The first international magazine for surface treatments
®
ISSN 2280-6083
ipcm digital on In this issue :
SPECIAL ON RAW MATERIALS, PIGMENTS, PAINTS& COATINGS
INTERNATIONAL PAINT&COATING MAGAZINE
www.myipcm.com 2019
10th Year - Bimonthly N° 55 - JANUARY/FEBRUARY
S PAC E S H U T T L E L AU N C H
Our obsession with collaboration leaves us standing in awe. We know the result is only as good as those who make it, and we’d never dare to go it alone. We work so closely with our customers that we anticipate their needs before they do. Exploring all possible solutions together ensures that every vision illuminates exactly as imagined.
W E ’ R E O B S ES S E D W I T H C O LO R Visit: oem.sherwin-williams.com; Contact: inver@sherwin.com
EXPLO RATIO N TOWER AT PORT CANAVERA
L, FLORI DA
MOMENTS AFTER SUNRISE
© ipcm ®
© Dariusz Jarzabek
CONTENTS JANUARY/FEBRUARY 2019
S P E C I A L O N R AW MATER I A L S , PI G MEN TS , PA I N T & C OATI N G TEC H N OLOG I ES
INNOVATIONS: PRESENT&FUTURE
HIGHLIGHT OF THE MONTH
Multi-Curing Waterbased PU Dispersion: Faster Drying, Robustness and Improved Performance Even Under Poor UV-Curing Conditions © Emil Frei GmbH & Co. KG
46 © ipcm ®
28
Euromask® Increases Its Hook Packaging Automation Level
S P ECI AL O N RAW M ATERI ALS , P I G M E N T S , PAI N T &CO ATI N G TECH N O LO G I E S
S P E C I A L O N R AW MATER I A L S , PI G MEN TS , PA I N T & C OATI N G TEC H N OLOG I ES
INNOVATIONS: PRESENT&FUTURE
HIGHLIGHT OF THE MONTH
54 03 04 10
Chemtec Expands its Plant and Develops a Laboratory Test Contracting Service
EDITOR’S LETTER
16
VOC-compliant Coating: Ultra-high-solid Platform Technologies
FOCUS ON TECHNOLOGY A New Application Technology with a 3D Part Scanning System and a Dynamic Reciprocator to Optimise the Production Time and Quality Level of Complex Products
BRAND-NEW HIGHLIGHT OF THE MONTH An Internationally Oriented, Technologically Advanced Company Closely Cooperating with Excellent Businesses: Lesta’s Success Story in the Field of Robotics for Industrial Coating
66
22
HIGHLIGHT OF THE MONTH The New ADAPTA APP, a Pioneer in the Powder Coatings Market as for Sustainability and Efficiency
24 25
BRAND-NEW SUSTAINABILITY
26
SUCCESS STORIES Ding Dong Merrily on High
33 34 38
S P E CI A L ON R AW M AT E R I A L S , P I G M E N T S , PA I N T & C O AT I N G T E C H N O LO G I E S
BRAND-NEW SUSTAINABILITY - 5 ON 5 Five on Five Interview: Sustainability According to the Industry Players
Orange Peel & DOI wave-scan
Multi-angle Color & Eect BYK-mac i
Measure what you see.
