, the support and lobby work of associations, and the concreteness and willingness of individuals can produce wealth even in times of recession. These strengths enable economies to emerge from the quagmire in the long run â&#x20AC;&#x201C; in spite of everything.

international PAINT&COATING magazine - MARCH/APRIL 2019 - N. 56

Opening photo: The global industry has had to deal with the immediate ramifications of the vote, by starting to question the future of investments and of the legislation and regulations in force.

ANALYSIS

BREXIT: Consequences and Possible Solutions for the Surface Treatment Industry Barbara Pennati ipcm® From an interview with Tom Bowtell, CEO of the British Coatings Federation

n June 23, 2016, the United Kingdom

The first consequences of the vote have been

The vote on Brexit also brought forth many

answered a referendum question

evident since the announcement of the result:

internal issues, which are to this day among

that will go down in history: “Should

the change of the pound fell in two hours by

the most difficult to tackle, starting from

the United Kingdom remain a member of the

10% compared to the US dollar and by 7%

Scotland and Northern Ireland, where in

European Union or leave the European Union?”.

compared to the Euro; the then Prime Minister

fact respectively 62% and 55.78% of citizens

The 51,89% of the 33,577,342 voters chose to

David Cameron announced his resignation

voted to remain a member of the

leave the European Union.

from his position.

European Union.

N. 56 - MARCH/APRIL 2019 - international PAINT&COATING magazine

ANALYSIS

Even the global industry has had to deal with

ipcm: Were you surprised at the outcome

different sets of chemicals regulations, and

the immediate ramifications of the vote, by

of the referendum on Brexit?

face tariffs of 6.4% on both raw materials,

starting to question the future of investments

Tom Bowtell: Yes, we anticipated the result

half of which are sourced in the EU, and on

and of the legislation and regulations in force.

would be close but we were surprised with the

finished products, costing the industry an

More than two years later, the United Kingdom

outcome.

estimated £150m. The impact of tariffs could lead to the loss of some of the £1bln UK

an official deal, although two options are on

exports of paints, coatings and printing inks,

the table, according to analysts: the so-called

and the European Union have not yet reached

making them significantly less competitive to customers in the EU.

Hard Brexit, for which the United Kingdom would abandon the European Union and all the European treaties and institutions to which

ipcm: How much does the UK contribute to

it belongs; or the Soft Brexit, through which the

the EU coatings market?

UK would exit the European institutions, but

TB: The UK is roughly 10% of the EU coatings

will remain, to some extent, within the single

market.

market. On March 12, the House of Commons rejected

ipcm: What are the negative and positive

Theresa May’s withdrawal agreement with the

effects that Brexit could have on the UK

EU by 391 votes to 242.

and global markets?

On March 14, the House of Commons voted to delay Britain’s EU departure and Theresa May asked the EU for an extension beyond March 29, the date previously set for the

Figure 1: Tom Bowtell.

TB: The devaluation of sterling has negatively hit BCF members, many of whom trade and report in euros. Longer term, we worry about the attractiveness of the UK as a manufacturing hub for Europe. Unfortunately, we don’t see

UK’s official exit. The European Council has conceded a small

ipcm: At the moment of writing, there’s

many benefits to Brexit. In the long-term, there

extension: now, if May’s Brexit agreement is

still no deal on Brexit. What could it entail

might be scope to influence certain regulations,

approved by the British Parliament by April 12,

for the coatings industry and what are the

such as the VOC Paint Product Directive, but

London will have until May 22 to pass all the

possible outcomes of a “soft” or “hard”

this will take time.

legislation needed to set up the new course.

Brexit?

If, on the other hand, May’s agreement is

TB: With a hard Brexit, the coatings industry

ipcm: How will the import/export be

not accepted, the United Kingdom will have

could suffer severe disruption, a loss of

affected by Brexit?

to propose a way forward by April 12 for

millions of pounds and a drain on investment.

TB: If there are tariffs on goods, we could

EU leaders to consider. European Council

BCF members are exporters, and the UK is

see imports and exports drop heavily, if

President Donald Tusk said:

a net exporter of paint and coatings. Several

6.5% is added onto both. The coatings

“The UK government will still have a choice

members use the UK as a hub for Europe. The

industry currently imports 60% of its raw

between a deal, no deal, a long extension or

UK will also become less competitive as a place

materials from the EU, so if there are tariffs

revoking Article 50”.

for manufacturing as a result.

or regulatory barriers to this, we could see this number drop. In total, 60% (£652m)

The situation is even more complicated by the European Parliament elections due to be held

ipcm: How did the coatings industry react

of the £1078m UK exported coatings and

on May 23-26, which the UK is supposed to

to Brexit?

printing inks in 2017 went to the EU, and

start organizing soon.

TB: The industry reacted with shock, however,

looking at imported coatings and inks as

While we wait to see the developments

have continued on with “business as usual”.

finished goods, which totalled £939m, 84% (£791m) of these came from the EU. This

of this complicated issue, ipcm® had the opportunity to discuss the impact of

ipcm: How are companies preparing to

is not just multinationals, as the UK SME

Brexit on our sector with Tom Bowtell,

face it?

coating and printing ink companies are

CEO of British Coatings Federation,

TB: “No deal” planning for the industry

also strong exporters. In addition, almost

a trade association representing the

consists of stockpiling key raw materials and

all coatings companies are importing a

interests of the decorative, industrial and

finished goods, hiring more warehouse space

significant proportion of their raw materials

powder coatings, printing inks and

and setting up legal entities in the EU. BCF

from Europe (there are no BCF members that

wallcovering manufacturers in the UK.

members are also preparing to grapple with

don’t buy something from Europe).

international PAINT&COATING magazine - MARCH/APRIL 2019 - N. 56

Figure 2: Brexit supporters in front of the Houses of Parliament asking to leave the EU, even without any deal.

ipcm: Do you think that Brexit will create a chain effect and other countries might go through the same process? What strategies could companies adopt to better monitor Brexit, its process and effects? TB: They should engage with their trade associations where possible, offering case studies and impact assessments on how their companies are being affected by Brexit. ipcm: What is the role of trade

2 1

associations like BCF in this scenario? TB: We feel it is our role to advise and guide

ipcm: How will Brexit affect

ipcm: Many companies are already

our members through this challenging time

environment, health and safety

relocating or planning future

period.

regulations, like REACH?

investments in other countries. Do

TB: We have been in regular contact with

you think this trend will continue? Is

ipcm: What actions had BCF

the government and informed them that

it something truly necessary or are we

undertaken to support UK industry

we want to maintain a high standard of

getting ahead of ourselves?

manufacturers?

health and safety, and still have access to

TB: This trend will only continue if we have

TB: The BCF has been proactive in

the REACH regulations. If we leave without

a “no deal” Brexit, where the UK looks like

supporting UK manufacturers in this

a deal, the government will put in place “UK

an unattractive place for manufacturing.

turbulent time. Last year, we ran a Brexit

REACH”. This means that BCF members

The prospect of tariffs, delays at the

seminar to give members a chance to

will have to deal with two different sets

border and a separate regulatory

listen to views from politicians and industry,

of regulations, resulting in extra costs for

system is unattractive for foreign direct

as well as give their own opinions on the

manufacturing. The Secretary of State for

investment. However, this would be a

UK’s departure from the EU. Also, we have

Environment, Michael Gove MP, has said

medium to long term impact. We don’t

published a “No Deal Brexit Guide”, which is

that he wants the UK to be at the forefront

see our member companies making

an amalgamation of all the current “no deal”

of health and safety and environmental

immediate decisions, but it will affect

Brexit advice out there, in one simple place

standards post-Brexit.

investment decisions in the coming years.

for members to consult.

state that the automotive market will be one of the most affected. What direct

ipcm: Seeing the state of

ipcm: Researches and forecasts

politics right now, what do you think will happen on in the future? Do you

consequence will this have

think that Brexit could

for the automotive coatings

result in the break up of

industry?

the United Kingdom (see

TB: Many automotive coatings

Ireland issue)?

companies are based near

TB: We believe “no deal”

car manufacturers, so shifting

should be avoided at

production or closing factories

all costs, as it would

means in a direct loss of business

be disastrous for the

for those automotive coatings

industry. At the moment

manufacturers. Coatings is a just-intime industry, so proximity matters to supply chains.

3 1

Figure 3: Protests against Brexit.

N. 56 - MARCH/APRIL 2019 - international PAINT&COATING magazine

we are asking for clarity and certainty from politicians.

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BRAND-NEW

Condoroil: Ultrafiltration for Degreasing and Phospho-Degreasing Baths Regeneration â&#x20AC;&#x201C; MINERVA Unit

ondoroil has been studying and

emulsified oils and the colloidal suspensions

In addition, the units provide

manufacturing, for over 25 years,

by ultrafiltration.

optional devices such as:

continuous regeneration units of

The phospho-degreasing solution, with the

-m anagement of several tanks

use of a MINERVA unit of adequate capacity, is

using the same degreasing agent

which are proposed under the commercial

therefore constantly maintained at maximum

(Mod. TWIN);

name of MINERVA.

efficiency allowing the user to achieve

MINERVA units carry out their regenerating

important ecological, economic and productivity

using different degreasing agents

action through three stages of mechanical

advantages.

(Mod. PLUS);

treatment in series that allow to remove all

The main features that differentiate the

the contaminants brought by the processed

MINERVA units from other ultrafiltration

demineralizer (Mod.

parts.

systems are:

CONDORDEMI) for the

In particular, from the polluted solution,

- total automation;

reintegration of the working tanks.

the sedimentable sludge is eliminated with

- total execution in stainless steel;

the aid of a lamellar decanter, then the free

- no manpower required;

For further information:

oils by means of coalescing and finally the

- low cost allowed by standardization.

www.condoroil.com

ÂŠ Condoroil Chemical Srl

degreasing and phospho-degreasing baths,

Figure 1: The use of MINERVA unit by Condoroil helps to maintain the maximum efficiency of phospho-degreasing solution and it allows to achieve important ecological, economic and productivity advantages.

N. 56 - MARCH/APRIL 2019 - international PAINT&COATING magazine

-m anagement of several tanks

- i nsertion of reverse osmosis

BRAND-NEW

BYK-1786 Showcased at ECS 2019

he proportion of aqueous formulations

coating with complicated application methods

used in the coatings industry has been

such as spray coating (HVLP), airless and airmix

steadily increasing for over thirty years.

applications. This form of delivery enables

What started out as regionally limited projects to

BYK-1786 to be incorporated more easily and

reduce housing emissions has since developed

dosed better. It is especially recommended for

into a global trend that extends to almost all

pigmented and non-pigmented architectural

areas of application. As things stand, over half of

coatings, general industrial, anti-corrosion, wood

all coatings are water-based, and it is generally

and furniture coatings, floor coatings, adhesives,

expected that this segment will continue to see

sealants, care products, and polishes. The additive

above-average growth. BYK recognized this trend

is VOC and APEO-free and has no impact on

at an early stage and has led the field for decades

transparency, haze, and cratering.

in developing suitable additives.

In other numerous BYK presentations which took

Additives for water-based applications were also

place during the ECS in three different exhibition

the highlight of BYK’s presentation at this year’s

halls, a broad range of products and services also

European Coatings Show (ECS). One focal product

were showcased – from automotive coatings via

here was the new defoamer, BYK-1786.

BYK’s regulatory expertise to additive applications

The new BYK-1786 defoamer, which was

in the wood and furniture coatings industry.

presented to the trade specialists in Nuremberg For further information:

removes any micro foam that might appear in the

www.byk.com

in March, is a defoamer emulsion. The additive

Figure 1: BYK-1786 offers excellent clarity in aqueous systems.

BRAND-NEW

Atlas Copco Launches a Clean, Clever and Compact Dry Screw Vacuum Pump

tlas Copco’s Industrial Vacuum

performance in its category. We set

division have launched the

out to build a pump that would create

Integration in the plant management system

DHS 065-200 VSD+ dry screw

a safer, cleaner and smarter industrial

Housed in a noise reducing canopy ensures a

vacuum pump offering lower lifecycle costs,

environment. The robust design, clean

noticeably quiet, vibration-free operation with

higher productivity, less energy consumption

operations and remote monitoring and

a low pitch sound level, the pump is equipped

and easy maintenance.

control capabilities makes it

and controlled with the MK5 Elektonikon®. This

Built for rapid cycling and continuous

the perfect pump for industrial

integrates the pump to plant management

operation applications, the DHS VSD+ is a

applications”.

systems. Users get the latest status updates on

truly clean, zero contamination dry vacuum

running and stopped hours, warning, and fault

Certified as oil-free in the category ‘Class

No oil migrates in the pump environment

Zero’ according to ISO standard 8573-1

Due to the completely dry operation of

the pump is free of oil emissions, including

the DHS 065 - 200 VSD+, no oil migrates

aerosol oil content in the outlet air stream.

in the pump environment. It helps to

The reduced number of parts within the

create a cleaner and safer working

The belt can be changed within 30 minutes

pump combined with the variable pitch

environment. “This is a great advantage

Reduced maintenance is an integral feature

screw design help increase efficiency and

especially in applications such as vacuum

of the DHS VSD+ series. The grease lubricated

reduce maintenance.

drying and cleaning, paper converting,

bearings and the belt are the only parts which

sensitive and regulations-driven electronics

require replacement. The belt itself can be

manufacturing and food

changed without external service support

packaging industries, because there are

within 30 minutes. The robust canopy retains

Alexander Frerichs, Product Manager Dry

no reactions with other process media or

the integrity of the internal parts and can be

Pumps, commented: “The new screw profile

deposits inside the vacuum pump”, says

removed easily. This greatly reduces installation

of the DHS 065-200 VSD+ offers best-in-class

Alexander Frerichs.

complexity and associated costs. Truly a clean,

pump that requires no water or oil cooling.

Best-in-class performance in its category

and shutdown indications. Combined with Atlas Copco’s SMARTLINK, the pump offers unrivalled remote monitoring capabilities.

clever and compact vacuum pump. For further information:

www.atlascopco.com

Figure 1: The new DHS 065-200 VSD+ dry screw vacuum pump by Atlas Copco offers lower lifecycle costs, higher productivity, less energy consumption and easy maintenance.

N. 56 - MARCH/APRIL 2019 - international PAINT&COATING magazine

BRAND-NEW

Evonik Introduces New Hybrid Crosslinker VESTANAT® EP-EF 201

vonik introduced the latest addition

With VESTANAT® EP-EF 201 we are helping to

The optimal crosslinker is selected from the

to the VESTANAT product family

meet our customers’ requests in this regard,

various options depending on the substrate and

at the European Coatings Show.

enabling them to formulate especially

curing temperature. VESTANAT® EP-MF 203 and

As a constituent of one-component clear

high-performance, but low-emission,

VESTANAT® EP-MF 204 are solvent-free,

coatings, the new VESTANAT® EP-EF 201

coatings,” says Dr. Guido Streukens, head of

ready-to-use hybrid crosslinkers that cure

silane/polyurethane hybrid crosslinker

VESTANAT Technical Service.

even at room temperature. They can be used

imparts a particularly sophisticated visual

At the trade show in Nuremberg, Evonik

as moisture-curing binders or in combination

appearance to metal and wood coatings.

also provided visitors with information

with suitable co-binders such as acrylic resins.

The environmentally friendly crosslinker

about other products in the VESTANAT®

The proven unaccelerated crosslinkers of the

contains only very small amounts of volatile

EF/MF family. All of these combine the

VESTANAT® EP-M grade, on the other hand, are

organic compounds. It is suitable for

advantages of silane chemistry with those

used when temperatures of 80°C to 160°C are

both professional use and do-it-yourself

of polyurethanes—and so provide excellent

reached during the coating process.

applications. Coatings formulated with it are

scratch resistance with simultaneous

very easily processed: They cure even at room

retention of polyurethane properties in

For further information:

temperature and are dry after just one hour,

coatings.

www.evonik.com/m-family

thus allowing fast downstream processing. “Environmental aspects such as low solvent content are playing an increasingly important

role in consumers’ purchasing decisions.

Figure 1: As a constituent of one-component clear coatings, the new VESTANAT® EP-EF 201 crosslinker imparts a particularly sophisticated visual appearance to metal and wood coatings.

ANALYSIS

Challenging Trends for Canada’s Chemical Sector Gary LeRoux cpca@canpaint.com

s noted by many in the

analysis showed that US tax reform

Other sectors would be less impacted by

business community, there

has eliminated one of Canada’s main

the US tax reform.

will be challenges on both

competitive advantages and that “this

For the chemical sector this new business

sides of the border with respect

loss will have a significant negative

environment is expected to have a

to manufacturing for a number of

impact on capital-intensive sectors

long-term impact with direct and indirect

reasons beyond the recent

GDP at risk in the order of

negotiations on NAFTA or

$10-billion, out of an overall

possibly the new agreement

negative GDP impact of

(USMCA), if and when

$85-billion in total. Also at risk

approved by Congress. The

are more than 78,000 direct

Business Council of Canada

and indirect jobs.

represents the largest group

How this will play out over time

of major companies in

will of course be tempered

Canada representing half the

by how the new USMCA

value of the Toronto Stock

trade agreement plays out

Exchange and they have indicated

in Canada. All else being equal, these

real concerns. The Council just

sectors as a whole would likely face a

released a report done for them by

significant shift in investments from

PwC confirming concerns related to

Canada to the US over the next

the potential impacts of recent US tax

10 years.” PwC notes that capital-intensive

reform on Canada’s economy.

sectors most at risk include

The US corporate tax rate is now

manufacturing related to chemicals,

two points below Canada’s and that

machinery, plastic, rubber,

is having a bullish effect on foreign

and transportation.

investment in the United States. Meanwhile Canada’s last eight quarters saw stagnation in direct foreign investment. This is largely due to the new US business tax rate, but others have argued it is also due to the nature of increasing regulations in Canada. It may also have to do with the number of large projects in Canada having been stalled for various business and political reasons over the past two years. PwC’s detailed

N. 56 - MARCH/APRIL 2019 - international PAINT&COATING magazine

over time. This will include whether or not Carsten Reisinger © AdobeStock

Canadian Paint and Coatings Association, Ottawa – Canada

ANALYSIS

Canada responds to US tax reform, how

the social and economic well-being of

- Require timeliness, policy coherence,

regulatory issues are aligned across the

Canadians, as reflected in legislation;

and minimal duplication throughout

Canada-US border, the impact of new

- Promote a fair and competitive

the regulatory process by consulting,

carbon pricing taxes, whether current

market economy that encourages

coordinating, and cooperating across

direct investments in key projects move

entrepreneurship, investment, and

the federal government, with other

innovation;

governments in Canada and abroad,

forward, and if regulatory approval processes are shortened. These are

- Make decisions based on evidence and

and with businesses and Canadians1.

many of the issues CPCA has been

the best available knowledge and

Given the foregoing, industry has little

addressing on for the paint and coatings

science in Canada and worldwide;

choice but to remain positive and

sector in Canada. This relatively new

- Create accessible, understandable,

support what’s best for the economy

trend for Canada all hinges on the need

and responsive regulation through

and address the real challenges where

to reduce business uncertainty and

inclusiveness, transparency,

we find them. For the coatings industry

accountability, and public scrutiny;

- and many others sectors - there

create a more focused economic growth agenda for Canada.

- Advance the efficiency and

appears to be much to ponder these

The paint and coatings industry must be

effectiveness of regulation by

mindful of the challenges and continue

ascertaining that the benefits of

to seek greater alignment of regulations

regulation justify the costs, by focusing

where possible. We were encouraged

human and financial resources where

by the renewal of the Canada-US

they can do the most good, and by

Regulatory Cooperation Council last June

demonstrating tangible results for

and remain hopeful that the ongoing

Canadians;

days.

1 Source: Federal Cabinet Directive on Streamlining Regulation, Treasury Board of Canada.

work plans of the RCC will lead to positive outcomes for industry. Positive approaches in this respect will ensure that both Canadian and multi-national companies operating in Canada have consistent regulations. This is most critical for the coatings that 50 percent of the total volume of paint and coatings sold in Canada is now imported from the United States. Much of the product now manufactured here in Canada is done largely by US-based companies. We were also encouraged to learn late in 2018 that the federal government had decided not to amend existing chemical management regulations in its current mandate, as that would create even greater uncertainty for the chemical sector. CPCA has long been advocating that the federal government must deal with regulations that conform to its own regulatory policy as noted below: - Protect and advance the public interest in health, safety and security, the quality of the environment, and

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

international PAINT&COATING magazine - MARCH/APRIL 2019 - N. 56

234-05/17-4c-GB

industry when one considers the fact

BRAND-NEW

ADAMOS IIoT Platform Is Growing: Five Further Mechanical Engineering Firms Have Joined he ADAMOS software platform

for the Industrial Internet of Things (IIoT) is being used by an increasing number of mechanical engineering firms. Most recently, another five reputable companies have joined the ADAMOS network. Among them are the mechanical

engineering firms Oerlikon Textile, Weber

Figure 1: By means of production data generated through ADAMOS, users are able to utilize digital services, such as apps for predictive maintenance and for maximizing machine utilization. This increases the efficiency of factories.

Maschinenbau (food packaging

apps for predictive maintenance and for

partner and Germany’s second largest

machines), ILLIG Maschinenbau

maximizing machine utilization.

software house, provides central

(thermoforming, packaging technology)

Ralf W. Dieter, CEO of Dürr AG and

software modules for the platform.

and Mahr (production metrology).

Chairman of the ADAMOS Advisory

The ADAMOS network currently consists

ADAMOS is a manufacturer-neutral IIoT

Council, says: “Digitization is the

of 12 companies, which cooperate

software platform, specifically tailored

most important trend in industrial

closely to develop apps and digital

to the mechanical engineering sector

production. German mechanical

business models.

and its customers. It offers simple and

engineering firms can benefit from

According to the CEO of ADAMOS,

flexible digitization of production to users

this trend by pooling their skills and

Dr. Marco Link, “we see ADAMOS as a

of machines and manufacturing facilities.

resources. And this is exactly what we

community of like-minded partners, who

The ADAMOS platform can be used to

are doing with ADAMOS: this platform

regularly share information on certain

interconnect machines, enabling them

stands for cooperation and efficient IIoT

topics to identify and implement new

to exchange information via the Internet.

solutions for our industry.”

business models in the mechanical and

By means of data generated through

ADAMOS was founded in 2017 by the

plant engineering sector”.

ADAMOS, users are able to utilize

mechanical engineering firms DMG MORI,

digital services and thus increase their

Dürr, Zeiss and ASM PT, together with

For further information:

production efficiency. Examples include

Software AG. Software AG, enabling

www.durr.com

N. 56 - MARCH/APRIL 2019 - international PAINT&COATING magazine

BRAND-NEW

ECKART Reacts Confidently to Unexpected Exchange of Raw Materials

ix months ago, the effect pigment

coatings and printing industries

The result is pigment series that

industry was unexpectedly faced

with products that meet regulatory

both comply with the latest global

with a new challenge: a raw

requirements.

regulations and meet current

material commonly used in the industry

At the same time, the company

customer requirements.

was classified as a chemical toxic to

attached great importance to keeping

“Due to our fast reaction we are

reproduction.

its customers constantly informed

able to offer solutions guaranteeing

It is a phosphoric acid isotridecyl ester

about the current state of affairs.

long-term product safety for

(CAS 52933-07-0), which up until now

The products concerned have been

our customers with the product

has been completely inconspicuous and

marked accordingly. An intensive

series HYDROXAL V, ROTOVARIO

which is widely used to stabilize aluminum

exchange with the customers took

Aqua Slurries, HYDRO PELLET

pigments for aqueous formulations.

place with regard to the reformulations,

and SHINEDECOR,” says Dr. Dirk

As part of its voluntary commitment,

in order to also map technical

Schumacher, Global Head of Product

ECKART was the first supplier on the

preferences and advancements in this

Management at ECKART.

market to react very quickly by developing

process. Another focus was on taking

alternative formulations in order to

into account the listing status applicable

For further information:

continue to provide customers in the

in each country.

www.eckart.net

Figure 1: ECKART was the first supplier on the market to react very quickly by developing alternative formulations to the raw material classified as a chemical toxic.

international PAINT&COATING magazine - MARCH/APRIL 2019 - N. 56

Opening photo: The power & free conveyor used for tests in CM Automazione’s headquarters.

HIGHLIGHT OF THE MONTH

Solid Company Know-How and Flexibility: CM Automazione’s Philosophy From an interview with Stefano Crotti CM Automazione Srl, Giussano (Monza e Brianza) – Italy

info@cmautomazione.it

uaranteeing high quality and

company based in Giussano (Monza e

history of a company that has succeeded

precision products while

Brianza, Italy) is specialised in the design,

in establishing itself in the automation and

trying to meet the most varied

production, and installation of industrial

industrial handling sector in just twenty

customer requests through production

handling systems (Fig. 1). ipcm had the

years, thus becoming a benchmark in the

flexibility, product customisation, and a

opportunity to interview Stefano Crotti,

Italian market. The firm is now planning

complete package of assistance services:

who started this business in 1999 together

to strengthen its presence also at the

that is CM Automazione’s mission. This

with Giuseppe Moscatelli, to present the

international level.

N. 56 - MARCH/APRIL 2019 - international PAINT&COATING magazine

HIGHLIGHT OF THE MONTH

Guaranteeing high quality and precision products while trying to meet the most varied customer requests through production flexibility, product customisation, and a complete package of assistance services: that is CM Automazione’s mission.” as hooks, bars, and specific accessories for coating plants (Fig. 2) that can be tailored to user needs (Fig. 3).

Figure 1: CM Automazione’s headquarters in Giussano (Monza e Brianza, Italy).

ipcm®: What is your core business and what are your target sectors? SC: The company’s core business is

ipcm : Can you briefly illustrate to our

Another key moment in the history of

the design and implementation of

readers the evolution of the company

CM Automazione was 2011, when we

internal handling systems, overhead

from its foundation to today?

acquired the well-established company FA

and floor conveyors, one-rail, two-rail,

SC: CM Automazione’s history started in

Ganci (Modena, Italy) and thus expanded

and manual conveyors for coating

1999, when Giuseppe Moscatelli and I

our offer with part hanging systems such

plants intended for a wide range of

the long-standing expertise gained in the technical office of another company in the sector, which enabled us to get to know our product and target market

decided to establish this firm based on

very well and to be able to produce high quality handling systems. During these first twenty years, we have achieved many of our goals. One of the most important was switching from manufacturing only one-rail lines to producing more complex systems, i.e. simple and dynamic (power & free) two-rail conveyors managed through software developed and tested in-house (ref. Opening photo). The choice to start producing power & free conveyors called for a change of vision and target market. At first, our customers could only be producers of coating plants. However, thanks to the development of our internal resources, we have acquired the skills and capabilities to collaborate directly with end users.

2 1

Figure 2: Following the acquisition of FA Ganci, CM Automazione manufactures hooks and hanging systems.

international PAINT&COATING magazine - MARCH/APRIL 2019 - N. 56

3 1

4 1

Figure 3: Swivel hooks.

Figure 4: Detail of the drive unit and lubrificator onto a CM conveyor.

specific customer needs.

products such as wooden doors and windows, aluminium profiles, plastic parts, iron, steel, and automotive components. In some market niches, we have been true innovators: in the enamelling sector, for instance, we were the first to offer handling systems for applying enamel on exhaust pipes. ipcm®: How is your production department structured? SC: CM Automazione covers a 3500 m wide area, two thirds of which are 2

CM Automazione’s history started in 1999, when Giuseppe Moscatelli and I decided to establish this firm based on the long-standing expertise gained in the technical office of another company in the sector, which enabled us to get to know our product and target market very well and to be able to produce high quality handling systems.”