BYK-Gardner your only choice for color & appearance control of metallic ďŹ nishes www.byk.com/instruments
Mottling cloud-runner
© Graco
© Fraunhofer IAP
CONTENTS JANUARY/FEBRUARY 2019
S P ECI AL O N RAW M ATERI ALS , PI G M E N T S , PAI N T &CO ATI N G TECH N O LO G I E S
INNOVATIONS: PRESENT&FUTURE
The Evolution from Single Component to Plural Component Paint
© BASF
80
Lacquering Before Polishing: Technical Coatings for Additive Manufacturing
INNOVATIONS: PRESENT&FUTURE
© ipcm ®
76
S P E C I A L O N R AW MATER I A L S , PI G MEN TS , PA I N T & C OATI N G TEC H N OLOG I ES
FOCUS ON TECHNOLOGY
108 58
HIGHLIGHT OF THE MONTH
Prifer and Solintellysys Develop an Innovative Compact Coating Line that Applies both Liquids and Powders
HIGHLIGHT OF THE MONTH
94
Novaresine: The Sustainable Approach of a Chemical Company Open to Everyone
70
HIGHLIGHT OF THE MONTH Research and Technological Innovation as the Cornerstones of Industrias Titan’s Philosophy
88
116
BASF Analyses the 2018 Automotive Colour Distribution
SUCCESS STORIES
96 102
BRAND-NEW HIGHLIGHT OF THE MONTH Deep Matt Powder Coatings with no Hazardous Substances
FOCUS ON TECHNOLOGY
106
Turning a Vision into a Reality: Eisenmann Builds First Skidless Paint Shop for Electric Vehicles
SUCCESS STORIES World Market Leader Kässbohrer Automates Production of its PistenBully with Painting Robot from Dürr
120 122 124
Electrical Cabinet Manufacturer Rittal Offers Insight into Their Production
SUSTAINABILITY BRAND-NEW STANDARD & LEGISLATION - UCIF INFORMS Ecodesign: Work on Electric Motors
128
ZOOM ON EVENTS
eosmarketing.it
For over thirty years Novaresine has been creating highly innovative products to meet the needs of the alkyd and polyester resin market. Continuous investments in research and technology allow us to offer a cutting-edge brand for various sectors, with a wide range of products to cover the specific needs of the clientele.
kwanchaiftŠfotolia
TO BE A TEAM
TO BE CLOSE TO THE CLIENT
TO BE FOR THE ENVIRONMENT
www.novaresine.com
TO BE NOVARESINE
A new generation coarse texture powder coating Our newly formulated Interpon Coarse Texture Low-E is a range of TGIC-free, polyester based powder coatings. This solution offers a consistent coarse texture finish across your product, and is excellent for use in situations where the quality of the substrate is low and small surface imperfections need to be hidden. It also offers the flexibility to use in both interior and exterior environments. As the product is part of our Low-E range, it can be cured as low as 150˚C, making it more energy efficient. • Uniform coarse texture effect • Enhanced coverage • Easy to apply • Low cure temperature (150-170°C) • Greater energy efficiency; environmetally friendly • 46 RAL shades, available from our Ready to Ship (RTS) range
www.interpon.it
EDITOR’S LETTER
Green Chemistry and Green Engineering Richiedi la versione in italiano a info@ipcm.it
A
lready in the middle of last year, in one of my editor’s letters I disclosed the creation of a new content section in the ipcm® magazine, devoted to one of the mega trends of our century: sustainability. Sustainable development is normally addressed with a triple bottom line approach, that is, as the interaction of three elements: economic development, environmental protection, and social equity. This section, therefore, includes news and articles not only on the sustainable technological and product innovations launched by companies in the surface treatment sector, but also on their efforts to ensure that production is environmentally friendly and guarantees the health and safety of workers and local society. With this first issue of 2019, our Sustainability section also introduces Five on Five interviews – 5 questions at a time asked to the senior managers of 5 international players in the field of surface treatment chemicals, with 15 questions altogether published on consecutive issues. An aspect in particular deserves reflection. When it comes to sustainability, we usually refer to the role played by the chemical industry. We speak of Green Chemistry, and rightly so. Decrease in the use of dangerous substances and their generation in synthesis reactions, development and synthesis of safer and more easily degradable substances, decrease in the use of solvents, use of renewable resources, and improvement of energy efficiency: these are some of the 12 principles followed by the chemical industry. What is the role of process engineering for sustainable development? Can we also talk about Green Engineering? Many elements underpinning the concept of sustainable development have been the prerogative of process engineering for years. The current development of technologies and production organisation methods is a big step forward in terms of sustainability. Green Engineering refers to the transformation of the disciplines and practices of engineering in order to promote sustainability. Indeed, the use of technologically advanced and economically valid products, processes, and systems can increase the well-being of humanity. Developing new concepts, optimising the use of raw materials, optimising production techniques, optimising distribution, reducing products’ impact during use, considering the actions required at the end of their service life, and preventing waste: these are the guidelines of the methodological approach to production and product sustainability, also in the surface finishing sector.