Our robotic welding department (Fig. 5) and the use of specific jigs enable us to supply hooks and coating equipment designed and created based on the workpieces’ size and the chains’ overall dimensions, thus optimising the yield of the plants and, therefore, their production capacity. The possibility of including both the construction of the handling line and the customisation of its hanging system in our offer allows us to fully meet the end users’ needs and forge partnerships with national and international installers.

dedicated to production. © CM Automazione

In terms of resources, the company has around 10 employees and longstanding collaborations

ipcm®: The evolution of CM Automazione was marked by the

with a few contractors.

launch of a power &

A large space is devoted

free conveyor designed

to the activities of

by you. What features

development, realisation,

distinguish this and

assembly, testing, and

your other products?

quality control of our

SC: Flexibility is the key

plants. We design and

element that unites

manufacture most of our

our products. Offering

components in-house, such

modular one-rail

as rails, curves, drive units

and two-rail handling

(Fig. 4), and lubricators.

lines means to offer

Our handling system can

versatile systems that

also be equipped with customised two-plane chains in order to meet

5 1

Figure 5: A production phase with a welding robot.

N. 56 - MARCH/APRIL 2019 - international PAINT&COATING magazine

are easy to assemble and disassemble and extremely adaptable

It’s up to you how to relax. But, just relax.

We do the rest.

www.alit-tech.com San Bonifacio – Verona - ITALY

FASTRIP T5 & FASTRIP T2 for paint stripping of metal parts

FASTRIP T5 is a range of mediumsized stripping tanks with capacity from 600 liters.

FASTRIP T2 is an ultrasonic tank with an integrated heating system combining a mechanical and a chemical action.

EASY TO USE time setting, heating function, constant temperature control, and real-time temperature display STURDY made of high quality steel. The cleaning basket can be supplied in AISI 304 stainless steel EFFECTIVE it features a powerful large-diameter transducer with a considerable cleaning effect SAFE electric circuit insulated from liquids for greater safety

www.alit-tech.com San Bonifacio – Verona - ITALY

HIGHLIGHT OF THE MONTH

in terms of arrangement. Depending on the

ipcm®: What does the revamping of a

characteristics of the lines, such as, for example,

conveyor involve?

their length, their windingness, and the weight of

SC: The goal is to solve the problem. If

the loads to be handled, we are able to develop

possible, the rail circuit is maintained,

specific designs to create customised solutions.

i.e. the track and its support structures.

The innovation introduced by our power & free

If necessary, worn curves are replaced

system is the possibility to implement curves

and a more or less radical intervention

with a very narrow radius thanks to the use of

is carried out on the drive unit and the

steering trolleys (Fig. 6).

two-plane chain. One of the most involved components in revamping is the lubrication

ipcm : For CM Automazione, being flexible

system, as old oil emulsion lubricators no

also means to offer revamping solutions

longer comply with current legislation.

for already existing plants. Not many ipcm®: What goals have you set for the

Why this choice?

short and medium term?

SC: Both in the national and international market,

SC: Once we have established our

there is a large number of conveyors that are

presence in the industrial handling and

obsolete or not in perfect operating conditions.

automation sectors, we aim at expanding

The maintenance of these systems is often

and strengthening our position in

difficult, because the company that designed it

the international market through the

no longer exists, the technologies have changed

development of new channels.

or been updated and spare parts are no longer

That is why we have undertaken new

available. CM Automazione decided to meet

communication and promotion strategies,

these needs: after a brief analysis of the existing

which have led to the launch of our new

line, our engineers identify its critical areas and

website and to our collaboration with

determine if it is necessary to replace the entire

international magazines in the industry. It is

handling system or if only obsolete components

the beginning of a journey that will lead us to

can be replaced.

further growth and evolution.

companies offer this service.

6 1

Figure 6: The new power & free conveyors are equipped with steering trolleys.

BRAND-NEW

Contactless and Precise Roughness Measurement in the Lab or Directly in The Production Process

hether a surface must be

The vertical transport of the measuring

exceeded. To reach a vast scope of

very smooth or show a

head uses an ultrasonic instead of a

tasks from roughness analysis to

certain texture or degree

common piezo drive. Thus, while combining

imaging the exact shape of whole

of roughness, the new Surface

speed with a high resolution, the usual

products such as screws or tooth

Roughness Analyzer – SRA precisely

height range of the measurement is widely

implants, lenses with magnifications from 2.5 to 100-fold can be

pictures the topographic condition of for optimizing the material or

exchanged quickly and easily.

a surface and provides information

Measuring head for robotic systems – ready for in-line quality control

production process. Contactless, quickly, and with an extremely high resolution, the SRA delivers a 3D image of a sample surface and the correlating data which exactly

With its small size and low weight,

describe its topography. Analyses

the SRA can be used at almost any

with the SRA also help to evaluate

place as a lab instrument, but is also

the contribution of roughness to

available as a measuring head to be

the wettability of a sample or to the

used for automatic processes

adhesion of coatings.

in the production line. This makes real-time sample

Technical innovations for precision and speed

evaluations for QC checks of work pieces possible. Adding to the versatility of

The SRA uses the confocal microscopy technique to create the

the SRA itself, the software

spatial representation of the surface.

can be linked to programs such as Matlab® in order

This happens by stacking layers of 2D images, each one with a very small

to integrate it in information

depth of focus, while lowering the

systems.

optics with extremely tiny increments,

The Surface Roughness

leading to a height resolution of

Analyzer – SRA is immediately

down to 10 nanometers.

available. KRÜSS will also present

To scan an area of the sample, usual

the instrument together with

confocal microscopes use a rotating

other solutions in the area of

pinhole disk to create an image at

non-destructive surface analysis

each height level. The disk inside

at the Control trade fair from

the SRA has micro lenses instead of

May 7 to 10 in Stuttgart

just holes, increasing the light yield and making it possible to analyze low-reflectivity or even transparent surfaces.

N. 56 - MARCH/APRIL 2019 - international PAINT&COATING magazine

Figure 1: The new Surface Roughness Analyzer – SRA precisely pictures the topographic condition of a surface and provides information for optimizing the material or production process.

(Germany): Hall 6, Stand 6419. For further information: www.kruss-scientific.com

BRAND-NEW

ACEMATT® 3400 – New Matting Agent with High Transparency and Soft-Touch Properties

CEMATT® 3400 is the new matting

the special after-treatment of ACEMATT®

ACEMATT® 3400 can be easily incorporated

agent in the ACEMATT product

3300 and ACEMATT 3400 prevents the

into the formulation; no high shear forces

family from Evonik Resource Efficiency

adsorption of associative thickeners in water-

are needed; thus, the bead mill can be

GmbH, specially developed for high-

based systems. Likewise, when formulated

skipped. Furthermore, ACEMATT® 3400

transparency clear coatings and soft-touch

with particular polyurethane binders, it can

can be added to the coating formulation

coatings with smooth surfaces.

also improve the soft-touch feel.

at the end of the process, allowing for a

post-adjustment of the

treated, thermal silica

gloss level.

ACEMATT® 3400 is a surfacewith medium-particle

ACEMATT® matting agents

size of 7.5 µm.

are high-performance

The improved grind

silica developed for gloss

performance results in a

reduction in a vast range

smooth surface finish with

of applications in

outstanding optical and

the paints and coatings

haptic properties.

industry.

This highly efficient silica is

Evonik’s best-in-class

intended for use in clear

recommendations for

coatings and water- and

high-quality coatings with

solvent-based coatings.

excellent transparency

Typical application fields

are the family of thermal

include wood coatings,

silica ACEMATT® TS 100,

plastics, and automotive

ACEMATT® 3300, and

coatings. In addition, this new

ACEMATT® 3400.

type of matting agent can be used in high-solids and lowVOC formulations. In regards to rheology,

Figure 1: Typical application fields of the new matting agent ACEMATT® 3400 include wood coatings, plastics, and automotive coatings.

For further information: www.evonik.com

Opening photo: EcoScreen Equipment Analytics is the latest product from Dürr’s Digital Factory. The software continuously collects and analyzes data from the paint shop, making painting processes transparent and efficient.

INNOVATIONS: PRESENT&FUTURE

Ecoscreen Equipment Analytics Optimizes Plant Availability and Product Quality Harald Pandl Dürr Systems AG, Bietigheim-Bissingen – Germany

info@durr.com

ürr EcoScreen Equipment Analytics

What is happening in the painting cell and

the pressure regulators, metering

brings transparency and intelligence

what is the condition of the technology?

pumps and color valves (Fig. 1). Main

to paint shops processes. The newly

EcoScreen Equipment Analytics provides the

needles, turbine speed, shaping air and

developed solution for the Industrial Internet

answers. The software records and analyzes

air heaters from the electrostatic rotary

of Things (IIoT) evaluates all robot and process

all relevant signals from the sensors and

atomizers are also connected to the data

data, traceable down to the millisecond, so that

actuators integrated in Dürr painting robots

recorder. The software also records the

faults can be quickly identified and rectified.

(ref. Opening photo). The application

positions, torques, and temperatures

The technological highlight is a streaming

technology of the front robot arm, for

of the painting and handling robots’

analytics application for real-time data analysis.

example, permanently provides data on

individual axes. Data from the conveyor

N. 56 - MARCH/APRIL 2019 - international PAINT&COATING magazine

INNOVATIONS: PRESENT&FUTURE

technology is additionally collected for the

different robots improve root cause analyses and help

positions of the bodies in the painting booth.

the plant operator to boost plant availability, increase

This information is compared with data from

the first-run rate, and improve the overall process

the painting cells, such as start and end time

sequence.” This creates transparency. For example,

of painting, or production data for individual

the signals collected from the metering pump together

bodies such as type and color code. All errors

with flow rates, pressure regulators, and main needles

and warnings from the painting process are

of the atomizers can be displayed synchronously on the control computer

also collected.

Visual representation creates transparency In addition to data recorder and database, the IIoT solution comprises a visualization for the graphical representation and analysis of the results. “With the help of the

and correlations can be defined. The software

Dürr EcoScreen Equipment Analytics brings transparency and intelligence to paint shops processes. The newly developed solution for the Industrial Internet of Things (IIoT) evaluates all robot and process data, traceable down to the millisecond, so that faults can be quickly identified and rectified.”

can display these process signals in a 3D view together with the trajectories traveled by the robots and the exact position of the body, and perform a comparison. By superimposing the signal curves, EcoScreen Equipment Analytics can

Visual Analytics module

also compare bodies by

we can precisely trace the

type and color.

data from the previous weeks with millisecond and CEO of Dürr Systems AG. “The detailed

Algorithms calculate the ideal plant condition and show anomalies

information helps us to identify and eliminate

The additional module Streaming Analytics goes

faults quickly. The cross comparisons of

one step further: it analyzes the data in real time.

accuracy,” explains Dr. Lars Friedrich, President

Figure 1: Paint robots equipped with sensors enable the acquisition of large amounts of data - an important driver for applications in the Industrial Internet of Things.

With the help of the Visual Analytics module it is possible to precisely trace the data from the previous weeks with millisecond accuracy. The detailed information helps to identify and eliminate faults quickly. The cross comparisons of different robots improve root cause analyses and help the plant operator to boost plant availability, increase the first-run rate, and improve the overall process sequence.”

the paint booth. EcoScreen Equipment

Analytics solution a powerful tool, since the

Analytics uses software from the IIoT

software automates the plant operators’

platform ADAMOS for the streaming

process knowledge using online analyses.

analytics function. Dürr operates and several mechanical engineering

Integration of machine learning in the future

companies.

“In parallel with Streaming Analytics, Dürr

ADAMOS together with Software AG

Model-based plant monitoring

is developing further modules for batch analytics applications that work on the basis

Streaming Analytics provides the plant

of artificial neural networks. The software

operator with easy-to-use graphical

learns the optimal process condition fully

interfaces that do not require any

automatically and registers every deviation.

programming expertise to create analysis

This means that the software will solve

models (Fig. 2). For this, Dürr developed a

problems itself in the future through machine

Model Editor that provides the user with a

learning,” explains Dr. Friedrich. “If the

library of analysis modules. These can also

self-learning modules detect trends,

be individually combined into new models

problems in the equipment can even be

(e.g. a model for monitoring the painting

identified in advance by specifying a forecast

Using algorithms, it calculates patterns

pressure during application).

of the event time.”

and correlations that describe the ideal

The data is displayed graphically on the

A number of car manufacturers have been

plant condition from the data collected.

screen. The operator can see that all values

using the EcoScreen Equipment Analytics

Even the smallest anomalies both

are within tolerance and with Streaming

software since 2018. The additional module

within the plant and in the process are

Analytics, he can create an analysis model

Streaming Analytics based on real-time data

automatically identified. Employees can

that automatically determines anomalies

has been used for the first time in a complete

initiate corresponding service measures

such as air bubbles in the paint from the

production line since the fourth quarter of

straight away and get to the bottom of

characteristics of the signal curve. These

2018. The Batch Analytics module, which uses

the deviation before the body even leaves

possible applications make the Streaming

artificial intelligence, is currently in the trial phase with a customer.

The EcoScreen Equipment Analytics software was developed in Dürr’s Digital Factory. In this competence center, founded in early 2018, around 100 software experts are working on solutions for the digitization of production processes.

2 1

Figure 2: With the new Equipment Analytics software, the plant operator can monitor the condition in the painting cell.

N. 56 - MARCH/APRIL 2019 - international PAINT&COATING magazine

A number of car manufacturers have been using the EcoScreen Equipment Analytics software since 2018. The additional module Streaming Analytics based on real-time data has been used for the first time in a complete production line since the fourth quarter of 2018.”

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SUSTAINABILITY

Hel en

HMG er, ld

, DSM ets M

lenius, Tekn Ca o ik

Fred er

John Fa

Five on Five Interview: Sustainability According to the Industry Players - Part II

a, Tikkurila kul ar

n our previous edition of the ipcm® magazine we published the first of a three-part interview to senior figures from within the Coatings and Resins industry on the role of sustainability within their organisations. We wanted to give our readers some unique and different content while at the same time embracing a noble element within our industry. If you didn’t catch the first article you can still read it online at

Joel Sv

Elis aM

5 ON 5

n, Belzona dse en

www.myipcm.com by selecting issue n. 55 of ipcm® (January/February 2019) and scrolling onto page 38. Below you can find the second part of the first Five on Five interview, with the answers to five further questions. Once again, we would like to call out that there are no right or wrong answers as regards sustainability and indeed each company has reached different points in their journey.

For this second instalment we once again had the sincere pleasure of working with the following industry leaders: Joel Svendsen - Belzona President Helen Mets - DSM President Resins & Functional Materials John Falder - HMG Paints Managing Director Fredrik Calenius - TEKNOS Chief Procurement Officer Elisa Markula - Tikkurila CEO & Minna Avellan - Director, Communications and Investor Relations of Tikkurila

N. 56 - MARCH/APRIL 2019 - international PAINT&COATING magazine

SUSTAINABILITY

W hy and when did your company get involved seriously with sustainability?

Joel Svendsen, Belzona – I would say it was really from the very beginning. When Belzona was formed, my father (Jorgen Svendsen) would travel around the UK and see rust and corrosion everywhere! Corrosion protection was really in its infancy at this time. For example, a bridge made out of metal would have a very short lifespan, rust away and large sections would have to be replaced fairly quickly. So, Belzona’s vision from the very beginning was that if we can begin to slow down corrosion, then we don’t need as much metal. Everybody knew it was a problem. But they struggled to come up with effective solutions for it. Steel is such Pumps rebuilt and coated by Belzona. an effective material. It is so integral in construction, that you want to use it all over the place 90% of them have waterborne coatings and in the beginning, you accepted that its resulting in a reduction in VOC emissions from lifespan was short. Gradually people began 160,000 tons per year to just 15,000 tons. to find solutions for it, but it has been a long process. Belzona certainly has been a leader John Falder, HMG – Since our inception HMG in extending the life of steel, being one of the has always aimed to be sustainable, even first companies to have effective solutions before it became a trend. We do this because for this. at every level it is the right thing to do and the right place to be. It makes business sense, Helen Mets, DSM – DSM has been highly personal sense and it shapes the future of the focused on sustainability not only from planet. an ethical point of view, but as a market differentiator and as a business driver Fredrik Calenius, TEKNOS – We are currently for about more than 10 years. With the updating our strategy for 2019-2025 with the recognition that there were truly viable, ambition to grow the company to EUR 1 billion greener and safer alternatives that delivered net sales by 2025. As of this year, sustainability equitable product performance, and with the will be integrated as part of our strategy from advent of innovative technologies enabling the boardroom down.

those developments, we began what can only be described as our sustainability journey, transforming ourselves to a company with sustainability as part of its DNA. For example, it was a decade ago that DSM, along with other coating players, founded the Waterborne China Platform to reduce VOC emissions in the booming industrial container sector by switching from solvent-based primers and topcoats to waterborne ones. Today, with over 3 million industrial container units in operation,

5 ON 5

Minna Avellan, Tikkurila – Responsibility and sustainability has been part of our business already for decades. Here are some of our key sustainability milestones: - Customer cooperation: Tikkurila first started training customers in the late 1920s. A customer magazine “Tikkurilan Viesti” was founded in 1929. The magazine has been published regularly ever since, except for a six-year break during World War II. - F irst waterborne products: Our first waterborne product in Finland, Tikkurila brand’s Joker interior paint, was introduced in 1953. In Sweden, the first waterborne product was launched in 1951 by Beckers. Today, an increasing number of paints are waterborne, low-solvent, solvent-free or high solids products. In 2017, 85% of decorative paints sold are waterborne products (2017). -T inting is an economic and ecological way to produce thousands of colours. Tikkurila launched its Monicolor tinting system already in 1970. This changed both paint-making and distribution. Producing coloured paints by tinting has a direct impact on the ecological footprint (less waste and improved material efficiency, improved production efficiency, logistics benefits). - I n 1994, Tikkurila in Finland got the ISO 14001 environmental management certification. The majority of our units have the audited and certified quality, environmental, and safety management systems. The list is available on our website at www.tikkurilagroup.com. - I n 1997, Tikkurila’s Eko-Joker paint received the EU’s environmental label – as the first paint product in Finland to do so. Nowadays we have some 300 eco-labelled products.

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SUSTAINABILITY © DSM

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DSM Decovery range is nearly 50% plant-based.

How are you measuring progress?

Joel Svendsen, Belzona – We regularly review our product portfolio to see where we can make our products more environmentally friendly. Are there ways that we can reformulate to use safer materials and, at the same time, more environmentally friendly? Can we incorporate more bio-based materials than petroleum-based? These issues and how we measure them are raised and discussed in our regular technical liaison meetings. From here we decide if things need to be altered and whether or not to pursue new developments. Helen Mets, DSM – We measure the effect that every one of our products has on people and the planet benchmarked against conventional, less sustainable equivalents. We call them Brighter Living Solutions and they currently account for 80% of our entire portfolio. We also measure our own sustainability progress through key performance indicators (KPIs) we’ve set within the business. An example is the goal of increasing our purchasing of

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John Falder, HMG – HMG uses a variety of means but the British Coatings Federation, Coatings Care statistics are one of the documented measures. We also work tirelessly to comply with relevant current and future legislation. As part of the strategic planning processes, we incorporate environmental objectives, where appropriate, into business decisions, and ensure all environmental

energy from renewable sources to 70% by 2030, for which we’ve made significant strides, going from 8% in 2016 to 21% in 2017. Allied to this, for many years DSM has been listed at, or near, the top of the annual Dow Jones Sustainability Index and last year we ranked 2nd in Fortune’s “Change the World” list based on the social impact woven into our core business strategy.

HMG Paints’ environmental accolade for its imaginative landscaping work on the banks of the River Irk.

SUSTAINABILITY objectives and targets are appropriate to the nature, scale and impacts of our activities, products and services. Fredrik Calenius, TEKNOS – We have defined concrete goals/targets and KPI’s for all of the areas below. - phase out of Reach substances of very high concern; - decrease of VOC; - increase secondary usage; - safe use of chemicals; - increase our understanding of customers sustainability needs; - increase customers’ awareness of sustainability in Teknos’ offerings; - occupational health and safety; - environmental efficiency; - production efficiency; - business ethics;

- supplier code of conduct implementation; - supplier CSR implementation; - employee satisfactory & fair treatment; - leadership; - sponsorships/support local communities. Minna Avellan, Tikkurila – The sustainability performance is measured in various ways, both on the Group-level and locally, e.g. we are following sales of waterborne products, energy efficiency, amount of waste, development of safety.

How does your company promote the sustainability of its activities/products?

Joel Svendsen, Belzona – Throughout our Marketing literature, videos, articles, we try and promote our sustainability in the industry. We

also have a case study library, our KHIAs, which is an incredible way of demonstrating how we have been successful for decades in preserving and prolonging the lifespan of equipment and structures. Aside from that, we do push energy efficiency. We have our coating, Belzona 1341, which is particularly useful for improving pump efficiency. This differs from our usual push, saying that we will extend the life of your equipment – whereas in this instance, we are saying we can improve efficiency. Which appeals to our customer base from an economic stand-point even more and of course, as an environmental benefit. Helen Mets, DSM – The industry we work within is quite a small world. We are finding that DSM is starting to be recognised by our differentiation brought about by our

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SUSTAINABILITY approach to sustainability. But beyond the immediate borders of the industry we operate within, it is important for DSM to advocate on sustainability issues with legislators, partners and customers. We need to continue to be not only outspoken, but to play a proactive guiding role to enable long term sustainable change. At DSM Resins, sustainability is addressed in all of our product communications. Recently, we have launched what we think are the boldest sustainability targets in our industry with the aim to change the industry into a more sustainable one. John Falder, HMG – Ironically this is something we don’t really “Promote” as we see them as key business values. We are actively engaged in promoting good causes and efforts both in the local community and industry. Nevertheless, in order to achieve competitiveness through

sustainability, activities need to be unique, and not imitable by competitors. In this respect HMG works alongside its stakeholders in developing tailored activities that revolve around the companies Value Chain. Fredrik Calenius, TEKNOS – Internally we have programs in place such as workgroups and training for all the KPI’s mentioned above and our employees are encouraged constantly to participate in every area. Externally we use our communication channels (web, newsletters to customer, social media, newsroom, Trade Press). We are also cooperating with the Finnish Chemical Industry association. The first Non-Financial-Information report will be released early 2019. Minna Avellan, Tikkurila – Sustainability is a key element in our communications, brand management and marketing, so it is highlighted as part of product

knos © Te

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Teknos has integrated sustainability into their business strategy.

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promotion, company communications and stakeholder cooperation.

What sustainability initiative are you most proud of?

Joel Svendsen, Belzona – That’s an interesting question. I’m tempted to say our early work/early days in the company. Because we were taking unprotected steel and making a really big difference. In terms of what we are doing lately, I would say it is from a regulatory standpoint. Working in the chemical industry, it goes without saying that over time there will be something that is eventually found to be hazardous. The realisation of these previously unknown concerns then leaves you with a choice to make. As a company there are two roads to go down. Road one - you can pop a label on it and say this chemical is nasty, be careful. Road

SUSTAINABILITY two - you can try and reformulate and replace it with something safer. Belzona has tried very hard to not just “label it”, but to be proactive in researching and developing ways to make the products safer and better. Whereas I think a lot of other companies label it and consider their work done. I feel much happier about the way we do it. Helen Mets, DSM – We are proud of so many genuinely pioneering innovations, but a particular one that comes to mind is our family of eco-friendly paint resins – that is, Decovery® for building, construction, interior decorating and furniture applications. Our Decovery range is nearly 50% plant-based, but with equitable or better performance characteristics than VOC-embedded crude oil-based versions – from coverage and applicability, to durability and colour finish (no yellowing). It’s one of our flagship brands and is testament to how sustainable product stewardship can be a successful business driver. Above and beyond specific product innovations, we are also immensely proud of our vision and ability to dare to take on the sustainability journey in the way that we have. We are not involved in occasional or half-hearted sustainable activity but rather have absorbed the philosophy and tenets sustainability into our very DNA. John Falder, HMG – The huge water saving initiatives we have undertaken as a business overall. The River Irk was the heartbeat of the Industrial Revolution in Manchester and flows through our site so we’re extremely conscious of maximising its resources.

Fredrik Calenius, TEKNOS – Currently we are really proud that we have succeeded to integrate sustainability as part of our strategy. To know more about our recent success cases, you can visit our website: http://www.teknos.com/about-us/ sustainability/ Minna Avellan, Tikkurila – Within the latest product launches, our new biobased product, Alcro A1, in Sweden. A third of the raw materials that usually are fossil-based have been replaced with bio-based ingredients in this interior wall paint. Another interesting product launch is our new product family for facades, Tikkurila’s Finngard Clean. It is one solution for challenges posed by climate change to building facades. Due to its special technical properties (the superhydrophobic surface), Finngard Clean products repel water and dirt from the surface but allow any structural humidity to evaporate through it. Facades are under increasing stress, and surfaces remain wet for longer periods. This is a favourable growth medium for microbes and fungi, causing exterior surfaces to suffer damage more quickly. Regarding our social contribution: In Sweden, Tikkurila has established a Paint Fund, which gives the general public the opportunity to realize socially beneficial painting projects. In practice, anyone in Sweden can apply with his or her painting project for a project within the Paint Fund. A jury of Tikkurila Sverige’s representatives decides which projects to support and donates the needed safe and durable paints. The repainting projects can include a worn asylum-seekers’ homes, forgotten club venues or dark pedestrian tunnels. In 2018, within all applicants some 10 projects have been realized.

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lmost 40 years ago 10 Aeverybody rushed to

go green, but the results where scarce. Do you feel like this is truly a time of change or is it just another marketing strategy?

Joel Svendsen, Belzona – As with everything, it goes in fits and starts – fast progress, followed by a plateau. But I don’t think it died. Living in the US for most of my life, I find it interesting to compare the US and the UK in terms of environmental regulation. Starting in the early 1970s, the US were pioneers in this field. But as result, they suffered a lot. For example, they were among the first to put emission standards on cars and automobile manufacturers really struggled to make the technology work. Whereas, when you compare to the UK, environmentalism came a little later. And because it came later, the big challenges that previously had been stumbling blocks were now overcome. That meant they were able to push it further forward more quickly. In the US, because they had this bad experience, there was a bit of an aftertaste that the environmental legislation was a nightmare. So now, there is more resistance in the US to improving regulations. But time heals old wounds and as things continue to change, environmental issues will become universally accepted rather than be a debate. Helen Mets, DSM – While we can see that there are undoubtedly cases of greenwashing, I absolutely believe we are at the cusp of real change. Although, as I’ve commented

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SUSTAINABILITY

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Tikkurila has established a Paint Fund, which gives the general public the opportunity to realize socially beneficial painting projects.

previously, as pioneers in sustainability, we still feel the need to pull the market along. We are nevertheless seeing more drive from within industry and certainly big shifts from the outside world. There is an increase in consciousness which gives me optimism. Sustainability used to be part of the “softer” stuff that companies adopted into their strategies, but now the softer stuff is becoming harder and more tangible – so much so that quite robust measurement and reporting is being implemented. John Falder, HMG – For many companies, Sustainability is seen as short-term public palliative actions that are expected of it by the public as

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obligations move from stockholders to stakeholders, and companies become more accountable for their impacts on stakeholder communities. For many companies, it is still merely a “cosmetic public relations” activity, that generates no long-term value to society or to the business itself. As mentioned, since our inception in 1930, this has been a key part of the HMG Paints ethics and values, exemplified by its Coatings Care Award wins and award-winning CSR initiatives that have had real impact on us as a company and our local community. Fredrik Calenius, TEKNOS – We truly believe that the successful companies in the future will integrate sustainability

into their strategies. We see a good possibility to build a competitive edge on sustainability. It is not a green washing. Elisa Markula, Tikkurila – In 2030, the human population will be 8 billion and we will consume 50% more food, 50% more energy and 40% more fresh water. There is an urgent need for all companies, governments, countries and individuals to start behaving so that we have something to leave for the next generations. Every company needs to do its part and we believe that our sustainable actions have a meaning to the bigger picture. To help save this planet for the next generations.

Opening photo: Speroni, founded in 1946 as a manufacturer of small water handling equipment, is now a leader in the field of water pumps and electric pumps.

FOCUS ON TECHNOLOGY

A 4.0 Connection Point: Speroni’s Plant Choices Are Projected into the Future, but in the Name of Continuity Alessia Venturi ipcm®

ne-piece batches have been the

approach was regarded with fear by the

For large coating lines integrated in green

industrial trend of the last two years,

manufacturing industry, for which productivity

plants with a low environmental impact,

due to the marked, and sometimes

is everything. This changed with the advent

process choices are made today following

even extreme, product customisation

of the Industry 4.0, which makes it possible

the 4.0 automation principles, e.g. optimising

required by consumers that are addicted

to maintain productivity and efficiency while

processing costs, guaranteeing high product

to abundance and, therefore, constantly

manufacturing very small batches with a wide

quality levels, and optimising the cost per

search for unique purchases. This productive

variety of part shapes.

unit produced. An example is the recent

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FOCUS ON TECHNOLOGY

investment of Speroni Spa (Castelnovo di

marketed through the brands Speroni, Marina,

and economically produce even one-piece

Sotto, Reggio Emilia, Italy). This company was

Airmec, and Euromatic. The modernisation of

batches have been the industrial trend of the

established by Giuseppe Speroni in 1946 for the

the last few years has decisively involved its

last three years. Therefore, in 2016, we made a

production of small water handling equipment

project and test centres, but also its production

significant Industry 4.0-oriented investment on

for the agriculture and livestock sectors;

departments. The aim was improving speed

both our machine tools and finishing systems.

now, it is a leader in the field of water pumps

and flexibility in order for Speroni to become

Our flexibility and ability to meet customer

and electric pumps. By creating a work team

an extremely flexible company, able to handle

requests in a few weeks have been, and will

composed of some of the best companies in

the large volumes required by the global retail

continue to be, crucial to the growth of Speroni.

the sectors of metal processing, treatment, and

markets without sacrificing quality.

That is why we had to invest in flexibility and

coating plants and process automation, Speroni

“We are highly customisation-oriented,” says

production speed with a high automation level

completely revolutionised its production

Giuseppe Speroni, one of the founder’s

and digital and paperless operations, not in

structure. The result was a smart factory

grandchildren and currently a manager of the

order to handle large volumes, but to speed up

that now enables the firm to guarantee the

our daily batch change processes.”

customisation degree required by the market

For Speroni, “personalisation” means to

without sacrificing productivity, cost efficiency, and product quality (ref. Opening photo).

Speroni: water handling technologies 70 years of experience. Over 150 employees. A very modern factory that covers about 45,000 m (Fig. 1). A production capacity of over 2

3000 items per day. Brand presence in over 80 countries. Total turnover exceeding 50 million Euros per year. These few figures summarise the business of Speroni, a benchmark company in the production of (submersible, surface,

70 years of experience. Over 150 employees. A very modern factory that covers about 45,000 m2. A production capacity of over 3000 items per day. Brand presence in over 80 countries. Total turnover exceeding 50 million Euros per year. These few figures summarise the business of Speroni, a benchmark company in the production of electric pumps for water.”

manage up to 18 different paint colours and use different packages for different workpieces or markets. “In order to acquire the flexibility needed to work with such specific customer requests with a response time of a few weeks, we had to invest in the flexibility of our production equipment, and especially of our coating plant, by speeding up batch change operations, reducing waste, and achieving a high automation degree,” explains Giuseppe Speroni. “A quick batch change operation is crucial for us: we have a very large market share, which helps compensate for possible demand decreases in some sectors with

and multistage) electric pumps for water

increases in others, but which can be tricky

intended for domestic, industrial, agri-food, and firm together with his sisters and cousins (Fig. 2).

when all industries are flourishing at the same

and motor-compressors.

“We have always enhanced our brand while

time and we must meet all demands in a short

During these seventy years, Speroni has

meeting even the smallest customisation needs

time.”

focussed on continuous innovation, product

of our customers. That is why we now serve

“We have always preferred coating our products

research, technological advancement of

many different industries and we find ourselves

with an in-house application line because, as we

production plants, and quality investment. In

managing a very wide range of products – all

have been working with large retailers for many

this period, Speroni has developed one of the

customisable of course, even in terms of colour.

years, we aim at supplying effective products in

largest product ranges on the world market,

Personalisation and the possibility to efficiently

terms of both surface protection and aesthetics.

gardening applications, but also of compressors

Figure 1: Speroni is headquartered in Castelnovo di Sotto (Reggio Emilia, Italy) in a very modern factory that covers about 45,000 m2.

international PAINT&COATING magazine - MARCH/APRIL 2019 - N. 56

electronic 2K dosing system and application with the electrostatic technology was designed by Verind. The main colours unit and five wildcard ones guarantee great versatility and very rapid colour changes (Fig. 6). Great attention was paid to the paint dispensing equipment in order to minimise waste and consumption, since the colour change operation takes place directly on the robot’s wrist. As for application, we confirmed the choice of electrostatic bells, which we have been using for twenty years, also for the new robot (Fig. 7). The possibility of managing the air blades and electrostatic charges reduces paint consumption and increases the coating transfer accuracy and efficiency in the most

2 1

difficult-to-reach areas of our electric pumps,

maximum protection and corrosion resistance,

The revolution 4.0 of Speroni’s paintshop

but also maximum gloss and film distension

“For its digital revolution, Speroni relied

(Fig. 3),” says Speroni. “The investment in this

on two well-established partners, HUBO

4.0-oriented plant required the combination of

Automation and Verind, which had already

our skills with those of the partners we chose

designed the application process on

to support us in our factory digitisation project,

the old coating line. They collaborated

with the aim of achieving the highest quality level

with CMV, which built the plant,” says

for both our professional and non-professional

production manager Devid Montermini.

product ranges.”

“We immediately chose to install a two-rail

Speroni’s pumps are made up of cast iron

overhead conveyor to manage different-

castings with a 50 micron anti-corrosion

sized components with bars that can carry

primer already applied by the foundry, some

a maximum of 3 workpieces and have

aluminium components (e.g. flap motor), and

a maximum capacity of 1000 kg (Fig. 4).

a few components in phosphate iron sheet

The management of hooks, which are all

(e.g. fan guard). The parts are processed in

certified, was specifically designed in order

a robotic cell composed of various machine

to optimise the hanging operations by

tools and a cleaning system, all interconnected

matching as many parts as possible with

with each other. This transfer unit ensures in

each hook and improving load ergonomics.

one step that the workpieces are machined

Such study was done for the whole Speroni

on four sides, cleaned, protected against

pump range, from the submersible to the

oxidation, dried, and immediately transferred

surface, standard, and displacement ones,

to a vertical warehouse managing both raw and

as well as compressors. As a result, all

finished parts, which are then picked up for the

parts move on the line at the same height,

subsequent assembly and coating operations1.

regardless of their shape and size.

Therefore, our coatings must guarantee

“The automatic cell for the application with 1 For the article on Speroni’s 4.0-oriented transfer unit integrating a cleaning and pre-treatment line, please see issue no. 15, February 2019, pages 12-18 of supplement ipcm®_ICT Industrial Cleaning Technologies.

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the anthropomorphic robot by ABB and the related interfaces were integrated by HUBO (Fig. 5). The system with the pumping unit,

e.g. around the flaps. We chose to maintain a manual touch-up booth just for doubt’s sake: we use it mainly as a technical base.”

Figure 2: In the middle Giuseppe Speroni, one of the founder’s grandchildren and currently a manager of the firm together with his sisters and cousins.

3 1

Figure 3: According to Speroni’s philosophy coatings must guarantee maximum protection and corrosion resistance, but also maximum gloss and film distension.

1999-2019

hi-tech

FOCUS ON TECHNOLOGY

conveyors

4 1

Figure 4: The coating plant is equipped with a two-rail overhead conveyor to manage different-sized components with bars that can carry a maximum of 3 workpieces and have a maximum capacity of 1000 kg.

“As for coating product, we are

For its digital revolution, Speroni relied on two well-established partners, HUBO Automation and Verind, which had already designed the application process on the old coating line. They collaborated with CMV, which built the plant.”

replacing the one-component product used on the old manual line in all 18 colours with a two-component water-based polyurethane coating developed by Beckers Industrial Coatings Italia, that we apply in one direct-to-metal coat with an average

CM AUTOMAZIONE srl

thickness of 70 microns. In case of special requests, we can also apply a two-layer primer+topcoat system with a double

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Figure 5: The anthropomorphic robot by ABB integrated by HUBO.

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

www.cmautomazione.it

phases that took place before design. This is rare, since in most cases we are faced with already-taken plant engineering decisions that make finding automation solutions really challenging,” says Sergio Castagna from HUBO Automation (Fig. 10). “With Speroni’s management and Verind, however, we analysed the type of conveyor, the storage buffer management, the application aspects, the type of robot to be integrated, and, above all, the most suitable system management methods for their needs. Only afterwards did we design the automation and software solutions.” “The plant receives the codes of the products to be painted directly from the central management system. This gets both the robot and the colour change device ready, while tracking all process phases and gathering all the data needed for the correct management of the coating phase,” states Castagna. “Special attention was paid to the man-machine interface. In addition to the conventional touch screens in which the operators can enter data and monitor

6 1

Figure 6: The paint mixing room designed by Verind with Dürr pumps: modular assembly, insulated concept and paint analog levels control for the SS tanks.

application process in the automatic

smart screens displaying in real time the

booth,” says Montermini. “The plant is

hanging and masking diagrams and the

equipped with 43 bars and frames with

coating program associated with the

a maximum size of 1500 mm in length,

product being processed (Fig. 9).”

600 mm in width, and 1000 mm

“In summary, we have cooperated

in height. It has a pitch of 1 bar every

with HUBO and Verind to achieve

3 minutes. After coating, the workpieces

high-level innovation through the

pass through a flash-off tunnel, a

choice of a 4.0-oriented communication

curing oven, and a cooling tunnel,

protocol,” states Giuseppe Speroni.

thus reaching a storage buffer and,

“In this way, we coat about 500 units a

finally, the unloading station (Fig. 8).

day with a perfectly reproducible quality

We manage the plant through the

and uniformity degree in controlled

company’s control software. The

conditions.”

logistics department sends all the to each bar through one paperless

Automation: the result of a planning process

message that also transfers information

“The operational success we achieved

to the 2K dosing device and the robot.

with Speroni’s coating line was the

The whole line was equipped with

result of a careful analysis of all process

information on the coating process

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operations through the characteristic

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Figure 7: Robot station completed with Dürr EcoBell 2 electrostatic direct charge technology.

FOCUS ON TECHNOLOGY

8 1

Figure 8: Workpieces in the storage buffer before the unloading station.

parameters, we have implemented two

Speroni strongly believed in this 4.0-oriented

that preceded its installation can be clearly

large format and high resolution monitors

system and supported us in all design

perceived (Fig. 12).”

installed in the loading and unloading

phases. In this way, together with Verind

“This plant represents the completion of a

stations. These assist the operators in

and CMV, we created a functional and

journey that began twenty years ago, when,

their activities by showing a photo of the

productive plant that is also well designed

together with HUBO, we developed an

workpiece, the type of hook required,

and beautifully done. All the study work

automation solution that was innovative for © Speroni

and information about the coating program. The loading and unloading stations also

that time: it involved the use of a chase reciprocator that moved on two axes while “chasing” the

feature photocells each, which

workpiece to increase application

perform factory and progress-

yield and efficiency,” says Giuseppe

based readings: based on the

Speroni. “This proves that our

information received from the

company was already seeking

system on the coating program

cutting-edge technical solutions.”

and product code, they detect

“HUBO designed the whole

the presence of hung parts,

software and hardware

by checking automatically

architecture for robot control and

the amount and by sending

programming, coating programs

information to the robot. If they

management, robot interfacing with the plants’ software

detect something different from what the management software communicated, is reported when a loading error has occurred (Fig. 11).

9 1

package and with the mixing and

Figure 9: The whole line was equipped with smart screens displaying in real time the hanging and masking diagrams and the coating program associated with the product being processed.

application systems, as well as part positioning management and product traceability. (Fig. 13).

international PAINT&COATING magazine - MARCH/APRIL 2019 - N. 56

10 1

11 1

Figure 10: From left to right: Speroni’s production manager Devid Montermini, Verind Technical Sales Manager for Emilia-Romagna region, Giovanni Benevelli, Verind Industry Sector Sales Manager, Alessandro Soba, Sergio Castagna from Hubo Automation and Matteo Caroli from Teknox.

Figure 11: Loading and unloading stations are equipped with photocells that detect the presence of hung parts, load the right amount, and send information to the robot.

The collaboration with Verind and CMV was

was also done for the choice of the coating

to identify the most suited coating system to

crucial,” states Sergio Castagna. “Automation

product. “With the installation of the new line,

our needs with the cooperation of Beckers’

starts with handling: a plant of this type can

we decided to switch from a one-component

engineers. The chosen system is of excellent

only be equipped with a two-rail conveyor,

product to a two-component one. Beckers

quality: it has been already approved and

in order to be flexible. Moreover, it was

Industrial Coatings followed the creation

adopted for several years by some of the most

important to choose bars enabling to hang

of the new plant right from the first design

important OEMs in the field of earth moving

one, two, or three workpieces depending

stages, supporting Speroni in all phases,”

machinery and tractors. The primer and the

on their size and to implement the smart

explains Devid Montermini. “This enabled us

topcoat, both two-component water-based

management of the parts’ rotation in the © Speroni

booth: the robot manages the three separate rotators via an interface as a controlled axis (Fig. 14).” “Depending on daily needs, production can be programmed to reduce the number of hook change operations while increasing the colour change ones or to apply the same colour but with numerous hook changes,” says Devid Montermini. “The software interface itself communicates to the operators what to do to optimise positioning or masking. It was designed to keep the whole coating cycle under control and to decide at any moment how, when, and why to save productive time or lose it in favour of flexibility.”

Research on painting products Speroni’s challenge was to automatically coat parts made of three different materials (cast iron, aluminium, and iron) with a uniform coverage and quality level. Much research

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12 1

Figure 12: Panoramic view of the coating plant.

FOCUS ON TECHNOLOGY

polyurethane products, allow to reduce the curing temperatures, in addition to guaranteeing excellent resistance performance and maximum environmental sustainability. Environmental responsibility is an integral part of Beckers’ values, perfectly in line with the choices adopted by Speroni for several years.”

Investing in technology “For Speroni’s application process, we designed and supplied a specific automatic system that integrates the EcoBell2 electrostatic application equipment to the automatic EcoDose 2K device implementing the fibre-optic technology for dosing and mixing 2K coatings,” says Verind Industry Sector Sales Manager Alessandro Soba. “The success and growth of Speroni SpA are linked to its ability to innovate and invest in cuttingedge technologies. The choice of application equipment and technologies from the automotive field is an example of this. Managing to integrate system engineering, know-how, and innovation was the winning factor that enabled Verind, that is part of the international Dürr Group, to meet the challenging industrialisation demands of Speroni.” “We installed one of the most up-to-date and innovative industrial technologies in the finishing sector,” says Verind Technical Sales Manager for Emilia-Romagna region, Giovanni Benevelli. “As already pointed out by Sergio Castagna, the preliminary collaboration established among all the technological partners involved in this 4.0-oriented investment project was extremely important, because it allowed us to define all process phases, but also all micro-application details ahead of time and in a precise manner. The technology provided represents the evolution of a 2K system that Speroni had already installed in 2014 on its manual line. We used that

“ The only thing I hate about my tractor is that it looks better than me

experience to automate this process. We chose to install a main colour feeding line for RAL 5010, i.e. Speroni’s blue, and five wildcard lines to manage the high variability of tints and reduce the colour change times. Moreover, we connected remotely the dosing and mixing panel inside the booth, again with the aim of speeding up the colour change operations and reducing paint waste.”

My diesel tractor is about my age, and it will probably outlive me. Actually, the chassis still looks as new. My service technician says it’s because of the coating. It protects effectively against corrosion and guarantees my tractor retains this same nice colour as when I bought it. You know, I even think it makes this old girl go faster.”

An overview of the new coating eco-technology The paint application equipment consists as follows: • Pumping units with a recirculation system for water-based coatings; • EcoDose 2K dosing equipment with fibre-optic flowmeters; • Volume-controlled cleaning and colour change cycles, recovering the product in a specific tank to prevent pollution in the booth with dry filters; • EcoBell direct charge, high transfer efficiency electrostatic technology; • An insulation system for electrostatic charges. Adding value beyond the sur face

Figure 13: The architecture for the robot control, programming and management was designed by HUBO.

Figure 14: The robot manages the three separate rotators via an interface as if they were a controlled axis.

A joint is a hinged connection system combining two rigid bodies or structures. It is synonymous with union, but also continuity. It therefore makes the perfect metaphor to describe what Speroni and its industrial partners have done: going along with the company’s innovation orientedness to implement cutting-edge technologies in the name of continuity with the equally innovative choices of the past, thus meeting the production needs of the present and future.”

The EcoBell2 electrostatic bells for

“In Speroni’s case, these process needs

and stability with a stoichiometric catalysis

water-based coatings guarantee significant

were met with the use of the EcoDose 2K

ratio ranging from 1:1 to 30:1, dosage

advantages such as the reduction of

mixer, an advanced electronic system for the

tolerance lower than 1%, injection dosing

overspray, paint consumption, VOCs,

stoichiometric dosing and mixing of

technology with an A and B dual channel

and sludge in the booth. The EcoHTG500

multi-component water-based paints able to

and separate cleaning circuits, closed loop

generator, with an electronic control

store over 1024 programs.”

paint flow rate control, and the modular

device and a high voltage raising unit,

EcoDose 2K guarantees high mixing reliability

and expandable automatic control of

13 1

14 1

the catalysis ratio and the colour change

well-distributed electrostatic field.

process for the coating and the catalyst.

provides for the generation of a strong and In this specific case, the unit is configured maximum value of 500 microampere

A technological “joint” between past and future

(Fig. 15).

A joint is a hinged connection system

“The two-component water-based

combining two rigid bodies or structures.

coatings are required a high degree

It is synonymous with union, but also

of stability and finishing quality. At the

continuity. It therefore makes the perfect

same time, the two-component product

metaphor to describe what Speroni and its

management system must ensure high

industrial partners have done: going along

precision and reliability in dosing and

with the company’s innovation orientedness

mixing,” says Giovanni Benevelli.

to implement cutting-edge technologies

in the constant current work mode with a

in the name of continuity with the equally innovative choices of the past, thus meeting Figure 15: General electric control panel by Verind according to the Industry 4.0’s parameters to manage the EcoDose 2K and EcoHTG500 high voltage generator.

N. 56 - MARCH/APRIL 2019 - international PAINT&COATING magazine

the production needs of the present and 15 1

future. Digitising also means this.

Â© Imel Spa

N. 56 - MARCH/APRIL 2019 - international PAINT&COATING magazine

INNOVATIONS: PRESENT&FUTURE

i4smallparts. The Overall Solution for Micro-Coating Stefano Bianchin Imel Spa - Codroipo, Italy

stefano.bianchin@imelspa.com

n 1980, Imel launched Rotover on the

diversity of workpieces, the smaller and

to have significant know-how in order

market, a machine allowing to coat small

smaller size of lots, the high level of quality

to define the most suitable preparation

and very small parts. It was a simple

required, and the increasingly restrictive

and coating cycles. However, they do not

system, able to immediately integrate into

product safety regulations have forced

always possess such expertise. There are

the production flow of small component

large producers to avoid relocating in the

many variables involved, e.g. component

coaters. Over the years, this machine has

Far East while investing in more automated

shape and material, preparation cycles,

evolved, adapting to safety regulations

and efficient production plants, including

paint and solvent type, and of course

and to the ever-changing requirements in

the finishing ones. With i4smallparts, Imel

the final result, which consists not only

terms of finishing.

works with its customers to build the most

of the colour but also of the chemical

In 2018, with over 500 systems sold

reliable and economical coating process to

and mechanical resistance as well as

in 45 countries worldwide to over 240

achieve their market objective.

the tactile and visual characteristics of

customers, Rotover strengthened its

the component. With the i4smallparts

focussing on servitisation, i.e. integrating

The i4smallparts process: Rotover 130 R2, chain-on-edge systems, and robotic tray systems

the sale of the machine with a package of

The bulk coating system is the core of

fastest possible start-up time.

services. These range from the definition

this process. The operating principle of

As a part of the offer, thanks to the

of the complete treatment cycle already in

Rotover 130 is simple: a rotating drum is

collaboration of its subsidiary

the offer phase (analysis of the necessary

surrounded by electrical resistances that

Varnish Tech, with over ten years’

pre-treatment stages, samples coating at

bring the internal environment to 80 °C,

experience in the coating sector and in

the Imel testing lab) to the development of

a sufficient temperature to guarantee the

the construction of plastic coating plants

the most suitable coating program for each

adhesion of the paint, which is sprayed

for high-profile customers, Imel also

type of product, staff training, management

with guns placed on the lid of the drum

includes in i4smallparts chain-on-edge

consulting, technical assistance, and spare

itself. Rotover 130 is easily customisable

coating plants for small-size, large-volume

part supply.

and it can store various treatment

parts that are not suitable to be painted

In 2019, Rotover has thus become

programs. However, the set-up of the

with Rotover 130. Chain-on-edge systems

i4smallparts – no longer just a machine,

machine for each type of product based

are highly customisable; coating is

but a global technical service offered

on the required gloss degree, aesthetics,

performed by a robot and the transport

by Imel for micro-coating operations in

resistance performance, and tactile

system is a chain. The technical solution,

industrial sectors such as the production

characteristics requires significant

the process, the coating preparation

of high fashion accessories and footwear,

field expertise.

centre, the line management software

small metal parts, furniture accessories,

The variability and flexibility of the demands

program, and the robot programming

fancy goods, and toys (ref. Opening

of the final consumers, i.e. the users of

process are entirely developed by the

photo). In these industries, the great

the painted products, requires the coaters

Imel-Varnish Tech team.

presence on the market and its reliability in the micro-coating field. However, it was time for it to further evolve, this time by

services, Imel’s technical staff handles the installation and fine-tuning of the coating programs for each product selected by the customer, thus guaranteeing the

Opening photo: Rotover has become i4smallparts – no longer just a machine, but a global technical service offered by Imel for micro-coating operations in the most varied industrial sectors.

international PAINT&COATING magazine - MARCH/APRIL 2019 - N. 56

In 1980, Imel launched Rotover on the market, a machine allowing to coat small and very small parts. It was a simple system, able to immediately integrate into the production flow of small component coaters. Over the years, this machine has evolved, adapting to safety regulations and to the ever-changing requirements in terms of finishing. In 2018, with over 500 systems sold in 45 countries worldwide to over 240 customers, Rotover strengthened its presence on the market and its reliability in the micro-coating field. ”

vintage effects, galvanic fixes to guarantee

Figure 1: A rendering of the tray system process’ core.

durability, and so on. In the case of limited batches and/or sizes not compatible with drum machines, i4smallparts can design and

Robotic tray systems are tipically used for

glazing, pad printing, digital printing, and

supply an application process tailored to the

accessories in the fashion industry requiring

PVD. As a part of the service, Imel provides

specific product and productivity needs.

high-gloss finishes that cannot be obtained

its own laboratory to perform the main

with tumbler plants. Layout and process of tray

resistance tests on the applied film to check

Target markets

systems are highly customizable: Imel is able

compliance with specifications.

The i4smallparts service is well suited to a

to meet these requirements thanks to its more

The i4smallparts processes can be applied

variety of industrial sectors, such as high

than ten years’ experience in the engineering

to any substrate, from metals to plastics

fashion (buckles, buttons, clips, zippers),

field (Figs. 1 and 2).

and even wood. The technical features of

footwear accessories, costume jewellery,

the coating programs, moreover, differ

cosmetic accessories, household appliance

according to the resistance requirements

accessories, toys, bottles, caps, containers,

linked to the product’s intended

industrial small parts (gaskets, springs, rivets,

With i4smallparts, Imel defines the

environment, e.g. corrosion, chemical,

screws). “i4smallparts’ target customers are

process depending on the base material

UV ray, water, or cleaning resistance.

both manufacturers painting their products

and the required technical and aesthetic

Finally, aesthetic characteristics are of

in-house and, above all, coating contractors,”

characteristics. The process is fine-tuned from

great importance: especially in the fashion

says Rotover sales manager Henry Panigutti.

the preparation and cleaning phases, which

industry, they are a crucial, but often

“The latter are the most demanding and most

can be done by brushing, flaming, or other

difficult-to-manage requirement in terms of

capable customers, because they need to

methods, to the coating application one and,

management of the various metal shades,

quickly adapt to new market demands while

finally, the finishing one performed through

pearled colours, metallic effects, rubberised

staying efficient and competitive. It takes time

various processes, such as laser marking,

or soft touch finishes, colour combinations,

to train an operator able to create different

Different finishing treatments on different types of materials

N. 56 - MARCH/APRIL 2019 - international PAINT&COATING magazine

INNOVATIONS: PRESENT&FUTURE

concept by integrating into the Industry

coating programs and fine-tune the paints required by these industrial sectors: that is why we started this project. With the i4smallparts service, we can define the coatings’ technical and aesthetic features together with the customer.” “The i4smallparts project is giving excellent results,” states i4smallparts Product Manager Massimo Gatti, with decades of field experience as a Rotover machine user. “Indeed, the service of defining pre-treatment and painting cycles, together with specific training and constant advice, reassure the customers and guarantee the achievement of their productivity and quality objectives in a short time and with a very quick ROI. Moreover, we are developing a new machine that will be released on the market in June. It will not replace Rotover 130, but it will complete the i4smallparts

With i4smallparts, Imel defines the process depending on the base material and the required technical and aesthetic characteristics. The process is fine-tuned from the preparation and cleaning phases, which can be done by brushing, flaming, or other methods, to the coating application one and, finally, the finishing one performed through various processes, such as laser marking, glazing, pad printing, digital printing, and PVD.”

4.0 and lean manufacturing-oriented approach that has characterised Imel since the beginning of the i4paintshop project1 last year.”

Case Study: the experience of Made Black Made Black (Chiuduno, Bergamo, Italy), currently one of the most representative companies in the coating field for the clothing, leather good, and footwear accessory sector, is the last customer in Italy to have chosen the i4smallparts project. Over the years, Made Black has grown by designing and offering technical solutions and innovations that have 1 For further information, ipcm®_International Paint&Coating Magazine no. 52, Vol. IX, 2018, pages 80-84 “Imel presents the i4paintshop platform for 4.0 management of coating plants and the facilitation of decision-making processes”

WHEN MAINTENANCE IS AN EASY GAME TO PLAY UV Ray is the major Italian manufacturer specialized in the production of highly resistant dichroic reflectors charecterized by low energy consumption and easy maintenance. Efficient, long-lasting and above all high manegeable, the UV Ray reflectors are the right answer of spray painting sector, for every challenge.