Alessia Venturi Editor-in-chief Direttore Responsabile
This issue of ipcm® delves into the topics of Green Chemistry and Green Engineering: we talk about innovation in raw materials for paints and coatings; investments made by chemical companies to strengthen their R&D labs to pursue sustainable innovation; and robotics and automation to simplify operational processes and material management. We also talk about the implementation of digital systems and machines to maximise process and consumption control; a pioneering application in the powder coatings industry where the latest versions of safety data sheets, analysis bulletins, and even one’s own coating warehouse situation are just a click away at any time; and a 3D scanning system for powder coating to optimise the finish and process quality of complex-shaped parts. But, above all, we talk about how important the human factor is in all this.
international PAINT&COATING magazine - JANUARY/FEBRUARY 2019 - N. 55
03
BRAND-NEW
AkzoNobel Launches a New Range of Coarse Texture Products
A
innovations to our customers,” explains Mark
“Metal usually has to be treated and
coating technology that allows its
Reekie, Global Segment Manager, General
smoothed before adding a gloss coating,
customers to achieve coarse texture
Industry, for AkzoNobel’s Powder Coatings
but even then, the slightest imperfection in
surfaces while reducing the environmental
business. “The key to this new coarse texture
the surface will show through,” continues
impact.
range is the Low-E
Reekie. “Coarse texture powder coatings
Initially being launched in Italy, Interpon
label – known as low bake in the
give a dimpled finish. They are popular
Coarse Texture Low-E is especially good at
industry – which means it can be cured
because as well as looking good, they can
covering small defects on metal, while also
from 150-170°C, without losing quality or
‘hide’ any imperfections and save the time
offering greater energy and production
the properties of the coating. So, customers
and money involved in preparing and
efficiency compared with standard products.
can reduce their energy consumption and
protecting metal.”
It’s aimed in particular at industrial producers
increase productivity.”
The new product is available from stock
of shelves, electrical cabinets, gym equipment
He adds that the polyester-based product
throughout Europe in the top 46 most
and office furniture.
is ideal for any interior or exterior industrial
popular industrial RAL shades.
“As the world’s number one supplier of
application. It gives a consistent effect in any
powder coatings, we’re always looking to
colour and it also offers excellent weather
For further information:
innovate and take great pride in delivering
and light resistance.
www.interpon.com © AkzoNobel
kzoNobel launched a new powder
Figure 1: The new powder coating launched by AkzoNobel is aimed in particular at industrial producers of shelves, electrical cabinets, gym equipment and office furniture.
1
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N. 55 - JANUARY/FEBRUARY 2019 - international PAINT&COATING magazine
BRAND-NEW
© Airbus Defence & Space
AkzoNobel Supplies Sustainable Coatings for Landmark Tanker Aircraft
1
Figure 1: The new A330 MRTT built by Airbus Defence & Space was coated with the AkzoNobel’s Aerowave 5001 water-based product.
A
double first has been landed by
which they have come to depend, while improving
AkzoNobel’s Aerospace Coatings business
sustainability and helping to ensure regulatory
after it supplied products for a new
compliance.”
long-distance tanker aircraft commissioned by the
The new A330 MRTT was built by
French Air Force.
Airbus Defence & Space, a global leader in
Featuring the company’s Aerowave 5001
designing, developing and manufacturing military
water-based coating, not only is it the French
aircraft. It’s considered to be the benchmark
Air Force’s first new generation A330 MRTT (Multi
for new generation, multi-role tankers, with 33
Role Tanker Transport) aircraft, it’s also the first
currently in operation – and another 27 on order.
aircraft of its size to be finished with an external
AkzoNobel has been collaborating with the
water-based topcoat.
Airbus Defence & Space team for nearly three
“We’re extremely proud of this substantial
years, helping to address the specific needs of
achievement, which is testament to the proven
their military program. The next milestone for the
performance of our coatings and our commitment
AkzoNobel and Airbus teams is to complete the
to sustainability,” said Maud Khelstovsky,
Airbus qualification process for Aerowave 5001,
AkzoNobel’s Key Account Manager for Airbus.
planned for all Airbus military airplane programs
“Aerowave 5001 is designed to provide all the
in early 2019.
benefits of a solvent-based coating, but with vastly lower VOC emissions. This allows aircraft to achieve
For further information:
the surface durability and chemical resistance upon
https://aerospace.akzonobel.com
BRAND-NEW
Freudenberg Strengthens Filter Business
T
he global technology group
(approximately 96 million EUR). The
especially in China, thanks to legislation
Freudenberg is expanding its filter
transaction still requires approval from
demanding stricter regulations and
business. The Freudenberg Filtration
increased environmental awareness.
“By purchasing the majority stake in
Experts estimate that the global
contract in China to purchase the majority
Apollo, we are strengthening our position
market for products of Apollo – filters
shares of Apollo Air-cleaner Co., Ltd.
in China’s rapidly growing market for
for room air purifiers, decentralized
The company is a leading supplier of air
filtration solutions,” says Dr. Mohsen Sohi,
ventilation systems and water
and water filtration solutions in China. In
Freudenberg Group CEO.
treatment – will have a total value
2017, Apollo had around 1,000 employees
Air and water filtration solutions are
of some 5 billion USD by the
and generated 750 million RMB in sales
enjoying strong year-on-year growth rates,
year 2022.
© Freudenberg
competition authorities.
Technologies Business Group has signed a
1
Figure 1: The Apollo Air-cleaner Co., Ltd.’s production site in Shunde, China.
06
N. 55 - JANUARY/FEBRUARY 2019 - international PAINT&COATING magazine
© Freudenberg
BRAND-NEW
from the transaction. Main examples are the complementary competencies in filter media and gas filtration, which is growing ever more important. “For nearly 20 years, Apollo has been offering innovative filtration solutions, improving the quality of life in China,” says Akihisa Yamamoto, CEO of Apollo Trading Group, and then adds: “The global development and production network and the more extensive portfolio of technological product solutions stemming from this joint venture will primarily benefit our customers.” For further information: www.freudenberg-filter.com
2 1
Figure 2: The production department at the Apollo’s factory.
“Apollo is a great fit for Freudenberg,” says Dr. Andreas Kreuter, CEO of Freudenberg Filtration Technologies. “It is an innovative technology company that complements our own portfolio of filtration solutions for indoor air and water purification. The company also has first class production expertise and excellent networks in the industry.” The product solutions of Apollo keep air or drinking water free of (ultra) fine particles, dangerous gases, odours and microorganisms and protect health. At its production site in Shunde, China, the company has established high standards for product quality, process efficiency and workplace safety, and is certified to ISO 9001, ISO 14001 and TS 16949. Apollo will continue as a joint venture between Freudenberg (major shareholder) and the current sole proprietor Apollo Trading Group, Japan, under the name Freudenberg Apollo Filtration Technologies. Freudenberg Filtration Technologies intends to bring its current consumer filtration business into the joint venture. Manufacturing, R&D and Customer Services at both Freudenberg Filtration Technologies and Apollo will benefit
BRAND-NEW
The Quality Is the Top Priority
P
rimatek Coatings is the
paints that will make metal surfaces
The labs of the plant have been
first powder coatings
look extra bright and vibrant. Future
equipped with cutting-edge
manufacturing facility in the
machinery, which will allow the new
include manufacturers of furniture
enterprise to develop quickly any
company will be sold to consumers
for Ikea, racks for supermarkets,
types of powder coatings.