UV Ray, for every challenge

www.uvray.it

2 1

Figure 2: The chain-on-edge systems are typically used for accessories in the fashion industry requiring high-gloss finishes that cannot be obtained with tumbler plants.

characterised the industry’s development in terms of technology and product quality. Therefore, this company can now offer a wide range of high quality coating cycles that are difficult to obtain in its target market. The evolution of the market has led Made Black to invest in new technologies, especially by developing the PVD deposition process with Magnetron Sputtering and heat; the latter, in particular, is used to obtain the Rainbow (or Northern Lights) effect. Another investment involved digital printing, necessary to create graphics, be they simple or complex, to be

different-sized parts, from zipper teeth with

The i4smallparts service is well suited to a variety of industrial sectors, such as high fashion (buckles, buttons, clips, zippers), footwear accessories, costume jewellery, cosmetic accessories, household appliance accessories, toys, bottles, caps, containers, industrial small parts (gaskets, springs, rivets, screws).”

printed directly on the objects, thus offering

a length of a few millimetres to eyelets and buttonholes with a 5-6 cm diameter.” “The possible colours are almost unlimited except for high gloss values (gloss >60) due to the tumbling of the workpieces inside the chamber,” states Belotti. “The possibility of processing up to 45 kg or 25 litres of material makes this technology very competitive compared with conventional solutions requiring the parts to be hang onto frames or arranged on plateaus. The dedication of our operators, the constant support of Imel’s engineers,

a very high degree of customisation. The last

appropriate equipment,” explains Made Black

and the development of specific technical

technology acquired by Made Black was Imel’s

owner Matteo Belotti. “After a first consultation

solutions have enabled us to offer and

Rotover machine.

phase, aimed at defining the technological

perform this type of processing even in the

“The market is always looking for the right

limits (e.g. glossy finishes) and advantages of

medium/high-end sector while achieving

compromise among quality level, lead time, and

this technology with the use of a pilot plant, we

aesthetic quality and durability performance

of course value for money: this can be achieved

decided to buy the Rotover-i4smallparts 130 R2

levels suited to the specifications

through the bulk coating technology with the

system. This plant allows us to work with

of our customers.”

N. 56 - MARCH/APRIL 2019 - international PAINT&COATING magazine

dn-chemicals.com

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SPEC IAL ON ARCHITECTURE & DESIGN

BRAND-NEW

FOCUS ON TECHNOLOGY

BRAND-NEW

102

AluK: Revamping as a Technological Development Strategy

Maximum Booth Automation for the Coating of Metal Components and Office Furniture

FOCUS ON TECHNOLOGY

Return to GLOBAL: The New Industry 4.0-Oriented Plant for Coating Aluminium Radiators

INNOVATIONS: PRESENT&FUTURE

Elegance Meets Design: Demand for Flat Matte Finishes on the Rise

FOCUS ON TECHNOLOGY

In Mexico, a Coating Line Was Updated To Optimise Control on the Quality of Aluminium Door and Windows Frames

HIGHLIGHT OF THE MONTH

vik173Â©adobe

A Flexible and Modular UV Tunnel Functional to the Development of Formulations in the Laboratory of Paint Manufacturer Arsonsisi

BRAND-NEW

S P E C I A L O N A RC HI TE C TUR E & DESIGN

Innovative AkzoNobel Powder Coating Offers Invisible Protection

ith the flu season upon us,

Suitable for a wide range of

performance powder coating, it

the need for robust hygiene

applications, it’s typically used in

also performs to the very highest

solutions is as important as ever.

hygiene conscious environments such

antimicrobial standards.”

AkzoNobel’s innovative powder coatings

as hospitals, clinics, changing rooms,

The BioCote® antimicrobial

help keep surfaces hygienically clean all year

schools and public transport.

technology active in Interpon AM

round, while tackling the invisible threat of

“Demand for antimicrobial coatings is

shows no mercy. It reduces up to

cross-contamination.

increasing due to growing consumer

99.99% of bacteria and mold on a

The company’s antimicrobial Interpon AM

concern for hygiene,” explains Mark

protected surface, making it easier

range – recently specified for use on 2,350

Reekie, Global Segment Manager

to keep hygienically clean and

door handles in a clinic in Abu Dhabi –

for AkzoNobel’s industrial powder

reducing the risk of

contains BioCote antimicrobial protection.

coatings. “The beauty of Interpon

cross-contamination.

It not only delivers outstanding decorative

AM is that as well as meeting all

“As the undisputed world leader in

characteristics, but also combats the growth

the protective and decorative

powder coatings, we’re committed

of microbes such as bacteria and mold.

characteristics expected of a high

to setting the standards for quality,

service and innovation,” continues © AkzoNobel

Reekie. “Interpon AM is a prime example of how we continue to develop world class products for our customers while always looking to grow and improve.” Adds Jennifer Collier, Partner Development at BioCote: “We work successfully with industry leading, global companies such as AkzoNobel to help them create more hygienic, premium antimicrobial products. We are extremely proud of our partnership with AkzoNobel, and to be part of such a high quality, reliable product. Interpon AM stands as an example of success for all companies that we work with as we continue to achieve greater levels of hygiene around the world.” BioCote is the market-leading antimicrobial solutions provider, with over 20 years of experience in

antimicrobial technology.

Figure 1: The AkzoNobel’s antimicrobial Interpon AM range is typically used in hygiene conscious environments such as hospitals, clinics, changing rooms, schools and public transport.

N. 56 - MARCH/APRIL 2019 - international PAINT&COATING magazine

For further information: www.interpon.com

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BRAND-NEW

S P E C I A L O N A RC HI TE C TUR E & DESIGN

UNStudio and Monopol Colors Develop ‘The Coolest White’ Paint

NStudio has partnered with

multilayered coating system was developed

currently developing a series of innovative

Monopol Colors to develop

for high-quality metallic facade elements and

building technology products in order

‘The Coolest White’, an ultra-durable

to advance the development of applied

The Coolest White provides not only

technology and future-proof our designs.

structures from excessive solar radiation –

remarkable protection against corrosion,

Our team partner with industry leaders,

thus slowing down the urban heat

but also achieves a TSR value which sets

bringing with them the combination of a

island effect.

entirely new standards. (TSR stands for ‘Total

product mindset, engineering know-how and

The paint is based on fluoropolymer

Solar Reflectance’, which, in simplified terms,

a strategic vision for building technologies.

technology. It has long lasting and

designates the powers of resistance of a

ultra-durable properties that prolong the

coating to the effects of sunlight.)

For further information:

lifecycle of the coating up to 30 years. The

UNSProducts and UNSknowledge are

www.unstudio.com

©UNStudio

aluminium, steel or fiberglass structures.

paint that protects buildings and urban

Figure 1: UNStudio has partnered with Monopol Colors to develop ‘The Coolest White’, an ultra-durable paint that protects buildings and urban structures from excessive solar radiation – thus slowing down the urban heat island effect.

N. 56 - MARCH/APRIL 2019 - international PAINT&COATING magazine

BRAND-NEW

S P E C I A L O N A RC HI TE C TUR E & DESIGN

The World has Another Blackest Black: British Artist Stuart Semple Launches ‘Black 3.0’

lack 3.0 is a super-flat, ultra-matte

by Surrey NanoSystems that holds the

However, Kapoor managed to get a tube

black that absorbs 98-99% of light

world record as the darkest man-made

of the product, dipping his middle finger in

and, contrary to Vantablack, anyone

substance), Black 3.0 is available to

it and flipping the bird to Semple the other

can purchase it – anyone but Anish Kapoor.

anyone, including private individuals –

protesting artists on Instagram.

After two years of development, artist Stuart

except artist Anish Kapoor. In fact, the

This is what brought up the decision to team

Semple claims that his team – made of artists

new paint is part of a long-running feud

up with other artists to develop a competitor

and paint makers based in Dorset, England –

between the two artists, dating back

to Vantablack.

has created the “blackest black paint

to 2016, when Kapoor licensed the

“We think that sharing your colours with

in the world”.

exclusive rights to Vantablack for artistic

others is nice! When Stuart heard that

“We wanted a super-flat, ultra-matte black

use, forbidding other artists to use the

Kapoor was the only artist that could use

that absorbed almost all visible light”,

pigment, which was originally developed

the blackest black, he felt sad but also a

explains Stuart Semple on the Kickstarter

for satellite and scientific applications.

bit bad that he’d been making awesome

page dedicated to this project. “To achieve

The art community heavily criticized

colours and only using them in his own

that we went right back to the basics of paint

Kapoor and Semple even developed

work. So, he started sharing his colour

making. The problem with existing black

and released what he claimed was the

creations on the internet with other artists”,

pigments is they are all slightly reflective,

world’s pinkest pink paint and made

the team stated.

so we created a whole new pigment in the

it commercially available to everyone

They also added: “Other super blacks

lab and we call it ‹Black Magick’, it is born

except Kapoor.

are complicated to use and extremely © Culture Hustle

matte! […] We’ve also managed to formulate a new acrylic polymer to hold the pigment, it›s special because it has more

expensive. Most require heat, science labs and specialist training to apply. We wanted to make a

available bonds than any other

super affordable,

acrylic polymer being used in

easy to use paint that was

paints. This means it can cling

familiar to artists so they

onto way more pigment, leading

could concentrate on

to a really dense pigment load

expressing themselves.

and a depth of colour not

We’ve been on a mission to

previously possible. We have

create exactly that for a long

sourced some brand new

while because we want all

nano-mattifiers which we have

artists to be able to express

added, these flatten out the

themselves with awesome

last bits of stray light without

materials. The limits of your

compromising colour”.

creations should be your

Easy to use, affordable and available to anyone Contrary to Vantablack (the super-black coating developed

imagination not how rich or successful you are”. 1 Figure 1: Black 3.0 brush applied to sculpture.

For further information: www.culturehustle.com

international PAINT&COATING magazine - MARCH/APRIL 2019 - N. 56

BRAND-NEW

S P E C I A L O N A RC HI TE C TUR E & DESIGN

Feltani Reti: Focussing on the Hanging of Aluminium Profiles

eltani Reti Snc (Campodarsego, Padua,

customisation and production flexibility. On

Feltani is very competitive.

Italy) has passionately devoted itself

the other hand, despite allowing less creativity

“For the manufacturing of these hooks, we

to the processing of metal wire for

use C72 carbon steel, i.e. with a carbon

systems enable to achieve a high productivity

percentage of 0.72%, instead of the more

production of coating hooks. Recently, the

rate with standard products.

commonly used copper-plated steel, i.e.

company has installed a few new production

“At the end of 2018, we purchased a new

obtained by copper-plating stainless steel

systems to serve the aluminium profile

mechanical control machine able to produce

wire. Carbon steel has higher strength and

coating industry more specifically. Already a

hooks with a diameter of up to 3 mm,” says

capacity properties than copper-plated

few years ago, the transition from mechanical

Isabella Feltani, at the helm of the company

steel, which makes them suitable for

control to numerical control machines

together with her parents Moreno and

hanging profiles of all types, including the

had enabled Feltani Reti to produce hooks

Ornella. “This will enable us to increase our

heaviest and largest-section ones.”

with the most varied sizes, types, and

market share in the aluminium coating sector.

materials (normal, galvanised, or stainless

Indeed, this system will allow us to double

For further information:

steel wire) while ensuring a high degree of

our production of J-hooks, a product in which

www.feltanireti.it © Feltani Reti Snc

in the design of hooks, mechanical control

almost forty years, mainly focussing on the

Figure 1: C72 carbon steel J-hooks are ideal for hanging aluminium profiles on coating lines.

N. 56 - MARCH/APRIL 2019 - international PAINT&COATING magazine

FATI

NOVITÀ

srl

NEW NEUHEIT

CATENE PER TRASPORTATORI - CUSCINETTI A SFERA

CATENE AD ALTE PRESTAZIONI HIGH PERFORMANCE CHAINS | LEISTUNGSFÄHIGE KETTEN

HPCOAT

con | with | mit HPCOAT

FATI srl

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

senza | without | ohne HPCOAT

LESS

Particolare dei cuscinetti con HPCOAT Detail of bearing with HPCOAT Ausschnitt der Lager mit HPCOAT

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

Opening photo: Panoramic view of the vertical coating line of AluK Belgium.

FOCUS ON TECHNOLOGY

S P E C I A L O N A RC HI TE C TU RE & DESIGN

AluK: Revamping as a Technological Development Strategy Alessia Venturi ipcm®

“R

evamping” is a term derived from

need to upgrade their production plants to

for architecture,” says Birger Vandevenne

the railway sector. It is used to

maintain competitiveness but, at the same

(Fig. 1), the Operations Manager of AluK

indicate general renovation work

time, cannot cease operations for as long

Belgium and AluK Netherlands. “When

on machines or systems to recondition and

as necessary. Coating contractors are an

AluK Belgium found itself having to

update them to state-of-the-art technology,

example.

update its coating system, we opted for

thus extending their service life and improving

“The aluminium market puts a lot of

a revamping project, planning a series of

their performance level while avoiding making

pressure on firms as regards three key

gradual investments that would not have

higher investments for their sudden and

factors: lead time, price policy, and product

forced us to stop our line for more than

unplanned replacement. The revamping

quality. Indeed, these three elements

two consecutive months. For a company

solution is the ideal choice for companies that

qualify a supplier of aluminium systems

like AluK Belgium, serving the entire

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FOCUS ON TECHNOLOGY

Benelux market, it was unthinkable

in Belgium, AluK also took over the

a production and distribution hub for our

to stop for the six to eight months

coating contractor Colors in order

roofing range”, states Birger Vandevenne.

needed for the full replacement of

to transform it into a paintshop at

“We receive extruded profiles from various

a coating line. Until now, we have

the exclusive service of its Belgian

European suppliers. Here, we process

changed our two application booths

and Dutch offices and markets. “In

them, assemble them with thermal breaks

together with SAT (Verona, Italy). In

October 2016, we started to reshape

and accessories, coat them, and prepare

the future of our coating plant (ref.

the operational model of AluK Belgium,

them for shipping. We have created a

Opening photo), there will be other

which manufactures products and

community of work groups within the

technological updating steps that we

accessories for both the national and

AluK Group, each dedicated to a different

are already defining with SAT. The

Dutch markets, as AluK Netherlands is

production phase, which focus on the © ipcm ®

goal is to have a completely updated coating system

analysis of best practices for the whole group

within two years, without

with a mutual exchange

ever ceasing to provide our

of knowledge and

customers with our profile

experience. In the past,

painting service.”

each branch was much more focused on its

From extruded profiles to door and window frames: a fully integrated cycle for the Benelux market

own business, whereas now the goal is to create synergies and exchange know-how.”

The first revamping phase: two cutting-edge booths

AluK Belgium was established in 2016 with Italian AluK Group’s acquisition of a local Belgian company with four (Great Britain, Belgium, Holland, and Poland). AluK had already acquired its

“Colors was a coating

production plants in Europe

contractor in the

Figure 1: Birger Vandevenne, Operations Manager of AluK Belgium and AluK Netherlands.

British and Dutch factories in

respectively. The Group is now a global leader operating in major countries in Europe, the Middle East, and Asia. It has more than sixty years of experience in supplying systems for high-performance aluminium door and window frames and curtain walls for many of the most innovative and prestigious buildings in the world (Fig. 2). The AluK Group’s general strategy is making sure that each production site has its related coating unit. That is why, with the acquisition

a three times higher production volume than that of AluK

2012 (the year in which AluK France was also established) and in 2014,

aluminium sector with

Belgium. This firm had four coating lines:

The aluminium market puts a lot of pressure on firms as regards three key factors: lead time, price policy, and product quality. Indeed, these three elements qualify a supplier of aluminium systems for architecture. When AluK Belgium found itself having to update its coating system, the company opted for a revamping project, planning a series of gradual investments that would not have forced it to stop the line for more than two consecutive months.”

an automatic vertical one, an automatic horizontal one, an express one, and a line finishing accessories. Aware that its volumes would have been too low to feed all these lines, AluK’s first intervention was dismantling two of them, the express one and the one devoted to accessories. The strategic goal was having a paintshop that only met the internal needs of AluK, without any room for contracting,” says Vandevenne. “In 2017 and early 2018, we remodelled the operational flow here, increased our stock, and decided to start a renovation project in which the coating line played a crucial role. We chose SAT as our partner in this revamping project because

international PAINT&COATING magazine - MARCH/APRIL 2019 - N. 56

SP ECIAL ON ARCH ITE CTU R E & DESIGN

Figure 2: AluK has more than sixty years of experience in supplying systems for high-performance aluminium door and window frames and curtain walls.

“The plant was already equipped with two booths that operated simultaneously,” says Corrà. “We maintained the previous spraying equipment, which had been recently renovated. It includes an Opticenter OC03 powder management unit with Gema AP01 dense phase pumps (Fig. 4) and 18 guns for each booth. However, thanks to technical support and excellent coordination with Inplasco, the Gema distributor for Belgium, it was possible to optimise the guns’ arrangement while adapting it to the new booths. Indeed, we implemented a configuration that allows maintaining a high line speed even when coating complex-shaped profiles (Fig. 5).”

Until now, AluK Belgium has changed two application booths together with SAT (Verona, Italy). In the future of its coating plant, there will be other technological updating steps that it is already defining with SAT. The goal is to have a completely updated coating system within two years, without ever ceasing to provide the customers with an profile painting service.” some of my colleagues, who already worked

installed are characterised by

for Colors with the previous owners, knew

the V shape that distinguishes

this company well. In 2012, it had actually

the SAT technology and

installed a SAT-patented revolving door on

they are bigger than the

our curing oven, thus enabling to turn off

standard machines in order to

the IR pre-gelling oven and guaranteeing

accommodate a greater number

considerable energy saving.”

of guns and profiles with a

“For this revamping project, we supplied

larger section. In addition to the

two new generation booths that implement a

booths, we also replaced the

different application technology,

reciprocators, the cyclone, and

with the guns arranged at the two sides

the final filter, thus completely

(Fig. 3),” says SAT General Manager

changing this customer’s powder

Alessandro Corrà. “The two booths

coating system.”

Figure 3: The two new booths supplied by SAT implement a new generation technology, with the guns arranged at the two sides.

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FOCUS ON TECHNOLOGY

smaller average hanging pitch, and, as

“We opted for SAT’s V-shaped booths with these features because, although the total coating volume had decreased, the variability of profiles and colours had remained the same. We therefore needed to perform more colour changes within the same time,” states Birger Vandevenne. “The biggest advantage we have achieved with this revamping project is the possibility to apply black and white coatings one after the other in the same booth.

AluK’s first intervention was dismantling two of its lines, the express one and the one devoted to accessories. The strategic goal was having a paintshop that only met the internal needs of AluK, without any room for contracting.”

a result, increased productivity with the same chain speed (Fig. 6). 80% of the complex-section profiles that we used to paint on the horizontal line (as it was equipped with a touch-up station) are now automatically coated on the vertical system. This will soon enable us to also dismantle our horizontal line, concentrating our whole production on the vertical one (Fig. 7),” says AluK Belgium Maintenance Coordinator

With the previous plant layout, one

Kurt Passemiers. “Moreover, the

booth only applied dark tints and the

cleaning cycle is much shorter than

is a great disproportion between the

Higher quality, higher productivity

demands for the two shades in the

“The two new booths only came into

this revamping intervention, because

Benelux market, as about 70% of orders

operation in mid-February, but we have

we had to increase the total number

require dark colours, and therefore

already found greater paint penetration,

of daily colour change operations.

production organisation was complex

greater general quality of the coatings, higher

The cleaning process can surely be

and inefficient.”

profile density along the line thanks to the

further optimised, but we have already

other light tints only. However, there

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SP ECIAL ON ARCH ITE CTU R E & DESIGN

observed a marked decrease in the required times. Finally, we also expect to find a reduction in our consumption of powders, although we cannot quantify it yet because the booths went into production only a few weeks ago and we are still adjusting our spray parameters to the new and more efficient technology. “Having the possibility to apply any colour in any booth, we had decided to start with a prudent approach and wait a few minutes from the beginning of the application of each colour before switching to “recovery” mode. However, we verified that there were no contamination problems with neither the new booths nor the new cyclones, and therefore we have already

4 1

minimised or even eliminated this © ipcm ®

Figure 4: The Opticenter OC03 powder management unit with Gema AP01 dense phase pumps.

delay in switching modes. This resulted in a further reduction of our powder consumption. In general, I can state that all objectives presented to SAT have been or are in the process of being achieved.” “In the first four weeks of production,

In 2017 and early 2018, AluK remodelled the operational flow, increased the stock, and decided to start a renovation project in which the coating line played a crucial role. The company chose SAT as its partner in this revamping project because some of colleagues knew this company well. In 2012, it had actually installed a SAT-patented revolving door on the curing oven, thus enabling to turn off the IR pre-gelling oven and guaranteeing considerable energy saving.”

we performed an average of 18 colour change operations per day. In the past, we had to stop at 10-11, whereas our goal is reaching 20-21 changes in a work shift (7 hours and 40 minutes) and a daily productivity of 3000-3100 m2; this equals to about 2000 profiles/ day, 85% of which with a length of 6.5 metres, 10% with a length of 7 metres, plus a 5% of various lenght” says Birger Vandevenne. “When discussing our revamping needs with SAT, we had asked them to reduce our 18-minute colour changing time. Now, our total cleaning time is 10-11 minutes, with a reduction of almost 50%. We aim at reducing it to 8 minutes.” “Our work environment is very clean, 5 1

Figure 5: Each booth has 18 guns, implemented with a configuration that allows maintaining a high line speed even when coating complex-shaped profiles.

N. 56 - MARCH/APRIL 2019 - international PAINT&COATING magazine

proving that the booths’ air suction system is excellent, whereas it was a critical issue with our previous plants,” explains AluK Belgium Quality

FOCUS ON TECHNOLOGY

edge coverage: the fact that now we

contamination or powder dispersion,

can also coat profiles that previously

even when we are coating in both

required a manual application

booths. When we started coating with

process proves that we have

the same parameters used in the past,

achieved this goal.” As further proof

we immediately noticed that the applied

of their excellent performance level

thicknesses were higher, i.e. our powder

and, in particular, of the advantages

transfer efficiency was greater thanks

of the their “dynamic” suction

to the new booths, all other conditions

system, able to adapt to operating

being equal. The higher the transfer

conditions, the two V-shaped booths

efficiency, the greater the amount

are arranged in a particular way

of fresh powder compared with the

within the factory: they are placed

recovered one in the application mix

side by side without any separation

and, therefore, in the deposited powder

barriers or containment structures

layer – and, as is well known, the use

and they are located in front of

of recovered powder is always a critical

a glass window, which remains

issue. As for quality, we expected greater

perfectly clean (Fig. 8).

AluK opted for SAT’s V-shaped booths with these features because, although the total coating volume had decreased, the variability of profiles and colours had remained the same. It therefore needed to perform more colour changes within the same time. The biggest advantage the company has achieved with this revamping project is the possibility to apply black and white coatings one after the other in the same booth.” © ipcm ®

Officer Timo De Clercq. “There is no

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Figure 6: Among the benefits of the new booths, besides a greater general quality of the coatings, a higher hanging density with the same chain speed.

international PAINT&COATING magazine - MARCH/APRIL 2019 - N. 56

SP ECIAL ON ARCH ITE CTU R E & DESIGN

Figure 7: The vertical line allows to coat also complex-section profiles, that before were coated using the horizontal line, as it was equipped with a touch-up station.

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Figure 8: The two booths are placed side by side without any separation and they are located in front of a glass window, which remains perfectly clean thanks to the “dynamic” suction system.

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N. 56 - MARCH/APRIL 2019 - international PAINT&COATING magazine

FOCUS ON TECHNOLOGY

The two new booths only came into operation in mid-February, but AluK has already found greater paint penetration, greater general quality of the coatings, higher profile density along the line thanks to the smaller average hanging pitch, and, as a result, increased productivity with the same chain speed.”

“Another change brought by the new booths concerns production planning,” says AluK Belgium Production Supervisor Evelien D’Hauwer. “For example, we can now apply a dark colour on a large-sized batch in the booth no. 1 while applying other tints on several small batches in the booth no. 2, without ever changing colour in the first one. Compared with the past, when the minimum batch size had to be 120 m2 to ensure efficiency, today we can plan the coating of very small, even one-piece batches without losing productivity and efficiency.” “In order to be a qualified player in the aluminium sector, a company must be able to offer any colour required by the market. We tried to channel customer requests into a limited colour catalogue, but we were not successful,” says Vandevenne. “That is why AluK Belgium chose to update its coating line based on technical choices oriented towards market demands. We adapted our system to the market and not the other way around. However, we still offer an 11-tint colour catalogue that we have developed exclusively with Axalta, our main supplier together with Tiger Coatings (Fig. 9).”

Technical and aesthetic trends in the Belgian and Dutch aluminium markets “We only use Qualicoat 1. We have encountered two operational problems with Qualicoat 2 products. The first one is the oven temperature, which must always be adjusted differently than for the other types of paint. The second one is greater film damage around the thermal break when this is assembled after profile coating,” says Vandevenne. “Currently,

SP ECIAL ON ARCH ITE CTU R E & DESIGN

65% of our profiles are assembled with

The major difficulty of a revamping operation is that the plant must be modernised and then immediately restarted in production conditions, which are supposed to be better than the previous ones. AluK is pleased with the collaboration of SAT. Its engineers coordinated the construction site in such a way as to meet the delivery deadlines.”

thermal break after coating. We are working on introducing a new thermal cutting material to change this proportion, but currently using Qualicoat 2 powders appear to be difficult for us. I think that we will start using them when it will be possible to

do so without changing all our coating parameters. Surely, these powders are an advantage for users, because they extend the guarantee of durability with a modest price change. There is much space in the market, but as applicators we should be able to use these products without having to continuously adjust operating parameters such as line speed, curing temperature, and so on,” states Vandevenne. “In terms of colours, as I already mentioned, the Benelux market is strongly oriented towards dark shades in the range of greys and blacks, with a few browns, and towards textured surfaces.”

Experience and collaboration to manage the critical issues of this revamping project “The major difficulty of a revamping operation is that the plant must be modernised and then immediately restarted in production conditions, which are supposed to be better than the previous ones,” says Kurt Passemiers. “We are pleased with the collaboration of SAT. Its engineers coordinated the construction site in such a way as to meet the delivery deadlines. We had planned to end in early December and enter full production by the third week of February. An AluK team conducted the first dismantling phase of the old booths in the second half of December; on January 4th, the SAT team took over to install the new booths. The first sample profiles were hung on February

9 1

14th and on February 20th we entered

Figure 9: AluK Belgium offers an 11-tint colour catalogue oriented towards dark shades in the range of greys and blacks, according to the market trends of Benelux.

N. 56 - MARCH/APRIL 2019 - international PAINT&COATING magazine

regular production, i.e. two days in advance of the set date.”

Opening photo: Temo Srl has been producing office furniture components since the 1980s.

FOCUS ON TECHNOLOGY

S P E C I A L O N A RC HI TE C TU RE & DESIGN

Maximum Booth Automation for the Coating of Metal Components and Office Furniture Monica Fumagalli ipcm®

y the late 1980s and for about a

during the economic contraction of the 2010s.

insourced in the mid-1990s in order

decade, the small and medium-sized

“When all our competitors outsourced their

to eliminate all problems related to

companies constituting the furniture

production phases, my father, the founder

logistics and material handling and

district of Veneto (Italy) turned production

of Temo Srl, decided to go against the grain

give us a winning tool to successfully

fragmentation and outsourcing into their

and insource some production divisions,

overcome the economic crisis that hit

strengths. This system, however, faltered

while the powder coating line was already

so many manufacturers in our sector,”

N. 56 - MARCH/APRIL 2019 - international PAINT&COATING magazine

FOCUS ON TECHNOLOGY Figure 1: From right to left: Temo Export Manager Paolo Rizzo, Alessia Venturi from ipcm®, and Andrea Grazi from GRT.

says Export Manager Paolo Rizzo, the son of the company’s founder (Fig. 1). Temo Srl is based in Piombino Dese (Padua) and specialises in the production of components

components including

for office furniture, such as

the plastic ones, and the

metal drawers, drawer runners,

punching and bending

pull-out racks, and metal shelves.

operations. Currently,

It is one of the most successful

we acquire metal sheet

companies in the office furniture

coils and we ship finished

subcontracting field (ref. Opening

product to our customers:

photo). “The activity was started

our 100% insourced

by my father in the late 1980s

production flow is one of

with the production of pull-out

our strengths, because it

racks and full extension drawer runners,” says Rizzo. “Around the

gives us a flexibility degree

that larger competitors

mid-1990s, the range expanded

cannot afford. We can

to include metal drawers at first,

meet any request, from small lots to large orders,

and then even end products, i.e.