in Scandinavia, the Baltic States
construction and warehouse
Primatek is an environmentally
and Northern Europe. The plant’s
equipment, components for cars,
conscious company that delivers
production capacity is up to 7,000
household and industrial equipment,
Environment Product Declarations
tons of powder coatings a year.
tools, aluminum windows and
(EPD) to its partners and customers
The output capacity of the plant will
architectural sections.
on a regular basis as well as verified
allow the new enterprise to occupy
The quality requirements established
and registered documents with
a dominant position on the market
at Primatek Coatings exceed
the transparent and comparable
of the Baltic States, and take up
considerably the quality management
data about lifecycle environmental
significant niches on the markets of
systems of most enterprises in the
impact of coatings pursuant to
Finland, Sweden, Poland and other
industry. Primatek is compliant with
ISO 14025 Standard.
European countries.
ISO 9001:2014 Standard. Primatek
The plant will manufacture a broad
powder coatings are also approved by
For further information:
range of durable and fade-resistant
Qualicoat and by GSB International.
www.primatek.eu
© Primatek Coatings
buyers of Primatek Coatings products
Baltic States. The products of the
Figure 1: The Primatek Coatings’ headquarters. It is the first powder coatings manufacturing facility in the Baltic States.
08
1
N. 55 - JANUARY/FEBRUARY 2019 - international PAINT&COATING magazine
Š Lesta
Opening photo: Lesta was established in 2010, in Dairago (Milan) and operates in the field of industrial robotics for coating.
HIGHLIGHT OF THE MONTH
An Internationally Oriented, Technologically Advanced Company Closely Cooperating with Excellent Businesses: Lesta’s Success Story in the Field of Robotics for Industrial Coating From an interview with sales manager Marco Morlacchi from Lesta Srl, Dairago (MI), Italy
10
info@lesta.it
N. 55 - JANUARY/FEBRUARY 2019 - international PAINT&COATING magazine
HIGHLIGHT OF THE MONTH
I
“2018 turned out to be a great year
taly’s industrial fabric presents several examples of young companies that have managed to establish themselves
on the market as reliable and successful players in a relatively short time. These include Lesta, a firm established in Dairago (Milan) in 2010 and operating in the field of industrial robotics for coating.
Lesta started out as an industrial automation firm and its core business is the coating sector – for both wood and metal and with both liquid and powder paints.”
in terms of production and growth, regarding not only our turnover but also our technical knowledge. In fact, we have faced some new industrial sectors, working with important customers such as Luxottica; for them, we have developed a 3D vision system able to
For them, 2018 was a very positive year
read the position of workpieces on
in terms of economic, structural, and
their holders and to adapt the coating
technological growth (ref. Opening
Morlacchi. “We are active on the national
process accordingly to obtain optimal
photo).
market and on the main international
results. This has enabled us to expand
ipcm has had the opportunity to
ones, particularly in Northern Europe,
our know-how in a very particular, niche
interview Marco Morlacchi, the sales
where we can count on the collaboration
market segment,” says Morlacchi. “Also
manager of Lesta, who identifies
of various local plant engineering
the automotive sector has regained
the reason for this growth in the
companies, and in Eastern Europe, an
importance for Lesta: we operate in the
internationally oriented vision that has
area that is very important for us. Actually,
car interior part coating field and we have
always distinguished the company. “Lesta
we have numerous sales representatives
just installed a large carbon fibre coating
started out as an industrial automation
and technical sales experts located in
plant in Turkey.”
firm and its core business is the coating
Poland, thanks to whom we are able to
Currently, Lesta has about 20 employees
sector – for both wood and metal and with
offer an even more careful and timely
and relies on several external consultants
both liquid and powder paints,” explains
service to our customers.”
to offer a complete service to its
© Lesta
© Lesta
®
1
2 1
Figure 1 and 2: In March, the operational area was extended and new spaces devoted to robot testing and R&D labs were added.
2018 turned out to be a great year in terms of production and growth, regarding not only Lesta’s turnover but also its technical knowledge. In fact, the company has faced some new industrial sectors, working with important customers such as Luxottica; for them, they have developed a 3D vision system able to read the position of workpieces on their holders and to adapt the coating process accordingly to obtain optimal results. This has enabled Lesta to expand its know-how in a very particular, niche market segment.”
© Lesta
customers. In March, the company’s facility also underwent a reorganisation: the operational area was extended and new spaces devoted to robot testing and R&D labs were added (Figs. 1 and 2).
International partnerships Since 2017, Lesta has been cooperating with KUKA, a global manufacturer of robots and industrial automation solutions, as their Official System Partner (Fig. 3). “The growth of our company, the possibility to integrate our products according to the Industry 4.0 paradigms, and the know-how we have acquired, especially in the coating sector, have led us to collaborate with several leading companies in the industrial automation sector, including KUKA and ABB. Lesta develops and integrates software packages and control panels for the coating process management,” states Marco Morlacchi. “Our philosophy is to make the use of this equipment easier without sacrificing application accuracy and final quality.
© Lesta
In particular, we have developed a software package to be
3 1
Figure 3: Since 2017, Lesta is Offical System Parter of KUKA for the development and integration of software packages and control panels for the coating process management.
Currently, Lesta has about 20 employees and relies on several external consultants to offer a complete service to its customers. In March, the company’s facility also underwent a reorganisation: the operational area was extended and new spaces devoted to robot testing and R&D labs were added.”
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N. 55 - JANUARY/FEBRUARY 2019 - international PAINT&COATING magazine
4 1
Figure 4: The new LeCRob electrical control for Lebot MV robots.
HIGHLIGHT OF THE MONTH
robot: in this way, the robot
implemented on KUKA’s robots, which creates dedicated and easily accessible painting programs. Moreover, for the coating of parts requiring a greater accuracy degree during application, we equip the robots with an offline point-to-point programming mode that allows to adjust and define the coating process in detail, also in terms of gun distance from the surface, parameter management, and application angle. The aim is creating programming operations that are as easy-to-perform as possible and do not require any engineering skills, but at
Lesta’s philosophy is to make the use of the equipment easier without sacrificing application accuracy and final quality. In particular, they have developed a software package to be implemented on KUKA’s robots, which creates dedicated and easily accessible painting programs.”
already knows which and how many parts have to be painted with a certain program and when the program has to be changed,” says Morlacchi. In 2018, a new version of this software package has been tested, which was a great success and will be one of the company’s focuses in 2019. “The new software package is a development of the standard
the same time guarantee perfect coating
version and it requires the
results.”
presence of RFID antennas located at different points of
4.0-oriented management of production queues
simple and intuitive way (Fig. 4).
the coating line (e.g. loading,
“If different types of workpieces, with
masking, unloading, or robot
One of Lesta’s flagship products is
different sizes and shapes, need to be
stations), which receive the
LeCRob ProdManager, a software package
coated, it is possible to communicate
RFID tag signals. The tags
enabling to control production queues in a
all load-related information to the
contain all process information,
www.cieeng.com info@cieeng.com
www.mstchemicals.com info@mstchemicals.com
© Lesta
An increasingly attentive customer service “In just eight years, our company has grown a lot and we all feel that we have actively collaborated in this development: this has created harmony and a sense of belonging among all Lesta employees, an invaluable added value,” states Marco Morlacchi. “We are a young company with extensive experience and
5 1
Figure 5: The founding members of Lesta. From the right: Emanuele Mazza, Marco Bresciani and Federico Comini.
expertise. Our team building ability enables us to tackle even the most difficult
customisable according to needs, and they are mounted on special hooks positioned on the conveyor in correspondence with the batch to be treated. The antennas read the messages contained in the tags and communicate them to the robot management software, which selects the right coating program for the specific workpieces. Depending on the position of the antennas and the information stored in the tags, it is possible to automate all process phases,” explains Marco Morlacchi. “The operators are also supported and facilitated in their tasks by Smart TVs placed along the line on which they can view the instructions related to each process step, e.g. how to load the part correctly, how to mask it, or how to pack it.”