Temo Srl is based in Piombino Dese (Padua) and specialises in the production of components for office furniture, such as metal drawers, drawer runners, pull-out racks, and metal shelves. It is one of the most successful companies in the office furniture subcontracting field.”

metal drawers. After thirty years in the office furniture subcontracting sector, we are able to supply furniture manufacturers with any component or accessory.”

The recession of 2000s hit many companies from the Veneto-based industrial districts, leading some of

right solution to please even the most demanding customer. Our insourced production process gives us total control over the quality of the products we manufacture.”

The insourcing of the entire production chain to overcome the crisis

always trying to find the

them to close down and others to find production alternatives. “Based on my father’s idea, the paintshop was the first department to be transferred into our factory. After insourcing coating, we understood that this could be the right way not only to overcome that critical economic period, but also to distinguish ourselves. That is why, over the years, we have decided to also insource other production phases and preserve several jobs: the welding of our drawers, the moulding of various

Figure 2: The new coating system supplied by Euroimpianti from Valeggio sul Mincio (Verona).

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S P E C I A L ON A RC HI T E C T URE & D E S I G N

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Figure 3: The outside of the GRT coating booth.

Replacing the previous plant “The flexibility of our paintshop is guaranteed by the effectiveness of the process automation and the speed of the colour change system,” states Paolo Rizzo. “The search for these two solutions was the actual reason why we decided to replace the plant installed in the mid-1990s and designed for painting small components, such as 40x80 cm and 50x50 cm metal frames and drawers. In 2011, the machine had undergone a revamping process to adapt its structure to the production of drawers, which was recording a peak in that period, and to integrate a new booth, more suited to our new range of products.” After only six years, the booth presented some critical issues linked above all to the suction of powder with a cyclone that was undersized for the application’s characteristics. “The difficulties encountered

GRT (Modena, Italy) provided Temo with a booth that has been in operation since September 2018, integrating it into the line supplied by Euroimpianti (Valeggio sul Mincio, Verona, Italy).”

FOCUS ON TECHNOLOGY

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by our operators

Figure 4: A detail of the nozzle-holding arm.

The GRT booth installed at the premises of Temo Srl belongs to the 12000 Superior series, the top of the range in terms of automation. It is made up by sandwich panels in a plastic and antistatic material and it is equipped with a manual pre- and post-retouching stations.”

convinced us to make a new investment that was not limited to the booth alone but, given the obsolescence of the plant, involved our whole coating line,” says Rizzo. “That is where GRT (Modena, Italy) came into play. It provided us with a booth that has been in operation since September 2018, integrating it into the line supplied by Euroimpianti (Valeggio sul Mincio, Verona, Italy - Figs. 2 and 3).”

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Figure 5: The inside of the coating booth.

The automation of the spray paint booth While replacing the spray paint booth, GRT also added a vertical AD horizontal optical bar for the dimensional detection of incoming components and automated the motorized bases and the already existing reciprocators (Fig. 4). “The previous reciprocators had been produced by us,” explains GRT owner Andrea Grazi.

SP ECIAL ON ARCH ITE CTU R E & DESIGN

a solenoid valve for automatically

Temo found several benefits: First of all, the colour change operation now takes less than 10 minutes. As it has switched from two to ten times the tints, the daily frequency colour changes has also increased and it is now similar to that of a coating contractor. Considering that the plant is in operation for 15 hours a day including Saturdays, a greater change speed had become crucial.”

switching on and off the emptying cycle, and a pipe for transporting the powder directly from the box to the big bag. The GRT 12000 m3 cyclone features a sieving system integrated into the base, easily opened for cleaning and inspection (Fig. 7). “The powder management unit (Fig. 8) is

the “brain” of the whole plant,” says

The new plant’s benefits

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“We found several benefits,” says Rizzo. “First of all, the colour change operation now takes

Figure 6: The manual post-retouching station.

less than 10 minutes: as we have switched from two to ten times the tints, the daily frequency our colour changes has also increased and it is now similar to that of a coating contractor.

“We decided to keep them while simply adding mobile bases to optimise process © ipcm ®

times with the possibility to treat several workpieces at the same time.” The GRT booth installed at the premises of Temo Srl belongs to the 12000 Superior series, the top of the range in terms of automation. It is made up by sandwich panels in a plastic and antistatic material (Fig. 5) and it is equipped with a manual pre- and post-retouching stations (Fig. 6). The bottom of the booth houses a suction

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Figure 7: The high suction capacity cyclone supplied by GRT.

and blowing system for automatic cleaning. The guns’ automatic external cleaning,

Grazi. “It manages multiple functions

instead, allows to significantly reduce the

automatically and it includes as follows:

colour change operations. The filter is

a gun powder feeding system, 2 fluidised

composed by a soundproofed fan and

powder tanks, an air storage buffer for

motor (<80 dB) and high-efficiency cartridges

cleaning the floats and the recovery pipe,

with an automatic integrated backpressure

a connection for the fluidisation of the

cleaning system. Resulting powders are

powder tank, a vibrating table for the

collected by a trolley box directly linked to

powder box, a capacitive probe for level

the automatic emptying system of the filter

control (Fig. 9), and a management PLC

box, made up by a high flow rate pump,

with a simple and intuitive, 4.0-oriented

a powder collection box with a fluid bed,

touch screen panel (Fig. 10).”

N. 56 - MARCH/APRIL 2019 - international PAINT&COATING magazine

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Figure 8: The powder management centre.

FOCUS ON TECHNOLOGY

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Figure 9: A detail of the gun powder feeding system.

Figure 10: The PLC control panel.

Considering that the plant is in operation

guns, outdated after twelve years, with

powders) and considerable improvement

for 15 hours a day including Saturdays, a

6 automatic and 2 manual Gema guns

in the coating uniformity degree, which was

greater change speed had become crucial.

(Fig. 11). The new application system has

fundamental for us due to the numerous

“As for application, GRT’s technical staff

guaranteed greater paint savings (we apply

colour matching operations that we must

advised us to replace our previous

epoxy, epoxy-polyester and polyester

perform for our customers (Fig. 12).

SP ECIAL ON ARCH ITE CTU R E & DESIGN

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12 1

“We found another advantage related to

Figure 12: The metal drawers made by Temo Srl.

Figure 11: The powder application operation.

GRT’s team was able to exactly understand the needs of Temo, which are similar to those of a coating contractor, even though we are not, considering the peculiarities of the sector.”

the high suction capacity of the cyclone and the automatic emptying system of the filter box (Fig. 13).”

Conclusions “The type of booth offered by GRT convinced us immediately,” sates Rizzo. “The characteristics we noticed during a visit to a company that used it were structural solidity and high suction

ourselves even more on foreign markets,

capacity, two elements that our machine

which have become our main target after

lacked. The automation of the system was

the recession phase and now account for

the most important factor for us, but any

44% of our production.

coating plant engineering firm is now able

“We have achieved a good product

to supply it. GRT’s team, however, was able

customisation and quality level, optimal

to exactly understand the needs of our

production flexibility, and the possibility

company, which are similar to those of a

of offering a complete service to our

coating contractor, even though we are

customers: with these premises, we

not, considering the peculiarities of our

might consider to further diversify our

sector. Our internal automation process

office furniture range by producing

will not stop here: GRT’s plant is ready to integrate a robot at the exit of the retouching station. With such a structured company, it will be easier to affirm

N. 56 - MARCH/APRIL 2019 - international PAINT&COATING magazine

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Figure 13: The filter box with the automatic emptying system.

cabinets and expanding even more our offer to a market that is currently recovering and proving increasingly demanding.”

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N. 56 - MARCH/APRIL 2019 - international PAINT&COATING magazine

FOCUS ON TECHNOLOGY

S P E C I A L O N A RC HI TE C TU RE & DESIGN

Return to GLOBAL: The New Industry 4.0-Oriented Plant for Coating Aluminium Radiators Monica Fumagalli ipcm® © GLOBAL

lways striving to offer information

required by an increasingly intensive mass production.

on surface

treatment technologies

In order not to

and products, for the

compromise the

editorial staff of our

final quality of our

magazine it is rare to have

coatings, after careful

the opportunity to visit

assessment we

a user twice in a narrow

decided to add a new

time frame in order to

plant to our existing

follow the evolution of

coating line. Our

its production system.

partner for the design

This article will provide a

and installation of

detailed overview of the

the new line was

4.0-oriented development of the paintshop of GLOBAL Srl (Rogno, Bergamo, Italy), of which we described the peculiar

Imel (Codroipo,

Udine, Italy), which

Figure 1: Carlo Salvadori from Imel, on the left, with Sandro Panteghini in front of the monitor with the data analisys of the coating process.

anaphoresis + powder

in 2018 took care of the project and coordinated the other suppliers of

application technology for

products and plant

coating in 20171 (ref. Opening photo). As

“The demand for aluminium radiators,

components, including Gema Europe for

a well-established company for aluminium

fortunately for us, it is not expected to

the booth and Futura Convogliatori Aerei

radiators manufacturing in the both

slow down or stop,” says Alessandro

for the conveyor.”

the national and international industry,

Fardelli, GLOBAL CEO and company’s

In this project, the new production needs

GLOBAL’s production focusses on the

responsible with the President

of GLOBAL were integrated with the

significant expertise acquired in almost

Giuseppe Delasa, while updating

Industry 4.0-oriented evolution of Imel’s

fifty years of activity and on the “know

us on its production status. “After

plant technology (Fig. 1), thus creating a

how” motto that unites the Fardelli family’s

improving our processes of foundry,

synergy that led to the construction of a

generations that have led the company,

machining, and anaphoresis with the

coating line with the maximum automation

while also pervading its surrounding area.

system provided by Axalta Coatings

degree and with the data analisys aimed

System Italy, we realised that coating

at the highest degree of efficiency and

1 M. Fumagalli, Anaphoresis technology without dialysis cells: a decisive advantage for GLOBAL Radiatori, in ipcm® International Paint&Coating Magazine no. 47 (September/October 2017), pages 82-88.

was still a bottleneck in our production

process control (Fig. 2).

flow, as our plant was dated and no

“When we approved the new project, we

longer able to handle the workloads

had not planned to build such a futuristic

Opening photo: The coating of aluminium radiators in the new 4.0 plant of GLOBAL Srl.

international PAINT&COATING magazine - MARCH/APRIL 2019 - N. 56

SP ECIAL ON ARCH ITE CTU R E & DESIGN

Figure 2: The final coating quality of GLOBAL’s radiators is guaranteed by the anaphoresis + powder coating system developed by Axalta for this company.

plant, a system projected to such an extent in the fourth industrial revolution,” says GLOBAL Plant Manager Sandro Panteghini. “We chose to also automate loading and unloading with robots. These clasp the radiators with gripping systems creating a vacuum effect between the two surfaces and hang them onto the coating line (Fig. 3). The loading robots are fed through carts identified with a QR Code matched with all the information related to a batch (Fig. 4).”

The structure of the new plant The new coating plant replicates the anaphoresis + powder application system of the old system, optimised for the production of GLOBAL’s radiators. “With this system,” states Imel Managing Director Carlo Salvadori, “for the first time we have combined all the most advanced technologies that our team developed last year on i4paintshop. This is a platform designed to turn coating lines into an open system able to interface with the entire production process and to enable users to draw value from the vast amount of data collected2” This new generation line is arranged on both factory floors, connected by the overhead conveyor designed by Futura Convogliatori Aerei (Robecco Pavese, Pavia, Italy - Fig. 5). The robotic loading and unloading stations are located on the 2 Imel presents the i4paintshop platform for 4.0 management of coating plants and the facilitation of decision-making processes, in ipcm® International Paint&Coating Magazine no. 52 (July/August 2018), pages 80-84.

The demand for aluminium radiators is not expected to slow down or stop. After improving its processes of foundry, machining, and anaphoresis with the system provided by Axalta Coatings System Italy, GLOBAL realised that coating was still a bottleneck in the production flow, as the plant was dated and no longer able to handle the workloads required by an increasingly intensive mass production.”

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Figure 3: The robotised loading of radiators.

N. 56 - MARCH/APRIL 2019 - international PAINT&COATING magazine

ground floor, while the spray and

FOCUS ON TECHNOLOGY

immersion pre-treatment tunnel, the anaphoresis system and powder coating line are located on the first floor (Figs. 6 and 7). The radiators’ pre-treatment stages are as follows: spray pre-cleaning and pre-degreasing, immersion degreasing, two immersion cleaning stages with demineralised water, acid deoxidation, two further immersion cleaning stages with demineralised water, conversion at 25-30 °C, and two final immersion cleaning stages with demineralised water. The first floor (Fig. 8) houses also the anaphoresis coating plant, without dialysis cells like the previous one (Figs. 9 and 11), cleaning tanks with

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ultrafiltrate recovery to replenish the baths, a curing oven at 180 °C

Figure 4: Each cart is identified with a code for batch recognition.

SP ECIAL ON ARCH ITE CTU R E & DESIGN

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Figure 5: The overhead conveyor installed by Futura Convogliatori.

of the main objectives

combined with a post-combustor providing for the abatement of emissions and the pre-heating of fresh air for the oven (Fig. 10), a Gema-branded automatic powder application booth placed inside a clean room, and a powder curing oven a 180 °C.

GLOBAL has organised the coating flow dedicating the old line to batches that are smaller or peculiar in terms of colours and part shapes, whereas the new plant handles larger batches to be coated with the two most requested white shades. This will enable it to process twice as many materials as today, which was one of the main objectives of this investment.”

of this investment. The other goals of GLOBAL were improving production quality and reducing consumption. As for the former, Imel worked with Gema to integrate its Optispray

The current state of the coating process

or peculiar in terms of colours

technology into the system, because

“The plant has been in operation for a

and part shapes, whereas the

it is particularly suitable for ensuring

few weeks and we are still in the

new plant handles larger batches

consistent and repeatable quality

start-up and test phase,” states

to be coated with the two most

results (Fig. 12). We also seem to have

Alessandro Fardelli. “Currently, we have

requested white shades. This will

achieved the powder saving goal, but

organised our coating flow dedicating

enable us to process twice as many

we will have to wait a few months for

the old line to batches that are smaller

materials as today, which was one

reliable data (Fig. 13).”

N. 56 - MARCH/APRIL 2019 - international PAINT&COATING magazine

dense application

FOCUS ON TECHNOLOGY

• management of coating programs, directly handled through data acquisition starting from the automatic loading, and management of information to be transmitted to the fully automatic unloading and packing system; • real-time control of all process parameters, with the activation of alarm systems if these do not meet the pre-set ranges;

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Figure 6: The pre-treatment tunnel located on the first floor.

4.0-oriented coating “The main innovation of the plant installed at the GLOBAL premises,” states Imel Service Manager Alessandro Cosivi, “is its ImelSW4, software program, developed to

The main innovation of the plant installed at the GLOBAL premises is its ImelSW4 software program, developed to communicate with the 4.0 platform and able to acquire and process a large amount of data, combined with a series of devices and sensors.” © ipcm ®

communicate with the 4.0 platform, i4paintshop, and able to acquire and process a large amount of data, combined with a series of devices and sensors.” Through the identification code assigned to each batch, the ImelSW4 program can collect information about as follows: • plant productivity and efficiency to better plan production and optimise work shifts; • coating quality control thanks to the traceability of batch processing parameters; • discarded part management; • monitoring of consumption (electricity, gas, and water) and its related costs; • monitoring of consumption linked to the coating process and its related costs;

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Figure 7: Workpieces entering the multi-stage pre-treatment tunnel. Figure 8: A detail of the radiators’ handling operations between the ground and first floor of the building.

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international PAINT&COATING magazine - MARCH/APRIL 2019 - N. 56

SP ECIAL ON ARCH ITE CTU R E & DESIGN

GLOBAL chose Imel’s 4.0-oriented solution because it is a digital platform completely integrated in the software package of the company management system and it allows to have a single provider for both the management of the process and the analysis of statistical data.”

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Figure 9: The anaphoresis tank without dialysis cells.

• maintenance of the main process parameters with the automatic replenishment of bath

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consumables; • development of preliminary maintenance plans, by identifying

Figure 10: The post-combustor providing for the abatement of emissions and the pre-heating of fresh air for the oven. © GLOBAL

time intervals based on the actual hours of operation and with the use of dedicated tools that warn of the need to perform routine maintenance operations; • access to maintenance manuals and operating procedures through QR Code reading performed with a tablet or smartphone. “This huge amount of data gives total control on the coating process in terms of performance and consumption (Fig. 14). One of the most important aspects is the optimisation of the coating quality control phase with the i4quality module, which closely monitors the discarded parts

N. 56 - MARCH/APRIL 2019 - international PAINT&COATING magazine

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Figure 11: The anaphoresis’ area with the control unit.

FOCUS ON TECHNOLOGY

while taking into account the production costs associated with them. Touch screen panels placed along the line detect the presence of workpieces that have not passed the checks and thus must be discarded. For each batch, the system identifies the radiators that have completed the production process by passing the checks and those that must be taken away from the line,” explains Corsivi. “Moreover, the i4efficiency module monitors the Overall Equipment Effectiveness (OEE) and shows it in the tables on availability, quality, and performance, also including the causes of any plant stops, the type and amount of discarded parts, and any details on the plant yield.”

Thanks to the abundant flow of data, GLOBAL’s team is now able not only to monitor every production phase in real time, but also to plan component maintenance and the costs related to each step, as well as accessing the data archive and all user manuals with the documentation management module i4smartdoc. And they can do all of this with a simple smartphone or tablet.”

The advantages of GLOBAL’s future-oriented approach GLOBAL chose Imel’s 4.0-oriented solution because it is a digital platform completely integrated in the software package of the company management system and it allows to have a single provider for both the management of the process and the analysis of statistical data. “When I entered the company at the beginning of 2017,” says Fardelli, “I encountered a difficulty: coming from a different sector, I needed to gather as much information as possible regarding the production flow and the painting process. However, these data were missing at that time. With the software program by Imel, we have solved this issue.

OptiFlex® A2 Set new standards with your powder coating equipment!

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www.gemapowdercoating.com

SP ECIAL ON ARCH ITE CTU R E & DESIGN

The integration of the i4paintshop platform with the robotic loading-unloading and packaging systems have turned GLOBAL into a smart factory fully in line with the Industry 4.0 philosophy.”

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13 1

Thanks to the abundant flow of data, showed with an interface easy to read, we are now able not only to monitor every production

Figure 13: Gema’s Opticenter powder management unit. © GLOBAL

Figure 12: Dense phase powder application.

phase in real time, but also to plan component maintenance and the costs related to each step, as well as accessing the data archive and all user manuals with the documentation management module i4smartdoc. And we can do all of this with a simple smartphone or tablet.” The return on the investment made by GLOBAL is still under evaluation: “We will have a precise idea of the results and advantages obtained only at the end of this year,” says Fardelli. “At the moment, we are very pleased, in particular, with the plant’s modular structure and ease of use. Moreover, the integration of the i4paintshop platform with the robotic loading-unloading and packaging systems have turned GLOBAL into a smart factory fully in line with the Industry 4.0 philosophy.”

N. 56 - MARCH/APRIL 2019 - international PAINT&COATING magazine

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Figure 14: Luca Maddalena, i4paintshop product manager, on the left, with Alessandro Fardelli discussing the flow of data coming from the coating system.

BRAND-NEW

S P E C I A L O N A RC HI TE C TUR E & DESIGN

istoric manufacturer of

Benelli Launches BE.S.T., an Anti-Corrosion Surface Treatment for Firearms firearms Benelli has developed a special coating to protect

the barrel of firearms from corrosion, abrasion, wear and external agents. The process – called BE S.T. (acronym of Benelli Surface Treatment) – employs a recently improved and still under development innovative hybrid technology to create a coating which characteristics are similar to the ones of a diamond: high hardness, aesthetic preciousness and corrosion resistance. It also doesn’t require protective oil for maintenance purposes. “In the frame of a society that is increasingly attentive and sensitive to ecological values, we find BE S.T. which, unlike other treatments, is a wholly ecological technology, as it does not produce waste nor harmful emissions for the environment. It is also one of the processes with the lowest

Figure 1: Benelli has developed a special coating to protect the barrel of firearms from corrosion, abrasion, wear and external agents.

environmental impact, chosen at

The treatment process

outer layer with properties similar to the

European level for the replacement of

A part of the plant uses state-of-the-art

ones of diamonds, as it contains chains of

traditional coatings: in fact, emissions

solid-state ion sources, which allow the

hydrocarbons in which the carbon forms

and waste are basically zeroed”, reads

deposition of compact layers free of

sp3 bonds, typical of the diamond.

on Benelli’s website.

defects (potential corrosion triggers) typical

The coating process is 4.0 oriented.

The complex deposition process is

of other technologies in use. Another part

carried out at the Urbino facility with

of the plant employs a radiofrequency

a plant entirely built in Italy, according

plasma source, which is able to separate

Durability and an ultra-black finish

to Benelli’s specifications. The plant

the gaseous precursors introduced into the

The deposited layer is made of a carbon

employs high vacuum technology and

chamber, in order to create the conditions

and hydrogen lattice, has an amorphous

uses the catalytic properties of plasma,

for their deposition.

microstructure, is chemically inert and

which allow the occurrence of chemical

The BE S.T. process by Benelli employs

very hard. In contrast, the steel substrate

reactions otherwise impossible at the

a liquid precursor, covered by industrial

has a crystalline microstructure, is

low temperatures needed to preserve

secrecy, which is vaporized before entering

chemically reactive and relatively soft.

the mechanical characteristics of the

the chamber. The liquid precursor, also

Therefore, the coating applied directly

barrel.

called diamantoid, is the key to create an

on the steel has a low adhesion, due

N. 56 - MARCH/APRIL 2019 - international PAINT&COATING magazine

BRAND-NEW

S P E C I A L O N A RC HI TE C TUR E & DESIGN

to the lack of chemical-physical affinity

which makes it bright, elegant, pleasing

still as new. The evaluation of the

with the substrate: for this reason,

to the eye and to the touch â&#x20AC;&#x201C; much

hunters involved was excellent, both

an intermediate layer with properties

like a precious diamond jewel. Its

from an aesthetic and functional

that gradually change from metallic to

colour, measurable by means of a

point of view. Ultimately, the whole

intermetallic is needed. These properties

spectrophotometer, is a deep black,

process is the result of a know-how

are similar to the ones of diamonds: high

so bottomless and intense that,

acquired while overcoming the several

hardness, toughness and heat, wear and

compared to it, a burnished barrel

challenges that the implementation

corrosion resistance.Â

looks greyâ&#x20AC;?, writes the company.

of this cutting-edge technology at

â&#x20AC;&#x153;In addition to the deposition phase,

an industrial level entail. This is what

post-treatment phases. The production

Tested in extreme environments

process is very complex: it required years

The validation of the process was

of research and development. Its difficulty

performed through a series of

For further information:

is what stopped many from pursuing

field tests in the most extreme

www.benelli.it

this pathâ&#x20AC;?, states Benelli. â&#x20AC;&#x153;Benelli is the

environments worldwide, where

first company in the world to succeed in

salinity and humidity loads generate a

applying it to gunsâ&#x20AC;?.

highly corrosive action - environments

â&#x20AC;&#x153;After the deposition treatment, a series

commonly found during hunting.

of operations is necessary to give the

â&#x20AC;&#x153;Tests lasted 3 years, with incredible

coating its final aesthetic appearance,

results: at the end the barrels were

the process also includes the pre- and

makes it unique and difficult to imitateâ&#x20AC;?, writes the company.

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BRAND-NEW

S P E C I A L O N A RC HI TE C TUR E & DESIGN

Europolveri Introduces the New 1R Arizona Series

polveri © Euro

uropolveri recently introduced the new 1R Arizona Series and it is now available the new

catalogue that shows all the colours of this new collection. The new Series is made of 44 products, all Ral references, with a fine texture finishing and different gloss level, developed to assure both a high level of quality and great aesthetic value. From an aesthetic point of view, the wrinkled finishing allows to hide possible defects of the substrate, but it also satisfies the need of an attractive look in line with the design requests.

All the colours available are part of the Pural Series and are formulated

Figure 1: 1R Arizona Series is made of 44 RAL product with a texture finishing and different gloss level, formulated in accordance to Qualicoat Class 1 requirements.

in accordance to Qualicoat Class 1

requirements. Due to the intrinsic characteristics, versatility and excellent applicability, all the products of 1R Arizona Series turn out to be ideal for the application in sectors that require high demand for protection and decorative effect, such as façade and windows elements, urban and outdoor furnishings. For further information: www.europolveri.it

Figure 2: All the products of 1R Arizona Series turn out to be ideal for the application in façade and windows elements, urban and outdoor furnishing sectors.

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N. 56 - MARCH/APRIL 2019 - international PAINT&COATING magazine

Opening photo: Ready for skylines around the globe: TIGER Drylac® Series 68 Flat Matte ensures many years of gloss.

INNOVATIONS: PRESENT&FUTURE

S P E C I A L O N A RC HI TE C TU RE & DESIGN

Elegance Meets Design: Demand for Flat Matte Finishes on the Rise Nora Pollmann TIGER Coatings GmbH & Co. KG – Wels, Austria

nora.pollmann@tiger-coatings.com

What is the trend in the finishing industry?

applications. Still, what is enjoyable to the eye

The first-generation products presented

presents great challenges to coaters. Flat matte

significant drawbacks during application.

Flat, satin and low gloss powder coatings are

powder coatings are nothing new, but only

Their gloss was heavily dependent on heating

extremely popular finishes in architecture as

recently they have become highly reproducible,

rate and curing temperature, with only a

well as in the automotive, sports equipment,

effective in application and can deliver

small curing window. This causes a particular

interior design and many others industrial

outstanding performance to the end-user.

problem for flat matte coatings, as even the

N. 56 - MARCH/APRIL 2019 - international PAINT&COATING magazine

INNOVATIONS: PRESENT&FUTURE

Flat, satin and low gloss powder coatings are extremely popular finishes in architecture as well as in the automotive, sports equipment, interior design and many others industrial applications. Still, what is enjoyable to the eye presents great challenges to coaters. Flat matte powder coatings are nothing new, but only recently they have become highly reproducible, effective in application and can deliver outstanding performance to the end-user.” minutest change can be perceived by the eye. In the last few years, research & development enabled a step change in performance for matte powder coatings for industrial applications, delivering several important user advantages. Among them, a higher curing stability and a lower curing temperature. With TIGER Drylac® Series 68 Flat Matte, TIGER Coatings succeeded in developing a new generation of highly weather-resistant powder coatings (Fig. 1). Depending on color, the innovative coating solution covers a gloss range from 12 to 4 units. Combined with second-generation metallic bonding, we are able to closely approximate C0-C35 anodizing effects (Fig. 2). The result: a finish with velvety haptics that adds value to the object (Fig. 3). Figure 4 highlights the gloss stability of the new generation across a

Upgrade to gain competitive edge

units occurred frequently whereas the new generation shows a variance

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

of only 3 gloss units.

highly repeatable powder application

curing range from 170 to 200 °C. In the past a difference of 10 gloss

n Significant powder savings due to higher efficiency and tight process control n No pump maintenance up to 4,000 hours n Intuitive advanced controls for operator convenience n Fast, reliable and automated colour change For a new fast colour change system or easy integration with your existing cyclone booth, get in contact with Nordson for more information. ics.eu@nordson.com | www.nordson.com/hdlv

Figure 1: TIGER Drylac® Series 68 Flat Matte is a new generation of highly weather-resistant powder coatings.