14
One of Lesta’s flagship products is LeCRob ProdManager, a software package enabling to control production queues in a simple and intuitive way. If different types of workpieces, with different sizes and shapes, need to be coated, it is possible to communicate all load-related information to the robot: in this way, the robot already knows which and how many parts have to be painted with a certain program and when the program has to be changed.”
N. 55 - JANUARY/FEBRUARY 2019 - international PAINT&COATING magazine
challenges and to offer our customers optimal solutions in competitive times (Fig. 5).” “2019 has just begun, but we already have many projects in progress. The most important one is the further expansion of our operational area to make room for a coating test booth: we already offer this highly demanded service by relying on contractors, but now it is time to insource it. Moreover, we would like to devote a part of the new area to an automated warehouse, in order to make the supply of components and spare parts even faster. Finally, we will continue to cooperate more and more actively with national and international plant engineering firms, and we are getting ready to tackle new markets,” says Morlacchi.
G R
T
© ipcm ®
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N. 55 - JANUARY/FEBRUARY 2019 - international PAINT&COATING magazine
FOCUS ON TECHNOLOGY
A New Application Technology with a 3D Part Scanning System and a Dynamic Reciprocator to Optimise the Production Time and Quality Level of Complex Products Monica Fumagalli ipcm®
© ipcm ®
“I
nnovation” is a recurring
the first company in Italy to install a
term when talking about
new powder coating system developed
manufacturing. Nowadays, for a
by Gema Europe. Through close
company, innovating means to equip
cooperation with Gema’s technical staff
itself with interconnected production
and thanks to the experience of its
systems managed through a perfect
operators applied on last generation
interaction between man and machine
devices, the company has been able
and, therefore, through the operator’s
to optimise its production times while
deep understanding of the new
maintaining a high finishing quality
devices’ features. However, in practice,
level, even for very complex-shaped
what does it mean for operators to radically change their work concept, and for companies to train professionals to manage their activities in a completely different way?
workpieces (ref. Opening photo).
1
Figure 1: From right to left: Pier Guido and Alberto Bianchi, the owners of Verniciatura Bianchi.
A high variety of different products and applications Verniciatura Bianchi was established
Especially for small and medium-sized
in Montodine (Cremona) in 1977. It
companies, there are concerns not
started as a liquid coating contractor
only about the installation time of a new plant or device, and therefore of downtime, but also, and perhaps above all, about the time needed to adequately train their staff to use the new system. The development of user-friendly and easy-to-understand operating systems is therefore a decisive element for the choice of innovative machines and products. Here below, we present the case study of a coating contractor, Verniciatura Bianchi Pier Guido & C. This has been
Especially for small and medium-sized companies, there are concerns not only about the installation time of a new plant or device, and therefore of downtime, but also, and perhaps above all, about the time needed to adequately train their staff to use the new system. The development of user-friendly and easy-to-understand operating systems is therefore a decisive element for the choice of innovative machines and products.”
for products characterised by different shapes, materials, and types, and then expanded its business up to the implementation of a powder coating plant. “We now treat the most diverse products,” states owner Alberto Bianchi (Fig. 1), “mainly from the heavy carpentry, mechanics, and electromechanics sectors. We coat products in carbon steel and, more rarely, aluminium and stainless steel. We treat components whose dimensions range from the smallest
Opening photo: Examples of products powder coated by Verniciatura Bianchi.
international PAINT&COATING magazine - JANUARY/FEBRUARY 2019 - N. 55
17
© ipcm ®
2 1
Figure 2: Verniciatura Bianchi coats a large number of boxed sections.
to the largest sizes (Fig. 2). That is why we have equipped our plant to make the production flow as quick and flexible as possible: the main bottleneck of companies like ours is the high number of colour changes required and of different part shapes treated.”