Performance by design

SP ECIAL ON ARCH ITE CTU R E & DESIGN

2 1

3 1

TIGER Drylac® Series 68 Flat Matte powder coatings were developed to be highly weather-resistant and ensure that they retain their attractive appearance for many years. The

Figure 3: TIGER Drylac® Series 68 Flat Matte adds value to the object through the finish with velvety haptics.

Figure 2: Combined with second-generation metallic bonding, TIGER Drylac® Series 68 Flat Matte is able to closely approximate C0-C35 anodizing effects.

and facade coating (ref. Opening photo). Different curing temperatures and heating rates have only a minor effect on the gloss of the innovative coating

products are approved based on

solution. In other words, different heat

QUALICOAT Class II (P-1547) and

levels in the zones of the oven,

hold up to over 1,000 hours of

the different geometries and

Xenon testing. Therefore, the new

wall-thicknesses have little to no impact

series can be used to meet the strict

on the quality of the finish.

requirements of metal architecture

Figure 5 shows that with the same

4 1

curing time and temperature, even different wall-thicknesses have only a

Figure 4: Comparison of generations: Gloss values of conventional and new flat-matte powder coatings between 170 °C and 200 °C.

Easy to process, batch-to-batch consistency, stable application, reproducible finish: these are the main advantages delivered by the new TIGER Drylac® flat-matte powder coatings. In addition, TIGER Drylac® Series 68 Flat Matte does not require special labeling nor any additional workplace safety measures during application.”

minor effect on the gloss development.

User-friendly, stable and highly weather-resistant Easy to process, batch-to-batch consistency, stable application, reproducible finish: these are the main advantages delivered by the new TIGER Drylac® flat-matte powder coatings. In addition, TIGER Drylac® Series 68 Flat Matte does not require special labeling nor any additional workplace safety measures during application. The

5 1

Figure 5: Even with steel plates of different wall-thickness, the flat-matte powder coatings from TIGER show a gloss-level that is consistent (oven temperature 200 °C).

N. 56 - MARCH/APRIL 2019 - international PAINT&COATING magazine

product is available from stock immediately in 24 exclusive shades, led by the most popular anodizing effects.

Powder coating lines since 1976.

EUROIMPIANTI SRL Via Cavour 44 - 37067 Valeggio sul Mincio (VR) Italy - Tel. +39 045 7950777 info@euroimpianti.com - www.euroimpianti.com

EUROIMPIANTI DO BRASIL LTDA SC 445, 16815 - 88-828 000 Pedreira Balneário Rincão (SC) Brasil

EUROIMPIANTI SL Baix Llobregat 18B Nave G 08759 Vallirana (BCN) España

EUROIMPIANTI USA LLC 1817 NW 79th Ave Miami, FL 33126 (US)

Opening photo: A bird’s eye view of the coating line installed by Euroimpianti in 2016.

FOCUS ON TECHNOLOGY

S P E C I A L O N A RC HI TE C TU RE & DESIGN

In Mexico, a Coating Line Was Updated To Optimise Control on the Quality of Aluminium Door and Windows Frames Monica Fumagalli ipcm®

N. 56 - MARCH/APRIL 2019 - international PAINT&COATING magazine

FOCUS ON TECHNOLOGY

ombining process automation with artisan

white to natural anodised, from bronze to grey, from black to olive green, up to all wood-effect

quality is among the

most difficult tasks to pursue

shades and the most particular

in a factory. On the one

RAL colours upon request.

hand, artisan production is and care for the aesthetic and

Manual pre-treatment issues

functional details of products,

In 2010, Euroimpianti had

but, on the other hand, it is often

installed a standard Komby

seen as a limit to the increase of

system with an overhead

production capacity. In Mexico,

conveyor with 5 bars to

a company manufacturing

transfer components

aluminium doors, windows and

through a manual cleaning

synonymous with attention

shutters for sixty-five years is

booth, a powder coating

an example of how it is possible to maintain a high quality level

booth featuring a suction wall, and a static drying and

Figure 1: A detail of the new coating line.

without sacrificing artisan value

curing oven. Six years later,

and with production volumes

the Mexican company’s

suited to requests. Thanks to its

management decided to

In Mexico, a company manufacturing aluminium doors, windows and shutters for sixty-five years is an example of how it is possible to maintain a high quality level without sacrificing artisan value and with production volumes suited to requests. Thanks to its collaboration with Euroimpianti, an Italian company specialising in the design, construction, and installation of coating systems, this Mexican manufacturer updated its coating line in 2016.”

collaboration with Euroimpianti, an Italian company specialising in the design, construction, and installation of coating systems, this Mexican manufacturer updated its coating line in 2016. Now, it is able to continue to meet its customers’ needs with products of excellent quality and considerable durability,

update and extend this coating line in order to streamline its process management, especially as regards pre-treatment, and update its application technologies. “Their requests were precise,” says Euroimpianti USA Executive Manager Luisa Accordini, while

and prestigious residential

describing the revamping

complexes (ref. Opening photo and Fig. 1).

mainly intended for hotels

intervention. “They asked our staff to improve the management of their

Development of customised innovative systems

pre-treatment process, which occurred in the manual cleaning booth,

“Customer satisfaction is our

with two main objectives:

best form of advertising” is the

Limiting operator exposure

slogan of this Mexican company,

to chemical cleaning

which develops both indoor

agents and minimising

and outdoor innovative systems

the risk of error in the

that can be customised with

use of chemicals, an issue

unique colours, configurations,

due this operation being

and designs in order to adapt to any type of architectural project. The company offers a wide range of colours, ranging from

manual. That is why this

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updating project involved

Figure 2: The new layout includes a spray pre-treatment tunnel beside the curing oven.

a considerable part of the existing coating line.”

international PAINT&COATING magazine - MARCH/APRIL 2019 - N. 56

SP ECIAL ON ARCH ITE CTU R E & DESIGN

Figure 3: A detail of the workpiece handling system with a mobile bridge crane.

profiles with a maximum length of 7 m using bars with a maximum width of 1.5 m. “The real challenge,” says Accordini, “was meeting the need to limit automation to certain stations, such as for example the manual booth featuring an automatic cleaning operation in order to control and manage the pre-treatment process according to the firm’s needs, but without revolutionising the already

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The 4-stage cycle takes place in two stations: In order to avoid chemical contamination between them, the hydraulic circuits are separate and they are activated sequentially through a mechanical interphase drainage system; - a new drying and curing oven a 120 °C, with a storage buffer and entry and exit sliding doors to avoid unnecessary heat loss and increase process flexibility; - a manual powder coating booth (Fig. 6);

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Figure 4: The new spray pre-treatment tunnel.

In 2010, Euroimpianti had installed a standard Komby system with an overhead conveyor with 5 bars to transfer components through a manual cleaning booth, a powder coating booth featuring a suction wall, and a static drying and curing oven. Six years later, the Mexican company’s management decided to update and extend this coating line in order to streamline its process management, especially as regards pre-treatment, and update its application technologies.”

established coating process.”

The project, therefore, included the installation of a new overhead conveyor

The paintshop revamping

with a mobile bridge crane for moving the workpieces along the department

The new paintshop covers a more

(Fig. 3) and a new coating line

than doubled surface compared with

composed as follows:

the previous one: It is equipped with a

- a 4-stage automatic spray

horizontal coating line devoted to aluminium

pre-treatment tunnel (degreasing,

profiles and specifically developed for

cleaning, rinsing, and conversion)

metal parts with large dimensions and

replacing the manual cleaning booth

limited thicknesses (Fig. 2). The plant layout

(Fig. 4 and 5).

was optimised to make it as functional as possible for the company, which treats

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The Mexican company’s asked Euroimpianti to improve the management of its pre-treatment process, which occurred in the manual cleaning booth, with two main objectives: limiting operator exposure to chemical cleaning agents and minimising the risk of error in the use of chemicals, an issue due this operation being manual. That is why this updating project involved a considerable part of the existing coating line.”

Figure 5: A detail of the cleaning tank.

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FOCUS ON TECHNOLOGY

- a curing oven at 200 °C with a ventilated hot air system, an

The client’s goals were focussed on another crucial aspect: installing a manual system with an automatic static cleaning operation to be able to check and modify pre-treatment times and chemicals simply by pressing a button on the panel’s touch screen and this is exactly the function that Euroimpianti implemented on the new line.” Conclusions “Adapting the design of our

indirect combustion chamber, an

coating systems to the particular

internal storage buffer, and entry

needs of each customer is

and exit sliding doors;

our main mission,” says Luisa

- cooling and unloading areas.

Accordini. “In the case of the Mexican company, the

The line was also equipped with

management requested a

a new touch screen control panel

substantial updating of the

to monitor the whole treatment

line that did not alter the

process, as specifically requested

artisanal characteristics of

by the company (Fig. 7 and 8).

their internationally recognised

“With this new plant,” states

products. Three years after the

Accordini, “the company has not

installation of the new system,

found any considerable increase

we can state we have met every

in production volume. In order to achieve it, in fact, it should have invested in an automatic line, with a one-rail conveyor and a vertical coating system. However,

request of this customer, giving

6 1

it greater control over all process

Figure 6: The outside of the manual coating booth beside the drying oven.

the client’s goals were focussed

phases and therefore over the quality of their products, which was its main concern. This manufacturer can continue

to offer its door and window frames on the

on the panel’s touch screen – and this

market with the aesthetic and functional

static) cleaning operation to be able to

is exactly the function that Euroimpianti

characteristics that have always made them

check and modify pre-treatment times

implemented on the new line.”

high-end products.”

7 1

Figure 7: The touch screen panel provided by Euroimpianti for the management of the various pre-treatment stages.

and chemicals simply by pressing a button

manual system with an automatic (but

on another crucial aspect: Installing a

8 1

Figure 8: A detail of the touch screen panel enabling to manage each phase of the coating process.

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Opening photo: The UV curing phase in the oven installed by UV Ray in Arsonsisi’s laboratory in Berlingo (Brescia).

HIGHLIGHT OF THE MONTH

S P E C I A L O N A RC HI TE C TU RE & DESIGN

A Flexible and Modular UV Tunnel Functional to the Development of Formulations in the Laboratory of Paint Manufacturer Arsonsisi From an interview with Stefano Lazzerini Arsonsisi Spa, Lainate (Milan) - Italy

stefano.lazzerini@arsonsisi.com

he characteristics of a research

manufacturing company that works on

In order to delve into the needs of an R&D

lab are not different from those of

shifts, an R&D laboratory cannot predict

department developing coating formulation

a manufacturing plant: maximum

when and for how long the tools needed

projects, the ipcm® editorial team visited

equipment flexibility and versatility are

to develop specific products will have to be

the international liquid and powder paint

required also here. However, unlike a

turned on and to remain operational.

manufacturer Arsonsisi Spa’s plant of

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HIGHLIGHT OF THE MONTH

The UV curing device supplied by UV Ray was the latest innovation of the laboratory. The Maxwell series oven has a solid structure made of extruded aluminium and it is equipped with a dichroic UV reflector with a 350 mm light arc and a belt conveyor.” synergy with customers and handle several programs for new formulations with different research institutes.” In addition to the laboratory for the development of

UV coatings, this Arsonsisi plant houses

Figure 1: From right to left, Arsonsisi Marketing Assistant Serena Maretti, Arsonsisi UV Coating Laboratory Manager Francesco Italiano, Arsonsisi Business Manager and UV Product Manager Stefano Lazzerini, and Monica Fumagalli from ipcm®.

a testing laboratory for raw materials and finished products and a research laboratory for non-UV thermal products.

Berlingo (Brescia, Italy), covering 9,000

this is a constantly evolving sector,”

m2 and recently expanded. Here, we

says Lazzerini, “only by keeping up with

The UV technology laboratory equipment

interviewed Business Manager and UV

the changing needs of the market is it

The laboratory for the development of UV

Product Manager Stefano Lazzerini, an

possible to remain competitive. The UV

coatings is equipped with a dry spray paint

expert in UV technologies (Fig. 1).

coating field is a clear example. Within

booth, a bench COWLES disperser for the

its Berlingo production plant, Arsonsisi

preparation of pigmented products up to

Arsonsisi’s R&D department

such as a grindometer and a suction hood

department plays a key role for this

cooperating with installers, raw material

for tests with potentially harmful volatile

coating manufacturer, because it is

suppliers, and analysis laboratories to

products (Figs. 2 and 3), and a UV tunnel

the core of its whole activity. “Since

manage specific, tailor-made projects in

provided by UV Ray (Cornaredo, Milan,

2 1

Figure 2: Paint mixing and dosing bench.

40 kg, standard laboratory instrumentation

the development of UV technologies,

has created a Competence Centre for

The research and development

3 1

Figure 3: Francesco Italiano shows the operation of the COWLES disperser.

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SP ECIAL ON ARCH ITE CTU R E & DESIGN

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Figure 4: The UV tunnel provided by UV Ray (Cornaredo, Milan).

Fig. 4). The UV curing device supplied

parameters without limiting to any specific

by UV Ray was the latest innovation of

type of workpiece or process. “The UV Ray

the laboratory. The Maxwell series oven

tunnel has perfectly met these needs,” says

has a solid structure made of extruded

Lazzerini, “because it is a very versatile and

The Arsonsisi laboratory needed to find a tool enabling its operators to set variable parameters without limiting to any specific type of workpiece or process. The UV Ray tunnel has perfectly met these needs because it is a very versatile and efficient system. First of all, it allows adjusting the advancement speed of the parts positioned on the conveyor belt from 0 to 10 m per minute. Secondly, it enables to vary the height of the UV lamp, thus increasing or decreasing its distance from the sample and making it possible to cure even three-dimensional objects with complex shapes.”

aluminium and it is equipped with a © ipcm®

dichroic UV reflector with a 350 mm light arc and a belt conveyor (ref. Opening photo). “We introduced this new device to streamline the activity of our lab. That is why we explicitly required UV Ray to equip the oven with a plastic case to prevent our operators from using UV protections, which would otherwise be mandatory because the rays can harm eyesight: this facilitates work. Moreover, previously there was only one UV tunnel used by both the testing and UV coating labs, with easily understandable overlapping issues. Thanks to the UV Ray oven, we have now separated our two activities and solved the problem.”

The advantages of the UV tunnel This Arsonsisi laboratory needed to find a tool enabling its operators to set variable

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Figure 5: Thanks to the possibility of adjusting the lamp height, the tunnel also allows curing three-dimensional components with complex shapes.

HIGHLIGHT OF THE MONTH

6 1

Figure 6: UV tunnel parameter management system.

efficient system. First of all, it allows adjusting the advancement speed of the parts positioned on the conveyor belt from 0 to 10 m per minute. Secondly, it enables to vary the height of the UV lamp, thus increasing or decreasing its distance from the sample and making it possible to cure even three-dimensional objects with complex shapes (Fig. 5). Finally, it allows adjusting the mercury lamp power from a few W/cm2 to a specific maximum power of 180 W/cm2 (Fig. 6).” A further benefit is the energy saving guaranteed by the UV Ray system. Turning on and off a UV lamp reduces the tool’s service life by 3 hours, thus resulting in rapid wear. Since a research laboratory is not a production plant where the lamp remains lit according to work shifts, but it is characterised by discontinuous activities, the UV Ray tunnel has been designed in order to enter stand-by mode to allow the lamp to save energy. The operators can thus concentrate the product preparation activities in a precise period and then, when they are ready for testing, they turn on the lamp, thus avoiding quickly degrading it. “The flexibility of this device is fundamental for us,” states Lazzerini, “as the UV sector is expanding and every day we are faced with very different requests in terms of type and size of parts (Fig. 7). An instrument with such flexible characteristics enables us to meet even the most particular needs.”

Projects in progress for the development of UV coatings The current projects of the laboratory are focussed on pre and post-UV coatings for sputtering processes on plastics and metals, 100% dry UV coatings, water-based UV coatings, LED lamp hardening coatings, and UV coatings for the automotive sector. The requests from the surface treatment industry are varied and constantly changing: that is why the Arsonsisi lab has

SP ECIAL ON ARCH ITE CTU R E & DESIGN

the surface; 2. A mixed system composed of a UV base-coat + a sputtering layer + a post-sputtering thermal coating, generally aliphatic polyurethane enamel; 3. A system composed of a pre-sputtering UV paint + a sputtering finishing layer; the longer dwell time of the workpiece in the sputtering chamber ensures higher thicknesses, so that repainting is no longer necessary.

The future of the UV market Arsonsisi’s R&D department has already completed and presented to the market numerous projects. Other studies have been completed, but they are not

7 1

easily accepted by the sector, such as

Figure 7: Products with different sizes and shapes for which Arsonsisi’s R&D department has developed successful projects.

those relating to powder coatings for MDF. “The main difficulties, especially for coating contractors,” says Lazzerini, “concern the high investment required

decided to equip itself with instruments

the elimination of CrVI, with a negative

to install a UV curing system also

able to meet even future needs.

effect on the development of alternative

optimised for cross-linking coatings on

“As for the development of UV coatings

solutions to polluting galvanic systems1.

complex three-dimensional parts and

that harden with LED lamps, our UV Ray

“If lawmakers do not establish a deadline

for handling large batches. However,

system is ready for the possible addition

for the ban on chromium VI, the market,

the very big orders are now handled

of LED lamps or the replacement of

especially in the automotive industry,

in China, whereas European coaters

the mercury-based one currently in

will continue to use traditional systems.

tend to characterise their production

use. We intend to devote ourselves

The galvanic process will continue to be

by applying special coatings on small

to the development of this type of

counterposed to the physical vapour

batches. Therefore, making such a large

paint in the future, but we looked for

deposition (PVD) technology, which is

investment can be an issue for them.

a tool that allows replacing the lamps

the most ecological alternative on the

“On the other hand, the systems that

without forcing us to purchase a specific

market and, in addition to giving the

include PVD sputtering coatings are now

instrument with LED lamps. The structure

same results, allows treating different

fine-tuned and they work very well, so

of the UV tunnel also ensures a very fast

materials.”

much so that they are now starting to

lamp replacement operation.”

In this framework, Arsonsisi has

be requested by our most far-sighted

developed three systems for PVD

customers (even those using conventional

sputtering coatings:

galvanic processes) that want to avoid

1. A base system with a UV paint + a

being in trouble when lawmakers will

State-of-the-art PVD/ sputtering coatings The continuous development of coating

sputtering layer + a post-sputtering

definitively ban the use of CrVI. Of course,

formulations suited to ever-changing

UV paint, possibly a dual cure product,

our research activity cannot stop at the

market needs sometimes clashes with

in order to harden the coating even

results obtained. Having found reliable

the slowness of institutions to impose

where UV beams do not directly hit

partners for the supply of the right equipment is a further guarantee that

limitations or substitutions of outdated systems in terms of sustainability and usability. An example are the continuous extensions to European regulations on

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1 ipcm® published the official statement of the Alliance of PVD Providers about this topic on its November/ December 2018 magazine: A sustainable alternative to CrVI: Manifest of the Alliance of PVD Providers, ipcm® no. 54, pages 36-37.

our projects can be developed flexibly and quickly and with the proper safety measures for our operators.”

Opening photo: The lab dosing machine is unique in the paint industry and ensures consistent quality and reproducibility of standard formulations.

HIGHLIGHT OF THE MONTH

BASF’s Lean Lab Sets New Standards: Fit for the Future Susanne Focken BASF Coatings GmbH, Münster - Germany

susanne.focken@basf.com

“E

veryone is talking about

Germany (Fig. 2), and is to be introduced

areas of responsibility allow BASF to respond

digitalization and automation. We

at additional sites in Europe: in Würzburg,

to future market requirements quickly and

have successfully implemented

Germany; Guadalajara, Spain; and Clermont,

flexibly. The laboratory employees in Münster

digitalized and automated processes for

France.

are supported by a lab dosing machine that

automotive OEM coatings in our new Lean

Lean Lab is the modular lab concept that

was specially developed for BASF and is the

Lab,” said Susanne Richert, Lean Lab project

ensures optimized, transparent processes and

only one of its kind in the paint industry (ref.

manager at BASF’s Coatings Division Münster

the efficient use of lab-related resources. The

Opening photo).

site, clearly pleased (Fig. 1). The first Lean Lab

use of standardized and automated processes

Since 2014, BASF has invested €24 million at

was opened in September 2018 in Münster,

and the segmentation of the lab employees’

the Münster site to completely overhaul an

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HIGHLIGHT OF THE MONTH

innovative and customer-specific products

existing laboratory building for Lean Lab, which included adding an extra story. The building now features four levels with spacious offices and functional, state-of-the-art lab workplaces (Fig. 3). All work orders and the corresponding tests are saved and documented digitally, which promotes transparency and reproducibility and serves as the basis for knowledge transfer and the use of synergies across different sites.

Discrete work processes The new division of labor between Lab Material Supply and the process and

Lean Lab is the modular lab concept that ensures optimized, transparent processes and the efficient use of lab-related resources. The use of standardized and automated processes and the segmentation of the lab employees’ areas of responsibility allow BASF to respond to future market requirements quickly and flexibly.”

product labs, which are intrinsically

and respond flexibly to new challenges,” Richert stressed. Lean Lab offers interesting development opportunities for lab employees, permitting them not only to rotate among the individual segments, but also to work at other sites. “In the future, the Lean Lab initiative will enable us to harmonize laboratory activities across the sites, which also makes job rotation among sites in different countries much easier, since the tasks and functions will be the same throughout Europe,” said Kues.

Automatic lab assistant © BASF

interconnected, offers new opportunities for

In Münster, a lab dosing machine supports the

optimizing workflows and

laboratory employees

focusing more heavily

with producing

on the core activities. In

standard formulas

the product lab, which is

or frequently used

divided into a customer

mixing bases. BASF

and a development lab,

collaborated with

the employees address

machine manufacturer

customers’ concerns and

FRICKE Dosing +

develop new products.

Filling Systems from

Their colleagues in the

Minden, Germany, to

process lab produce the

develop the machine.

paint samples, carry out

At 12 meters long and

tests and optimize lab

weighing 8 tons, it can

processes. For many of the employees, the reorganization of the work has been the biggest challenge. “Many colleagues

manufacture standard

formulas from over 300

Figure 1: Susanne Richert, Lean Lab project manager at BASF’s Coatings Division Münster site.

found it difficult at first to

liquid raw materials (Fig. 4). In so doing, it significantly contributes to streamlining work,

dispense with processes, patterns and

incorporated their ideas and supported

assuring quality and reproducibility, and

workflows that they had been used to for

them. Today, we can say that all of the

boosting efficiency (Fig. 5). “It is extremely

decades,” Richert recalled. For this reason, it

new gears are working together more

difficult to use automation processes in

was crucial for the success of the Lean Lab

and more smoothly,” added Dr. Jan-Bernd

the lab, because the processes are highly

for all employees to be on board early on

Kues, who is responsible for the process

complex,” explained Alexander Blaser,

and to include them in the planning phase.

lab. For instance, it came to light that

who is responsible for automation and

“What is working well? Where are things not

dividing up work processes allows individual

digitalization at the new Lean Lab in

working so well? What can we improve?”

employees’ strengths to be leveraged

Münster. “We spent a long time looking

Numerous workshops offered the affected

much better. In addition, the specialization

for a manufacturer who would be able to

colleagues opportunities to help develop

ensures that tasks are executed more

implement our high standards. At the Lean

new ideas for optimizing workflows. “We

efficiently. “The laboratory employees

Lab, people and machines work hand in

took the employees’ concerns seriously,

ultimately have more scope to develop

hand to manufacture samples together.”

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109

2 1

3 1

Figure 2: The new Lean Lab building at the Münster site was officially opened in September 2018.

Figure 3: All job orders are digitally stored and documented, which promotes transparency, reproducibility and knowledge transfer.

The raw materials for the machine are

the associated order is generated and guided

organized in the machine storage area one

Transparent and traceable processes

through the process via bar codes.

floor up. Nearly 400 meters of pipelines

“The new lab dosing machine is a core

The machine automatically pulls in the

were installed in a tight space to connect

module of the connected digital laboratory

container, scans the bar code and doses the

the storage area with the dosing machine.

and unique in the paint industry. The

raw materials as specified by the formula.

Manufacturing is carried out directly on site.

guarantee for the concept to succeed,

If needed, the mixture can be stirred during

Each raw material is connected with the

however, is laboratory software that is

weighing. The new lab dosing machine

machine with a dedicated line, pump and

specially developed to meet our needs,”

relieves the lab teams of routine jobs.

dosing valve.

Blaser said. The software ensures that all

For this purpose, a formula is prepared and

The new division of labor between Lab Material Supply and the process and product labs, which are intrinsically interconnected, offers new opportunities for optimizing workflows and focusing more heavily on the core activities.”

Figure 4: Over 300 liquid raw materials are organized in the machine storage area for the dosing machine.

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HIGHLIGHT OF THE MONTH

Efficient and reliable

The formula is prepared and the associated order is generated and guided through the process via bar codes. The machine automatically pulls in the container, scans the bar code and doses the raw materials as specified by the formula. If needed, the mixture can be stirred during weighing. The new lab dosing machine relieves the lab teams of routine jobs.”

solutions for surface coating since 1988.

processes in the Lean Lab are transparent and traceable. “We’re able to precisely identify in a laboratory sample which raw material has been processed in which batch. With Lean Lab, laboratory work is more efficient and sustainable.” For instance, there is now only one central storage area

electrostatic systems for liquid painting

with managed inventory of all standard raw materials. These include in particular chemicals, as well as semi-finished and finished products. Each new delivery and each consumption and of course the best-before date

electrostatic systems and spraying booths for powder coating

are recorded directly in a bar code-based system. When volumes drop below a defined minimum quantity, raw materials and intermediates are reordered immediately. This ensures that all the materials required

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

for daily work are available and prevents duplicate orders, enabling all raw materials to be used optimally, which saves material and time and conserves valuable resources. When an employee needs to add a prescribed raw

IR and UV drying systems

material to the manufacturing formula, he or she first scans the bar code on the raw material container. The computer releases the raw material for weighing only

robot and reciprocators

if the employee has scanned the raw material specified in the formula. The precise quantity of a raw material to be added is displayed on the monitor. “As the developer, I can obviously also include new components in a formula,” Blaser added. “So working digitally enables us to manufacture samples in line with requirements while also retaining the development freedom that we need in the laboratory. Our lab technicians are therefore able to carry out their usual tasks in a digital context.” lab are digitally stored and documented, which guarantees reproducibility and knowledge transfer.

www.cmspray.it

eosmarketing.it

All job orders and the associated experiments within the

CM SPRAY s.r.l.

5 1

Figure 5: The lab dosing machine ensures high dosing accuracy and reproducibility of weighings.

in Europe. Lean Lab is our new

All of the laboratory employees have attended training courses for using the new software. “Even colleagues who have had little exposure to the digital world are able to work with the software very easily,” Blaser said. “Using the software is very intuitive. With Lean Lab, we have taken a significant first step on our journey to digitalization. It’s an ongoing learning process.”

New standard in the paint industry Lean Lab in Münster is BASF’s pilot project. “Since late 2017, we’ve been gathering experience that we can use for the roll-out at the other sites

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There is now only one central storage area with managed inventory of all standard raw materials. These include in particular chemicals, as well as semi-finished and finished products. Each new delivery and each consumption and of course the best-before date are recorded directly in a bar code-based system.”

European standard and will open up many possibilities for us to intensify development work and respond flexibly and agilely to new challenges,” said Dr. Wolfgang Reckordt, head of Product Development Europe at BASF’s Coatings division’s Automotive OEM Coatings business unit. “Lean Lab makes us fit for the future and enables us to position ourselves as a future-oriented and innovative company and reliable partner for automotive manufacturers. We are using our long-term solutions to reinforce our customers’ innovative strength.”

Â®

ÂŠ Saveral

Opening photo: The core business of Saveral, a company based in Almenno San Bartolomeo (Bergamo, Italy) and established in 1954, is the powder coating of components for various industrial sectors, including automotive.

FOCUS ON TECHNOLOGY

Saveral: The Innovation-Oriented, Pioneering Company in the Italian Powder Coating Sector Barbara Pennati ipcmÂŽ

he development of markets and the

result of a synergy of choices, strategies,

Saveral, a company based in Almenno

emergence of new demands call

and collaborations, which guarantee the

San Bartolomeo (Bergamo, Italy) and

for innovation. However, innovation

continuation of the innovative process

established in 1954, has adopted precisely

does not stop with individual technologies

and the advent of ever more numerous

this philosophy, thus becoming one the

or successes and, very often, it does not only

expressions of human ingenuity.

first companies in Italy to perform powder

involve an individual party. Indeed, it is the

The coating sector is no exception.

coating operations. Founded by Abele

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FOCUS ON TECHNOLOGY

2 1

Figures 1 and 2: Saveral in its early years and today.

and levers for motorcycle brakes (ref.

Preda as a galvanic processing firm, Saveral devoted itself to liquid coating in 1960 and then abandoned it in 1970 with the installation of one of the first powder coating plants. The company now covers a 10.000 m

area, it has about forty employees, and it has several high-profile customers in the automotive, mechanical carpentry, architecture and furniture and electromechanical/electric and electronic components industries (Figs. 1 and 2). The significant growth recorded in these sixty-five years would not have occurred without the orientation to innovation that distinguishes the company and without the collaboration of technological partners able to share this approach, as CEO Luigi Preda explains

Innovation is the result of a synergy of choices, strategies, and collaborations, which guarantee the continuation of the innovative process and the advent of ever more numerous expressions of human ingenuity. The coating sector is no exception. Saveral, a company based in Almenno San Bartolomeo (Bergamo, Italy) and established in 1954, has adopted precisely this philosophy, thus becoming one the first companies in Italy to perform powder coating operations.”

Opening photo). The other half consists of carpentry components for different uses, such as parts for horizontal packaging machines, for pellet stoves, and for high-end furnishings for hotels and cruise ships. The dimensions and material of the workpieces are also varied. Therefore, over the years, it has become increasingly important to equip ourselves with pre-treatment and coating lines that guarantee greater production flexibility,” explains plant manager Vincenzo Montesanti. “That is why we turned to M.I. Due, which took care of the design and installation of all the coating plants now present in our factory.” Saveral has four pre-treatment plants: - a fluotitanation system with a nanotechnology process; - a phospho-chromating system;

(Fig. 3): “Saveral has always been an

- a phospho-degreasing system;

innovative firm: we were among the first

- a degassing system.

to introduce powder coating in Italy.

A system for every need

However, in order to be innovative and

Powder coating has been the core business

continue to meet our customers’ needs,

of Saveral for over forty years. In 2014,

brake pads, equipped with a continuous

we need equally innovative partners

the company began a modernisation

flow belt linked to the powder application,

to support us in the development and

process to achieve maximum quality,

curing, and cooling stations;

implementation phases.” One of these

flexibility and production efficiency.

partners is M.I. Due (Besana in Brianza,

“Half of Saveral’s production is intended

size of H 1800 x W 4000 x D 1000 mm,

Monza e Brianza, Italy), specialising in

for the automotive market, for which we

featuring a Wagner quick colour change

the design and construction of industrial

paint different components such as,

Supercube booth with reciprocators and

surface treatment plants, which installed

for example, brake callipers and pads,

two manual stations (Figs. 4 and 5). The

Saveral’s four coating plants.

wheels, engines for motorcycles, cylinders,

colour change operation takes place in

There are four coating lines: - a industry 4.0 oriented line dedicated to

- a line for coating parts with a maximum

international PAINT&COATING magazine - MARCH/APRIL 2019 - N. 56

115

about 7 minutes in a fully

parts up to a maximum of

automatic manner, through

H 2500 x W 6000 x D 2000 mm,

the new SuperCenter EVO

installed at the end of 2018 and

powder management

equipped with an in-line

centre (Fig. 6); it allows the

pre-treatment station and a

setting of over fifty painting

manual coating booth.

programs, connecting to

The booth is equipped with an

the management system

automatic fire detection system.

during the cleaning phases,

The project of the new line for large-sized workpieces

maintaining constant the

The plant that can handle parts

quality and timing standards.

up to 6000 mm in length was

(Industry 4.0). The operator doesn’t have to intervene

The powder centre is also equipped with an UltraSieve 200-micron which allows a very high finish. The booth is equipped with

the last one to be installed at

3 1

the premises of Saveral. M.I.

Figure 3: From left to right, Saveral CEO Luigi Preda and plant manager Vincenzo Montesanti.

an automatic fire detection system and it is industry 4.0-oriented; - a line for coating parts with a maximum size of H 1000 x W 1000 x D 700 mm, equipped with a booth for manual application and reciprocators. The booth is equipped with an automatic fire detection system;

Industry 4.0 principles (Fig. 7). “The decision to equip ourselves with this system stemmed from the will to meet the requirements of a particular group of customers needing to coat larger workpieces,” says Montesanti. “This line is able to handle large-sized parts, but we can actually use it also to coat smaller components. This gives us extreme production flexibility (Fig. 8).”

Saveral has always been an innovative firm: it was among the first to introduce powder coating in Italy. However, in order to be innovative and continue to meet the customers’ needs, it needs equally innovative partners to support it in the development and implementation phases. One of these partners is M.I. Due (Besana in Brianza, MB, Italy), specialising in the design and construction of industrial surface treatment plants, which installed Saveral’s four coating plants.”

- a line for painting large-sized

Due designed it according to the

5 1

4 1

Figures 4 and 5: The line for coating parts with a maximum size of H 1800 x W 4000 x D 1000 mm, featuring a Wagner quick colour change booth.

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FOCUS ON TECHNOLOGY

Air Protection Technology airprotech is active worldwide with a wide range of solutions and products for the control of industrial emissions including VOC volatile organic compounds, solvents and other gaseous pollutants.

6 1

Figure 6: The Wagner SuperCenter EVO powder management centre.

The line also performs a three-stage in-line pre-treatment including a phospho-degreasing operation followed by two rinses

with osmotic water (Fig. 9).

The process continues as follows: oven drying, masking, coating in a manual application booth with a floor suction system and two mobile platforms (Fig. 10), and curing (Fig. 11). “This coating line has enabled us to meet new market needs without sacrificing production efficiency and sustainability, another very important factor for Saveral,” states Luigi Preda. “The choice to integrate the pre-treatment into the line has

CMY

allowed us to reduce our production and lead times by enabling us to paint different-sized parts with a continuous flow.” “The system was designed for greater energy efficiency.

Half of Saveral’s production is intended for the automotive market, for which it paints different components such as, for example, brake callipers and pads, wheels, engines for motorcycles, cylinders, and levers for motorcycle brakes. The other half consists of carpentry components for different uses, such as parts for horizontal packaging machines, for pellet stoves, and for high-end furnishings for hotels and cruise ships. The dimensions and material of the workpieces are also varied.”

www.airprotech.eu

Figure 7: The last system installed by M.I. Due.

The centralised diathermic oil boiler reduces

7 1

This coating line has enabled Saveral to meet new market needs without sacrificing production efficiency and sustainability, another very important factor for the company. The choice to integrate the pre-treatment into the line has allowed it to reduce the production and lead times by enabling it to paint different-sized parts with a continuous flow.” greater quality and production efficiency

heat loss and optimises fuel consumption

to our customers and a healthier and

while improving the temperature control of

more comfortable working environment to

the drying and curing ovens,” says Vincenzo

our employees,” says Luigi Preda. “We are

Montesanti. “The application booth is

constantly looking for innovative solutions and

also equipped with an extraction unit for

products. Therefore, it is important to surround

overspray recovery, which has allowed us

ourselves with partners and suppliers who can

to reduce the consumption and disposal

keep up with us with customised and equally

of powder, with a benefit also in terms

innovative solutions.”

of environment. Finally, we installed an

“Our collaboration with M.I. Due has allowed

osmosis system for water recirculation in

us to implement our projects and confirm

the pre-treatment tanks and a waste water

our reputation as a company offering flexible

treatment plant.”

productions with low lead times. Especially thanks to our last plant, we have expanded our

Close cooperation with suppliers “Saveral never stops: in 2014, we started

a modernisation project to guarantee

Figure 8: The line is able to handle workpieces with maximum dimensions of H 2500 x W 6000 x D 2000 mm.

8 1

Over the years, it has become increasingly important to equip Saveral with pre-treatment and coating lines that guarantee greater quality and production flexibility. That is why it turned to M.I. Due, which took care of the design and installation of all the coating plants now present in our factory. ”

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Figure 9: The inside of the pre-treatment tunnel.

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Â© Saveral

FOCUS ON TECHNOLOGY

Figure 10: The coating booth.

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119

business by making Saveral even more competitive and strengthening its market position. In the past, we could only treat our parts in our pre-treatment systems and then transfer them to the coating lines. The new plant has reduced production times by around 30%, with a positive impact on production costs,” states Montesanti. “As for the powders applied, it is important for us to guarantee a high quality level to our customers. We use more than 500 powder coating types and we buy about 500 tonnes of powder a year from both Italian and foreign manufacturers, with whom we work closely together to develop unique solutions.” “Saveral also deals with upstream and downstream processes, from pre-assembly to assembly, serigraphy (Fig. 12), and packaging. That is why quality and control are crucial factors for us,” says Montesanti. “We are already ISO 9001-2015 certified. Starting from April 2018 is in place the “Administrative Responsibility of Companies” certification conforming the Italian Legislative Decree no. 231/2001. Soon we will also obtain the ISO 14001 and ISO 18001 certifications.” “Although the new plant has only been in operation for a few months, we have already been approached by several new customers. Having highly efficient coating lines and being even more flexible in terms of production has enabled us to grow a lot and continue

11 1

Figure 11: The entry of the curing oven.

The collaboration with M.I. Due has allowed Saveral to implement its projects and confirm its reputation as a company offering flexible productions with low lead times. Especially thanks to the last plant, it has expanded the business by making the company even more competitive and strengthening its market position.”

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Figure 12: Saveral has a department dedicated to additional processes, such as serigraphy.

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Tutti i colori in pochi minuti

www.salcomix.com www.akzonobel.com

0087–04019

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 diversità di prodotto.

Opening photo: With over 200 tints applied including RAL colours, special colours, and primers, Metalux is a benchmark powder coating contractor in the whole Marche region.

FOCUS ON TECHNOLOGY

At Metalux, the Pre-Treatment Process Becomes Decisive for Obtaining the Powder Coating Quality Label Monica Fumagalli ipcm®

he elements that characterise a

certifications for the application technologies

contractor, but also a pride for the partners

winning business strategy in the

used. A quality certification is not a mere

that have developed the plant systems and

coating contracting field include the

seal with which coating processes are

chemical products with which the certified

frequent updating and renewal of plants

labelled as high quality treatments. It can

products are processed.

and products to adapt to the continuous

become a growth tool to face a market

“Metalux Trattamenti e Finiture (Castelfidardo,

evolution of the market and the search

that is made even more complex by the

Ancona, Italy) was established in the 1980s

for productive solutions to obtain quality

fragmentation of the sectors served by the

for metal polishing,” says Giacomo Bettucci,

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FOCUS ON TECHNOLOGY

currently at the helm of the company

The paintshop structure

with maximum dimensions of

(Fig. 1). “With time, its core business

In addition to the three powder coating

2000 x 1500 x 5000 mm

has become the application of powder

lines, Metalux is equipped with a shot

(up to 5500 mm for linear workpieces).

coatings. It was however completely

blasting system to remove any oxidation,

It mainly treats metal carpentry, fence,

transformed in 2008, when my brothers

calamine, and other residues deposited

and urban furniture components,

and I inherited the company created

on the components to be treated (Fig.

and in general any kind of product

by our father and, at the same time,

2). “We have structured our factory so

requiring excellent outdoor resistance.

a negative economic period began.”

that our coating lines have different

The plant features a one-rail conveyor

During these ten years, Metalux has

characteristics in terms of shape

and it consists of a nanotechnology

faced several market fluctuations,

of the parts treated and chemicals

pre-treatment system installed by

the go-to contractor in the

Dollmar in 2011 and a

but it is now back to being

new generation, quick

Marche region for a large

colour change coating

group of customers from the

booth equipped with

most diverse sectors, such as

photocells and a robot

street furniture, household

(Fig. 3).

appliances, lighting, interior

The #2 line is devoted

and exterior furnishings,

to small workpieces

construction, automotive,

(1800 x 800 x 2000

and metal carpentry (ref.

mm). These are

Opening photo). Precisely

pre-treated with a

this extreme diversification has

phospho-degreasing

allowed us not to tie ourselves

process using iron salts,

to a particular sector and,

suitable for metal alloys

therefore, not to suffer any market. “For our company, it has also been crucial to continue

of different types, such

stagnation or crisis in a specific

as zinc and aluminium,

Figure 1: From left to right, Metalux manager Giacomo Bettucci, Alessia Venturi from ipcm®, and DN Chemicals Sales Manager André Bernasconi.

investing in updating our

partners, including DN Chemicals (created from the merger of the Surface Treatments’ Divisions of Dollmar Spa and Noxorsokem Srl) for our pre-treatment plant. Our 4800 m2 wide factory was equipped with four coating lines: we now have only three lines, but we are able to process

such as small parts, sheet metal, and boxed parts. Its low takt time

machines and products with the collaboration of several reliable

and objects of all kinds,

enables the company to rapidly

For Metalux it has also been crucial to continue investing in updating machines and products with the collaboration of several reliable partners, including DN Chemicals (created from the merger of the chemical division of Dollmar Spa with Noxorsokem Group Srl) for the pre-treatment plant.”

meet even urgent requests for small production lots. This line is also equipped with a quick colour change booth. The #3 line is devoted to the coating of carpentry parts, profiles, pipes, furnishings, and metal components with a maximum size of 3000 x 700 x 2000 mm. The phosphochromating pretreatment

twice as many parts thanks to the

performed by this system is

implementation of new pre-treatment and coating technologies that increase

applied, but, at the same time, they are

among the highest performance ones

the value of our products and

interchangeable if we need to paint large

for galvanised steel, aluminium, and

guarantee constant monitoring

batches. This enables us to meet even

stainless steel intended for outdoor use.

of our process and consumption

the most complex requests in terms of

This line is also equipped with a quick

parameters, according to the recent

material quantity and deadlines.”

colour change booth with photocells.

innovations brought by the Industry 4.0

The #1 line is devoted to medium

“The most significant changes to our

paradigm.”

and large-sized components

factory,” states Bettucci, “were carried

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123

replacements of chemicals, which laid the foundations of our current cycle. Thanks to the collaboration first with Dollmar and now with DN Chemicals, we have implemented the best pre-treatment cycle and selected the best chemicals for our new needs.”

The evolution of Metalux’s pre-treatment process The pre-treatment cycle of the #1 line includes the following stages: alkaline degreasing + two rinses, phospho-degreasing with iron salts + two rinses, a rinse with osmotic water, and application of a nebulised multi-metal nanotechnology solution (Fig. 4). “Based on its corporate strategy aimed at finding the best possible solution for the satisfaction of its customers,” states DN Chemicals Sales Manager André Bernasconi, “Metalux has followed the entire evolution of chemical pre-treatment technologies starting from the introduction of nanotechnology, occurred in 2011 due to the need to replace hexavalent chromium, with which aluminium and galvanised steel were exclusively treated.” The choice of a solution that would enable to process components in different materials and eliminate chromium led to the replacement of the cleaning tunnel and pre-treatment tanks, as well as the chemical product. “The old plant limited the types of material that we could treat,” says Bettucci. “This issue was overcome with our multi-metal plant. We

Figure 2: The shot blasting system removes any oxidation, calamine, and other residues deposited on the components to be treated.

2 1

out in conjunction with market transformation phases, in order to adapt to new trends and offer our customers a good service as well as high quality coatings. The #1 line is the biggest one and the one on which we have invested more. Since the 1990s, its pre-treatment system has become increasingly important and it has undergone numerous modernisation operations and

Metalux has structured its factory so that the coating lines have different characteristics in terms of shape of the parts treated and chemicals applied, but, at the same time, they are interchangeable if it needs to paint large batches. This enables it to meet even the most complex requests in terms of material quantity and deadlines.”

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Figure 3: The powder coating application station of the #1 line.

FOCUS ON TECHNOLOGY

AUTOMATIC POWDER COATING BOOTHS

4 1

Figure 4: The workpieces are subjected to nebulisation in the pre-treatment tunnel.

also decided to implement a SoftRain nebulisation system because, based on a few tests, it proved to be the most functional in terms of consumption, application control in order to avoid dragging, and coating stability. This guarantees a consistent process quality level and therefore result repeatability, so much so that we intend to install this system also on our other lines (Fig. 5 and 6). As for the chemicals used, we relied completely on DN Chemicals’ suggestions for the choice of the best products for our plant, with the aim of maintaining the high quality level of our pre-treatment results. We currently use as follows: Dollcoat S434 for alkaline degreasing, Dollcoat SC183 for phosphating, and Dollcoat SA 118 for passivation.”

G RT

All the chemical products applied are constantly monitored through digital controls, in order to ensure pre-treatment uniformity and effectiveness. The tanks’ automatic parameter control system is one of the advantages found. About a month ago, Metalux introduced a further innovation: a real-time process parameter verification system able to track the whole production even after some time, thanks to a log that records all data and collects them in an archive.”

5 1

Conclusions “The #1 line is now in full operation,” states Bettucci. “Thanks to the technologies we have implemented, the next step could be the Qualisteelcoat certification, specifically related to the steel coating field. This would be in line with our continuous development philosophy: our company is already ISO 9001:2015 certified and we would like to obtain this label for the à pre-treatment cycle and basecoat + topcoat application that we perform on the #1 line, in order to increase our chance to break into new markets. “Finally, we have already started a new project with DN Chemicals to replace our phospho-chromating system in compliance with new regulations, offering alternative cycles to our customers and transferring their most particular needs to our partners. © ipcm ®

Figure 5: The SoftRain system installed in the Metalux factory.

The aim will be finding the right solution together and getting the best results. This will be a challenging project, because it will take time

Digital control of chemical products

and further investment, but we have decided to finish it

All the chemical products

as quickly as possible. Our

applied are constantly

factory is like an ever-evolving

monitored through digital

open construction site,

controls, in order to ensure

ready to incorporate all the

pre-treatment uniformity

innovations launched on the

and effectiveness. “The

market in order to remain

tanks’ automatic parameter

the go-to powder coating

advantages found (Fig. 7),” explains Bettucci. “About a month ago, we introduced a further innovation: a real-

contractor in our area.”

6 1

Figure 6: The parameter and consumption management unit.

control system is one of the

time process parameter verification system able to track the whole production even after some time, thanks to a log that records all data and collects them in an archive. A further benefit of this plant is related to waste water: the entire coating line is fed with the recovered water from the nanotechnology pre-treatment process, thus becoming a zero discharge plant.” Figure 7: The real-time process parameter verification system ensuring the traceability of the entire production.

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7 1

Opening photo: One of the plants built by Airprotech Srl (Magenta, Italy).

INNOVATIONS: PRESENT&FUTURE

Management and Abatement of Emissions Generated by Industrial Coating Processes Ruggero Baldi Airprotech Srl – Magenta, Italy

info@airprotech.eu

ndustrial coating processes using

supply of technologies and plants for air

variety of different applications, performed

solvent-based products require the adoption

purification and VOC emission control.

either automatically or manually on metal,

of systems that reduce the emission of the

the plants’ air intake. Airprotech is a leading

Fields of application of industrial coating processes

company in the design, production, and turnkey

The industrial coating sector includes a wide

volatile organic compounds VOC present in

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polymers, wood, glass, fabrics, synthetic leather, and much more. Coating processes involve the use of more or less automated and complex systems and machines,

INNOVATIONS: PRESENT&FUTURE

depending on the application. Surface finishing processes have

The use of liquid paints allows to obtain very well finished

both an aesthetic and functional

surfaces with countless aesthetic

purpose and they provide the

effects. This process is suitable

treated surfaces with chemical

for all industries requiring a high

and physical characteristics that

finishing and gloss degree of

guarantee their protection over

products or excellent resistance

time.

to external (environmental or

In the case of metal, the coating

chemical) aggressions.

process preserves their raw

Liquid coatings are divided into

surfaces against atmospheric

two main categories:

and chemical agents, in addition

namely, solvent-based and

to enhance its aesthetical aspect.

water-based products.

In the case of plastic, different

Table 1: Project data of the case study.

primers are used depending on

The former generally guarantee a higher quality level making

the raw material that makes up the

the surfaces smooth and shiny, precisely thanks to the use of solvents that

adhesion of the applied coating film.

Industrial coatings and application technologies

Another important application field is that

There are two main coating processes,

optimal results and at the same time high

of wood and its derivatives, which generally

requiring different technologies and

chemical resistance. Water-based coatings,

includes the sectors of furniture and design.

featuring different characteristics:

on the other hand, were developed with the

namely, liquid and powder coating.

aim of reducing the presence of potentially

The choice between the two systems

toxic components in paints. However, they

The plants used are mostly spray coating

is based on the specific application

provide lower quality finishes due to the not

machines, booths, or continuous flow

needs, the materials to be coated

perfectly homogeneous drying phase.

lines painting with pump and gun devices

and the required results.

that can finish components with various

The main difference lies in the drying

sizes and shapes. Pressurised booths

temperatures, which are higher in

are closed systems that allow to obtain

the case of powder coating (about

Management and abatement of emissions generated by industrial coating processes

top-level aesthetic and functional results

140-180 °C), thus limiting its fields

In coating processes using solvent-based

thanks to a controlled atmosphere

of application. Liquid coating, on the

paints, a key role is played by the part of

environment. This type of plant must

other hand, generally guarantees

the plant dedicated to the management

be designed with extreme accuracy

more flexibility and a wider range of

and abatement of emissions. The presence

in order to prevent dust and other

possibilities, in addition to simpler

of volatile organic compounds VOC as

impurities from entering the system and

drying systems reaching lower

solvents in the coating products requires

thus compromise the final quality of the

temperatures (about 60-80 °C).

the adoption of abatement systems

substrate, in order to guarantee maximum

Types of coating plants

product. Continuous flow

ensure a homogeneous drying process,

lines are composed of rail conveyors or carousels.

to comply with the emission limit values of waste gases. Indeed,

They are employed for

during application and

the industrial coating of

drying, the solvents

large-sized parts or large

contained in the

quantities of workpieces

paints evaporate and

and they can operate in a

they must be suitably

manual, semi-automatic,

sucked and conveyed

or fully automatic mode

to a system that

depending on the customer’s needs and production processes.

Figure 1: The pre-concentration process.

prevents them from being released into the atmosphere.

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129

ÂŠ Airprotech Srl

The purification plant consists of two basic units: a pre-concentration unit using a zeolite wheel and a efficiency RTO regenerative thermal oxidizer that guarantees high-energy efficiency. The operating principle of the pre-concentration wheel is based on the properties of the zeolite rotor.â&#x20AC;? Zeolites offer great advantages because they are not combustible, they are inert, very stable, and resistant to water and acids, and

2 1

they can withstand high temperatures.

Figure 2: A comparison between the investments required by a regenerative thermal combustor and by a system including pre-concentration and regenerative thermal combustion processes. Such investment costs include the amortisation costs of the emission treatment plant, its maintenance costs, and financing costs.

The process takes place in three distinct, but connected and interconnected phases (Fig. 1): Adsorption (A): the process air from the production departments is conveyed to the pre-concentration unit, where it is

An emission abatement system for a furniture panel coating plant

The operating principle of the pre-

purified when passing through the

concentration wheel is based on the properties

roto-concentrator. Then, it can be sent directly

Here below, we present the example of a

of the zeolite rotor. This is the core of the

into the atmosphere by means of a chimney.

typical solvent emission abatement system

system and it is made up of active adsorbent

In this phase, the zeolites are loaded with the

developed for a coating plant treating panels

material contained in a rotating structure.

pollutants removed from the process gas.

This includes various automatic coating lines and carousels connected to a main air purification plant. Table 1 shows the project

ÂŠ Airprotech Srl

and profiles for the furniture industry.

data related to this case study. Given the need to reduce VOC emissions and considering the low concentration level, has been foreseen a system composed by a pre-concentration unit plus a regenerative thermal oxidizer RTO (ref. Opening photo). This purification plant consists of two basic units: a pre-concentration unit using a zeolite wheel and a RTO regenerative thermal oxidizer that guarantees high-energy efficiency.

Figure 3: A comparison between the operating costs of a regenerative thermal combustor and of a system including pre-concentration and regenerative thermal combustion processes. Such costs include the cost of auxiliary fuel and electricity.

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INNOVATIONS: PRESENT&FUTURE

A small part of process air, up to 10-15 times less than the total capacity, is removed before entering the zeolite wheel and sent to the K sector. It is then used for the desorption of the pollutants transferred to the zeolite wheel. Cooling (K): the desorption air taken from the process gas upstream of the plant passes through the rotor, thus cooling the newly regenerated wheel K sector. Desorption-concentration (R): the desorption air is heated to a pre-set temperature and sent to the R desorption sector, where it is loaded with solvents while regenerating the rotor. The flow exiting the desorption zone, loaded with VOC, is sent to the thermal oxidizer, where the concentrated flow is completely purified by the solvent. Regenerative thermal oxidizers RTO are specifically designed to destroy the pollutants through thermal oxidation at high temperature, the chemical energy contained in the pollutants is transformed in thermic energy to sustain the combustion itself. Design is focused to optimize the gas mix and distribution inside the combustion chamber, to achieve the required residence time for a complete oxidation process. The polluted gases are burned together with the support fuel such natural gas, LPG, gas oil etc. Regenerative thermal oxidizers exploit the capacity of a mass of inert material to accumulate cyclically and give back the heat generated by the combustion process. The efficacy of the thermal recovery can reach up to 96%, thus drastically reducing the consumption of the support fuel and consequently the plant operating costs. Energy efficiency is guaranteed by optimal system sizing, the optimisation of each phase of the pollutant abatement process, the use of the proper ceramic materials and the overall quality of the plant itself. This pre-concentration and regenerative thermal combustion system is the ideal plant solution for the treatment of significant airflows containing low concentrations of pollutants, which would otherwise require large-sized plants with high management costs. As shown by the graphs, this plant has substantially reduced the management costs faced by the customer each year. As shown by Figures 2 and 3, in this specific case a regenerative thermal combustor alone, although effective in terms of compliance with emission limits, would not have proved to be the most suitable and sustainable technical solution in terms of operating and management costs.

SUCCESS STORIES

Henkel’s New Bonderite E-CO DMC Digital Multichannel Controller Helps Customers Optimize the Performance and Cost of Metal Pretreatment Processes

enkel has introduced a new

it maximizes the benefits derived from

neighbouring buildings. It can control a

process control system that

Henkel’s leadership in sustainable metal

virtually unlimited number of process

addresses key challenges in

pre-treatment technologies and process

parameters and devices.

metal pre-treatment as customers

expertise.”

Further Bonderite E-CO DMC is equipped

are increasingly seeking to implement

Bonderite E-CO DMC minimizes chemical

with an internal memory that stores all

data-driven Industry 4.0 solutions. In

usage, water and power consumption as

parameter data and events for creating

combination with the company’s New

well as waste. In addition, it helps to avoid

numerical, graphic and consumption

Generation Conversion coatings (NGC)

manual work and chemical exposure in

reports as well as maintaining a historical

for multi-metal substrates, the Bonderite

metal pre-treatment. All equipment and

database. The controller’s comprehensive

E-CO digital multi-channel (DMC)

process setup, adjustment, control and

connectivity easily links the system to

controller enables maximum corrosion

monitoring can effectively be managed by

other resources in local area networks

performance and sustainability at

the controller, including bath preparation

and provides access for remote devices,

minimized overall process costs.

and refill. The multi-channel system

such as tablets and smartphones.

Bonderite E-CO DMC is a process control

supports both single and multiple

It enables alerts with discrete data to

system that allows users to run complex

production lines in one and the same or

be sent to selected recipients by SMS or email and can be

up to fifteen or more stages. It

integrated in cloud-based

features an intuitive touch screen DMC (PLC) interface and supports

metal pre-treatment lines with

data-driven solutions. “The system underscores

fully digitalized process control

Henkel’s total solutions

with flexible communication and

approach and our

remote access functionality

commitment to

(Fig. 1).

supporting customers as

“Thanks to its adaptive open

they implement Industry

system architecture, our new

4.0,” adds Brancaleoni.

digital multi-channel control

“Users can run automatic

system will easily integrate

parameter checks and

in metal customers’ existing

even automate the

conversion processes and

dosage of chemicals

automation concepts,” says

in the tanks by using

Maurizio Brancaleoni, Global

a special function to

Business Development Manager

correlate analysed data with outputs – all without

Henkel’s European Functional Coating Equipment Center in Funo di Argelato (Bologna, Italy) (Fig. 2). “Together with our New Generation Conversion coatings,

132

Figure 1: The Bonderite E-CO DMC controller has an intuitive touchscreen and an internal memory for storing a virtually unlimited number of process parameters in metal treatment lines of up to 15 or more stages.

N. 56 - MARCH/APRIL 2019 - international PAINT&COATING magazine

involving any personnel on site.” While the performance benefits of Bonderite

SUCCESS STORIES

Get more from water

2 1

Figure 2: Maurizio Brancaleoni, Global Business Development Manager at Henkel’s European Functional Coating Equipment Center in Funo di Argelato (Bologna, Italy).

Turnkey solutions for industrial waste water treatment Spraybooth water treatment systems and chemicals Chemical-physical systems Sludge compactors Reverse osmosis & ion exchange water demineralization units De-oiling & degreasing units

E-CO DMC can be tapped with any of Henkel’s existing metal pre-treatment process, including conventional phosphating, the technology unfolds its maximum sustainability in combination with

Filtering systems Water treatment chemicals & consumables Technical service & maintenance of water treatment systems

the company’s New Generation Coatings. As zirconium-based alternatives for multi-substrate metal conversion and corrosion protection, these NGC contain neither phosphates nor heavy metals, simplify water management and can reduce process steps, contact times, energy consumption and sludge. Leaving only a nano-thin non-toxic coating layer on substrates, Henkel helps customers to optimize the cost, control and reliable quality of production. The European Functional Coating Equipment Center, based in Funo di Argelato (Bologna), Italy plays an instrumental role in the success of Henkel’s innovative new metal pre-treatment solutions with a full line of dedicated Bonderite process control and automation systems. The Center includes a Development Department, a Warehouse and a Maintenance Lab. The Bonderite E-CO DMC system is available throughout Europe and North America, and belongs to a complete range of application, control and support equipment for Bonderite metal pre-treatment processes from Henkel.

info@waterenergy.it

www.waternergy.it

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FOCUS ON TECHNOLOGY

MagicCylinder® EquiFlow®: The New Powder Coating System Installed by the Procicchiani Group Ilaria Paolomelo ipcm®

hen a company’s mission is

as a leader in the fields of sheet metal

painting sector for the ACE industry

focussed on understanding

processing and metal surface treatment,”

in the past, the surface treatments

its customers’ needs and

says Enrico Procicchiani (Fig. 1), the

we have provided to many leading

meeting them by providing products

owner of the Procicchiani Group together

companies in the household appliance

and services of excellent quality,

with his brother Franco. “We are a

sector for several years have led us

it is crucial for it to carefully select

complete contractor company, with fifty

to reach a high quality level in terms

its commercial partnerships. The

employees and three factories. We deal

of both pre-treatment and finishing,

Procicchiani Group was established in

with light metal carpentry, liquid coating,

which we can now apply on any type of

1980 with this strategy in mind. Located

powder coating, assembly, and in some

product (Fig. 2).

(Ancona), the Procicchiani Group

Precisely our focus

in Central Italy, in Monsano

on quality recently

immediately established itself

prompted us to install an

in the liquid coating contracting

innovative powder coating

sector. However, in the 1990s

system: Gema Europe’s

did it strengthen its position in

MagicCylinder® EquiFlow®

the market thanks to the start

(Fig. 3).”

of new collaborations and the services and processes that

Procicchiani’s paintshop

attracted many well-known

The coating line is

companies in the household

equipped with a five-stage

appliance and electromechanics

pre-treatment tunnel,

development of innovative

sector. evolved in these thirty-nine years in order to keep up with market changes. Established

performing as follows:

“Our company has significantly

phosphodegreasing, two

Figure 1: From right to left, Marzio Marcolini from the technical sales department of Gema Europe and Enrico Procicchiani, the owner of the Procicchiani Group.

with the aim of providing

rinses with mains water, a rinse with demineralised water, and nebulisation of the nanotechnology

coating services mainly to the built-in

cases even screen printing. We can also

passivation solution with a Soft-Rain

appliance sector, in 2008 it converted

offer further services according to our

device. “The choice to install the

its production, doubled the range of

customers’ needs, in order to become

Soft-Rain system to apply the passivation

processes performed, and embraced a

their sole subcontractor. Within our

product stemmed from our willingness

vast number of target sectors, including

production department, however, coating

to enhance our coating department with

automotive, electromechanics, and

is our forte. In addition to the long-

a cutting-edge pre-treatment system,

furniture. Finally, it established itself

standing experience I gained in the liquid

but without revolutionising our existing

Opening photo: The coating application occurs through two reciprocators and eight new generation OptiGun GA03 guns.

international PAINT&COATING magazine - MARCH/APRIL 2019 - N. 56

135

2 1

One of the reasons why Procicchiani Group opted for this type of system was its need to solve the problems it had encountered with the previous booth. These included a difficulty in performing quick colour change operations. As the company was very pleased with the choice made in 2007, in 2018 it decided to expand the coating department by adding a new booth and installing Gema’s new MagicCylinder® EquiFlow®.”

Figure 2: Some examples of parts coated by the Procicchiani Group.

treatment line,” explains Procicchiani.

performs ten to twelve colour changes per

management unit (Fig. 4), with a capacity of 5

Procicchiani’s paintshop features

day, to increase production speed and thus

kg, is completely sealed to minimise pollution

three production lines, two of which

optimise production,” states Marzio Marcolini

and powder dispersion. It is also equipped

are dedicated to powder coating and

from the technical sales department of

with an automatic fresh powder replenishment

equipped with Gema systems. The

Gema Europe. “Unlike the machine installed

system, collecting the product directly from the

company’s collaboration with the Gema’s

in 2007, the new OptiCenter OC02 powder

box next to the machine. The lower amount of

the Group decided to replace one of its booths with a MagicCylinder® machine.

Italian branch started in 2007, when

“One of the reasons why we opted for this type of system was our need to solve the problems we had encountered with the previous booth,” states Enrico Procicchiani. “These included a difficulty in performing quick colour change operations. As we were very pleased with the choice made in 2007, in 2018 we decided to expand our coating department by adding a new booth and installing Gema’s new MagicCylinder® EquiFlow®.”

Features of the new plant “One of the main characteristics of MagicCylinder® EquiFlow® is precisely its very quick colour change process, taking between 5 and 15 minutes. This has enabled the Group, which

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3 1

Figure 3: The innovative MagicCylinder® EquiFlow® powder coating system supplied by Gema Europe.

FOCUS ON TECHNOLOGY

4 1

Figure 4: The new OptiCenter OC02 powder management unit.

powder into play compared with the previous system further speeds up the colour change operation. Moreover, the updated cyclone recovery system enables to automatically recover a large amount of raw material, thus ensuring the constant availability of an equal volume of fresh and sieved powder, whereas the ultrasonic sieving system guarantees the high quality level of the recovered powder.” “The edge-free cylindrical shape, the non-conductive walls, and the new self-cleaning floor of MagicCylinder® are other important features that ensure fast cleaning operations. The plant also includes two reciprocators and eight new generation OptiGun GA03 guns (ref. Opening photo).” “The booth installed by Procicchiani is completely in line with the Industry 4.0 principles. The new generation MagicControl 4.0 (CM40) software program gathers and monitors all

5 1

Figure 5: A detail of the OptiFlow injectors.

the parameters and data related to

stems from the high variety of shapes and

booth, we have found several advantages.

the powder application process. Its

sizes treated by our company and, above all,

First of all, as already mentioned, powder

connection is designed for better remote

our frequent batch change operations, as we

saving has improved and, currently, it

supervision and assistance and it allows

also paint very small lots. The new OptiFlow

is around 15-20% compared with the

to customise countless programs that

technology guarantees optimal powder flow

previous installed booth. Nowadays,

can be used at any time. Finally, the booth

and minimises the Venturi injector’s wear, thus

it is essential for a company to check

features a system for workpiece shape

ensuring constant flow over time,” explains

its consumption in real time in order

recognition and automatic adjustment of

Procicchiani.

to identify any possible areas for

the gun-part distance,” says Marcolini.

“The CM40 management software program

improvement. Our colour changing and

manages a parameter for the daily adjustment

booth cleaning speed allows us to optimise

of the powder flow rate based on the state

production and quickly meet customer

“When we decided to expand our

of wear of the Venturi injector. This daily

requests. Another advantage offered by

paintshop, we had to choose between

adjustment, set according to the coating

Gema is the excellent assistance service

dense phase powder pumps and

program and the type of powder used,

that the company has been supplying for

conventional pumps with Venturi

compensates for any flow rate loss, thus

about twelve years. Last but not least, our

injectors, specifically the new IG07 pump

ensuring spraying consistency and coating

products present a very high quality level.

with an OptiFlow injector (Fig. 5). The

uniformity,” says Marzio Marcolini.

We are all very pleased and optimistic,”

reason why our choice fell on the latter

“Since we installed the new MagicCylinder®

says Procicchiani.

The reasons for a choice

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STANDARD & LEGISLATION - UCIF Informs

Sustainable Growth Fund Marcello Zinno UCIF – Italian Surface Treatment Equipment Manufacturers’ Association, Milan, Italy

info@ucif.net

he Decree of 21 November 2018

and business development in complex crisis

structure, the reuse of production facilities,

called ‘Allocation of resources from

areas.

and the relaunch of the economy of areas in situations of complex crisis of national

the Sustainable Growth Fund to

importance, achieved by signing program

interventions of conversion and productive

The Fund is intended for the financing

requalification of areas affected by the

of programs and projects with a

industrial crisis’ was issued in the Official

significant national impact on production

Journal of the Italian Republic in February.

competitiveness, especially for the following

companies and the attraction of foreign

The regulation allocates resources from

purposes:

investments, also in connection with the

the Sustainable Growth Fund to the

• the promotion of research, development,

actions that will be carried out by the

agreements; • the promotion of the presence of international

conversion and requalification operations

and innovation projects of strategic

Agency for the promotion abroad and the

referred to in the law no. 181/1989,

importance for relaunching the

internationalisation of Italian companies (ICE).

specifically referring to the coverage of

competitiveness of the production

the costs of the agreement between the

system, also through the improvement of

All the details relating to the Fund are

companies’ R&D centres and structures;

available on the website of the Ministry of

Ministry of Economic Development and the national agency for attracting investments

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N. 56 - MARCH/APRIL 2019 - international PAINT&COATING magazine

• the strengthening of the production

Economic Development.

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APRIL 2019 BAUMA MRO AMERICAS

Munich, Germany April 8-14, 2019 www.bauma.de Atlanta, USA April 9-11, 2019 https://mroamericas.aviationweek.com/en/home.html

MACTECH & INNOTECH

Sofia, Bulgaria April 15-18, 2019 www.machtech.bg

INTERMOLD

Tokyo, Japan April 17-20, 2019 www.intermold.jp

POWTECH

Nuremberg, Germany April 9-11, 2019 www.powtech.de

INTERSTROY EXPO

St. Petersburg, Russia April 18-20, 2019 www.interstroyexpo.com

CHINA REFRIGERATION

Shangai, China April 9-12, 2019 http://www.cr-expo.com

MINING WORLD RUSSIA

St. Petersburg, Russia April 18-20, 2019 www.miningworld.ru

POLYURETHANEX

Moscow, Russia April 23-25, 2019 www.polyurethanex.com

ALUMINIUM 2000 SALONE DEL MOBILE

Treviso, Italy April 9-13, 2019 www.aluminium2000.com Milano, Italy April 9-14, 2019 www.salonemilano.it

MAY 2019 AISTECH

LAMIERA

Rho, Italy May 15-18, 2019 www.lamiera.net San Diego, USA May 19-24, 2019 www.icmctf.org

EASTERN COATINGS SHOW

Atlantic City, USA May 13-15, 2019 www.easterncoatingsshow.com

ICMCTF

ASIA COATINGS CONGRESS

Hochimihn City, Vietnam May 14-15, 2019 www.coatings-group.com/acc

ENGINE EXPO

MADE IN STEEL

Milan, Italy May 14-16, 2019 www.madeinsteel.it

Stuttgart, Germany May 21-23, 2019 www.engine-expo.com

SF EXPO CHINA

Guangzhou, Cina May 21-23, 2019 www.sf-expo.cn

Basel, Switzerland May 14-17, 2019 www.swisstech-messe.ch

COAT EXPO

Guangzhou, Cina May 21-23, 2019 www.coatexpo.cn

AQUA-THERM KIEV

Kiev, Ukraine May 14-17, 2019 www.kdm-international.com/aqua-therm-kiev/

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Guangzhou, Cina May 21-23, 2019 www.chinaplasonline.com

WORLDBUILD KYIV

Kyev, Ukraine May 14-17, 2019 www.worldbuild-kiev.com.ua

SWISSTECH

MOULDING EXPO

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Brno, Czech Republic May 15-16, 2019 www.stainless2019.com

INTERZUM

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Zurich, Switzerland May 15-16, 2019 www.architectatwork.ch

MATERIAL WEEK OSAKA

EUROFINISH

142

Pittsburgh, USA May 6-9, 2019 www.aist.org/conference-expositions/aistech/

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N. 56 - MARCH/APRIL 2019 - international PAINT&COATING magazine

BIE

Stuttgart, Germany May 21-24, 2019 www.messe-stuttgart.de/moulding-expo/en/ Cologne, Germany May 21-24, 2019 www.interzum.com Osaka, Japan May 22-24, 2019 www.coating-kansai.jp Brescia, italy May 23-25, 2019 www.fierabie.com

Fiera specialistica internazionale per materiali, componenti e sistemi industriali

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FIERA SVIZZERA SPECIALIZZATA PER MACCHINE UTENSILI, UTENSILI E TECNOLOGIA DI MISURA

ZOOM ON EVENTS

The Coatings Summit 2019: The Meeting Point for Global Industry Leaders to Discuss the Main Sector Trends, Challenges, and Solutions he whole spectrum of

Sustainability was a much-discussed

coatings manufacturers

topic: sustainable raw materials,

and raw material suppliers

the switch from solvent-based to

met in Paris from January 30 to

water-based coatings, and the

February 1st, on the occasion of

awareness not only of producers

The Coatings Summit, organized by

but also of consumers are among

IPPIC (International Paint & Printing

the key elements that are driving

Ink Council™) and Vincentz Network.

the pursuit of this practice. The last

ipcm took part in this important

speech to close the summit was

forum to get to know, analyse, and discuss the latest global trends, challenges, and innovative solutions

of a Dynamic Industry”. Possible strategies for global growth were

manufacturer Industrias Titan, who asked the audience an interesting question: is the coating industry a conservative industry? Data show

held in the elegant setting of The the slogan “Shaping the Future

CEO of Barcelona-based coating

Figure 1: The Coatings Summit 2019 was held in Paris from January 30th to February 1st.

for the sector. The event was Westin Paris-Vendôme hotel with

delivered by Daniel Llinás Sala, the

that only 50% of firms in the sector are digitised and that digitisation is creating a significant economic gap:

discussed, as well as the significant

the companies that did not adapt

role that the Asian markets are

to the Industry 4.0 paradigm in time

starting to play, especially the

are now struggling to compete with

Chinese one, where industrial

top leaders. Nevertheless, there is

paints are the core business and

still room for improvement through

the industrial fabric is fragmented

the combination of functional

and composed of small-medium

management practices promoting,

enterprises.

for instance, staff training, with productivity and innovation.

There were also several examples of companies that have been able to grow and succeed despite the obstacles encountered along the way. These included Vitex-Yannidis,

2 1

In addition to debates and speeches of sector leaders, there

Figure 2: AkzoNobel CEO Thierry Vanlacker analysed the significant role of the Chinese coating market.

were convivial moments and networking opportunities for all participants, such as a dinner at

a Greek coating manufacturer that faced three significant challenges: the Greek financial crisis, its

La Maison des Polytechniciens, an eighteenth-century villa in the historic

own economic debt, and tensions within the owner family.

centre of Paris.

Vitex has managed to prevail, thus establishing itself among the main Greek industrial businesses and recording a 47% increase

For further information:

in sales volume in six years.

www.coatings-summit.com

international PAINT&COATING magazine - MARCH/APRIL 2019 - N. 56

145

ZOOM ON EVENTS

New Perspectives for Production: Additive Manufacturing Provides New Momentum to Industry

rom 29 till 31 January 2019 about 300

IWS-led innovation consortium AGENT-3D

but also in manufacturing sectors.

international experts meet in Dresden

alone more than 120 partners from industry

With this process, wear parts can be produced

(Germany) for the 3rd International

and science jointly work at the advancement

cost-efficiently and quickly even in small

Symposium Additive Manufacturing

of additive manufacturing processes,

batches making them immediately available

ISAM 2019 to discuss the development

also known as 3D printing. Together they

for maintenance and repair work. All needed

and future perspectives of additive

are shaping the evolution of production

for production is a computer model that is

manufacturing in application industries.

processes and launching a new printing age”,

replacing the traditional, more expensive mold.

“The venue is definitely not a coincidence”,

Prof. Leyens adds.

The layering principle allows any complex

says Prof. Christoph Leyens, Director of the

geometry or inner structure and offers almost

of the institute for Materials Science at TU

Additive Manufacturing: tool-less, cost-efficient, fast and on point

Dresden, one of the German Universities

Additive Manufacturing, in which materials

these production processes to build prototypes

of Excellence. “Dresden is one of Europe’s

are layered in order to “print” a product, tool,

of a new design that make air- and spacecrafts

leading research and innovation sites for

or prototype, is already being used in various

lighter, more flexible and more cost-efficient

industrial applications: At the Fraunhofer

traditional industries such as rail technology

(Fig. 1),

hosting Fraunhofer Institute for Material and Beam Technology IWS and Director

unlimited freedom in design and construction when handling materials. This did not go unnoticed by the aerospace industry: It uses

Agency said at the symposium. Today additive manufacturing is mostly using materials such as plastics, ceramics, synthetic resin or metal. Composites like carbon fibre composites or nanomaterials have recently gained in importance. In addition to guaranteeing specific product characteristics the integration of new functionalities into the component is a key objective of modern material sciences.

From niche technology to disruptive power Additive Manufacturing has been in the industry analyst’s eye for a long time already: The market is growing rapidly, in 2017 it reached about seven billion dollars. More and more companies seek and find their place in the value chain. Especially additive manufacturing

using metals is already making the leap from

Figure 1: Aerospace is one of the industries that use additive manufacturing, to build prototypes of a new design that make air- and spacecrafts lighter, more flexible and more cost-efficient.

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N. 56 - MARCH/APRIL 2019 - international PAINT&COATING magazine

a niche technology to industrial maturity. “Additive Manufacturing brings new momentum to production and shakes through traditional

ZOOM ON EVENTS

industries and markets”, says Prof. Leyens.

in industrial environment. In her

the components and the more flexible

Fraunhofer IWS supports established

speech “We Print to Drive: Mobility

their application even in wear-critical

players on their way to the future. The

goes Additive” Stefanie Brickwede of

applications. China is already printing whole

researchers are focusing on using different

Deutschen Bahn AG explains, which

houses.”

materials in one component, scaling

solutions additive manufacturing

The European focus is more on the

component dimensions and topologically

offers for mobility and Chang-Woo Lee

application in industrial production. For

optimizing structures. “Our partners from

of KITECH shows in “Metal Additive

these fields one also requires new materials

the aerospace industry, tool manufacturing

Manufacturing Process Technology of

and material mixes that can meet the

or medical technology benefit from our

Medical Applications in South Korea”,

increasing challenges of flexibility and

unique infrastructure”, Prof. Leyens adds.

how medical technology benefits from

stability. At the same time, costs cannot be

“We offer a wide process variety in additive

printing processes. Prof. Frank Brueckner,

ignored. “In the end, process quality and

manufacturing, our own industry-proved,

head of the Additive Manufacturing unit

productivity are the linchpins for the rung

technological systems development and

at IWS and coordinator of the Additive

in triumph of additive manufacturing – that

supporting systems for non-destructive

Manufacturing Center Dresden (AMCD),

is what international researchers put all

testing.”

which offers tool and process solutions

their know-how in for. We are happy that

for aerospace, automotive, energy,

IWS and AMCD play a major role in the

tool and mold engineering as well as

development of additive manufacturing”,

medical technology, knows: “Those are

Prof. Leyens concludes.

ISAM 2019: Experts for the next technology leap At this year’s ISAM international experts

examples for the technology’s manifold

from science and industry discuss new

application possibilities. The more reliable

For further information:

applications of additive manufacturing

the processes become, the more stable

www.isam.network

Dates Announced for the 2019 Powder Coating Summit

aint & Coatings Industry magazine and the Powder

“We are currently setting up an agenda chock full of

Coating Research Group have announced dates

innovation spanning powder coating materials, processes

for the 2019 PC Summit. This year’s event has

expanded to include a short course on powder coating formulation, cleverly dubbed the PC Kitchen. This short course will be held in the PCR Group lab on October 1-2, and the PC Summit will be hosted at the Polaris Hilton in Columbus, OH on October 3-4.

and industry trends.” The PC Summit is a powerful, annual event offering engaging lectures and fascinating lab demos from the nation’s top raw material technologists, equipment suppliers, pretreatment experts and formulators. You’ll learn the latest powder

“Back by popular demand and

coating technology and industry

expanded to include an intensive

trends that will help you obtain

formulator’s course, the 2019 PC

that competitive edge to not just

Summit has something for every

survive, but thrive.

powder coating technologist,” says Kevin Biller, aka Joe Powder,

For further information:

and the founder of the Summit.

www.pcimag.com/powder-coating-summit

international PAINT&COATING magazine - MARCH/APRIL 2019 - N. 56

147

ZOOM ON EVENTS

he 13th Guangzhou International Surface Finishing, Industrial Paint

Focus on the Surface Finishing and Industrial Coating Event in Southern China and Coatings Exhibition will be held in Poly World Trade Center on May 21-23, 2019. The scale is estimated to reach 20,000 sqm. More than 300 domestic and overseas enterprises will come to exhibit, including WAGNER, ABB, Gema, Chemetall, PAT, Parker Engineering, UYEMURA, Helm Hellas SA, New Fortune, Potencer, Ching Feng, Mengde, Pentatomic, XIN LI GUANG, NIPPON, TONSON etc. The exhibits cover the latest technologies and products such as paint & coating line, industrial coatings, powder coatings, coating equipment

and accessories, electroplating equipment and raw materials, finished products of industrial coatings, coating intelligent

Figure 1: The 13th Guangzhou International Surface Finishing, Industrial Paint and Coatings Exhibition will be held in Poly World Trade Center on May 21-23, 2019.

manufacturing, electroplating waste water treatment, electroplating and

SF EXPO has been approved by UFI

products etc. And surface finishing

coating waste gas treatment etc. It will be

since 2012 and audited strictly by UFI

is an important part of industrial

the biggest and most influential surface

annually. In November 2018, SF EXPO

manufacturing, so there is a huge

finishing, paint and coating industry event

won the “the most valuable brand of

market in South China. More than

of 2019 in South China.

exhibition” honour of the 2018 Golden

450 exhibitors and 25,000 visitors will

In the meantime, concurrent events are

Finger Award of China Event Industry.

gather in Poly World Trade Center on

essential, including but not limited to The

SF EXPO is based in the Pearl River

May 21-23, 2019.

Fifth International Summit on Surface

Delta of Guangdong Province where

Let’s meet at the most influential

Finishing Industry Development, 2019

is the most important manufacturing

surface finishing industry event of

China (Guangzhou) Automotive Surface

base for automobile & parts,

2019 in Southern China!

Engineering & Anti-corrosion Technology

home appliance, digital products,

Seminar, 2019 Asia-Pacific Powder Paint &

IT, electronics, hardware, sanitary

For further information:

Coatings Application Technology Summit.

products, plastics, aluminium

www.sfexpo.cn/en

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ZOOM ON EVENTS

Milano Is Getting Ready for the Third Edition of Packaging Première, the Selective Exhibition Dedicated to Luxury Packaging

ilan is getting ready to host

wish to boost this percentage to 40-50%

Art and design will have a leading role within

the third edition of Packaging

in a long-term time frame, thus proving

Packaging Première: design represents an

Première, the selective

the global allure of the event” underlines

essential element, a source of inspiration

exhibition dedicated to luxury packaging,

Pier Paolo Ponchia, organizer of Packaging

for new products and materials. The Art

taking place from May 28th to May 30th in

Première. “This upcoming edition confirms

Gallery, which last edition was dedicated

the new larger spaces of the renowned

an increased number of exhibitors

to paper, this year will emphasise artists

exhibition centre of Fieramilanocity.

compared to the last season, as well as

that use various materials such as wood,

Packaging Première is the one and only

an enlarged itinerary, without losing the

plastic and glass to create artistic elements.

event in Italy dedicated to the packaging

quality, our key value”.

industry, considered as an efficient marketplace for designers, manufacturers and international brands

material generally used for packaging that, through an artisanal process, can become an artwork.

discerning packaging as

Lorenzo Petrantoni, the

a pivotal communication

renowned artist creating

element, especially for high

illustrations through the

quality products.

assembly work of antique

Ruled by strong brand

dictionaries from the

personalities, luxury

nineteenth century, has been

packaging develops original

appointed image consultant.

expressive forms, thanks

The exhibition will be

to the efficient supply

enriched by conferences

chain, designed to pursue

dedicated to exhibitors –

excellence at its best, from raw materials to final products. Packaging Première offers previews, ideas, innovations and a precious help to understand trends

thus able to illustrate their

successful case histories

Figure 1: Packaging Première the selective exhibition dedicated to luxury packaging, is taking place from May 28th to May 30th in the new larger spaces of the renowned exhibition centre of Fieramilanocity. It is the one and only event in Italy dedicated to the packaging industry.

– as well as to the research – thanks to the survey conducted by Smithers Pira, the worldwide authority in the packaging industry.

and market situation. The event, launched in 2017, aims to

Among the Italian and international

increase the number of international

exhibitors showing for the first time at

Packaging Première – Shaping Luxury

exhibitors and visitors. “Every year

Packaging Première we can find also

Fieramilanocity Hall 4

we notice a growing interest in

niche sectors, such as fabrics, upholstery,

May 28th – 30th 2019

the exhibition from international

primary plastic or glass packaging and

companies. In 2017 international

components, creating a perfect balance

For further information:

exhibitors represented the 25%, we

among the different industries.

www.packagingpremiere.it

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Dr. Antonio Tolotto: Marine and industrial anticorrosive coating cycles

Dr. Fulvio Zocco: Environment and quality

Kevin Biller The Powder Coating Research Group

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