Plant equipment The coating line is equipped with two pre-treatment systems. The first one is a 5-stage pre-treatment tunnel installed in 2014 and linked to both one of the two liquid application booths (devoted to small components) and the powder application plant (Fig. 3). Its stages are as follows: phosphodegreasing, cleaning with mains water, cleaning with © ipcm ®
demineralised water, nanotechnology process, and final rinsing with demineralised water. On the other hand, larger components are treated with a 2-stage static pre-treatment plant performing a phosphodegreasing stage with more aggressive chemical products and a rinsing stage. Besides the static booth for the application of liquid coatings on small workpieces (1 x 1 x 1 m, Fig. 4), there is a second booth devoted to large-sized
3 1
Figure 3: Workpieces entering the
components (6 x 2 x 2.5 m). 5-stage pre-treatment tunnel.
© ipcm ®
FOCUS ON TECHNOLOGY
4 1
Figure 4: The liquid application stage in the static booth.
“As for the powder application,” says Bianchi, “we use epoxy-polyester paints for products intended for indoor use and polyesters for outdoor components, with a percentage ratio of 65:35. In most cases, these are one-coat systems; only 20% of our products require two coats, i.e. base coat and finish. Our previous powder plant, also provided by Gema, worked optimally for eighteen years. In August 2018, it was replaced by the new booth, equipped with an innovative application system. Our choice was motivated by the need to optimise our production flow and to innovate a department that was using an
© ipcm ®
outdated technology.”
Characteristics of the new application technology “One of the problems that Verniciatura Bianchi asked us to solve during the design phase of their new powder coating booth,” says Gema Europe Sales Manager Gianluigi Baroni, “was that the line speed was slowed down by the presence
5 1
Figure 5: A detail of the 3D part scanning device.
of workpieces with complex shapes and variable dimensions. The manual touch-
© ipcm ®
manual application cannot guarantee (Fig. 7).”
Dynamic reciprocator and robot: two application systems compared
There are 3 reciprocators in the powder coating
“The main advantage of Gema’s new
booth: in addition to the dynamic one, there
application system compared with the
are 2 traditional reciprocators and a robot for
anthropomorphic one,” says Bianchi, “is
coating series of identical products (Fig. 8).
the possibility to manage the entrance of
difficult-to-penetrate edges and subframes, and it provides a thickness consistency level that
© ipcm ®
different parts into the booth without being forced to pre-set the application program for the robot self-learning activities, starting from the workpieces’ hanging mode to ensure proper spraying. Indeed, with Gema’s new technology the components can be hung in any way, since the scanner detects the parts’ geometry in real time and the reciprocator adjusts its movement accordingly. Considering that identical products with the same shape only account for 2% of our entire
6 1
production, this clearly helps optimise our production times.”
Figure 6: The dynamic reciprocator in function.
Advantages of the new powder application system
ups required to perfect the coating of complex elements such as boxed sections and frames resulted in a loss of production efficiency. Therefore, Gema’s team developed a solution based on
“After almost twenty years of use of the old 7 1
Figure 7: The post-retouching of difficult-to-penetrate areas.
coating plant,” states Bianchi, “our operators were worried about the implementation of the new system: despite the experience gained over the years, they raised doubts about the
the combination of a 3D laser scanning © ipcm ®
system, placed at the entrance of the booth, with a dynamic reciprocator equipped with 6 guns, which was able to reduce manual retouching operations by 40%. “The device placed at the booth’s entrance is a smart system using a three-dimensional object recognition laser scanner, which does not only detects the length and height, but also the depth of the workpiece (Fig. 5). Each of the 6 guns located on one side of the booth (Fig. 6) moves independently and, based on the detected shape, it can penetrate inside the product, e.g. in the cavities of electrical panels, while keeping the same distance between its dispensing point and the area to be painted. This facilitates the manual retouching operations, mostly limited to
20
8 1
Figure 8: The robot.
N. 55 - JANUARY/FEBRUARY 2019 - international PAINT&COATING magazine
© ipcm ®
FOCUS ON TECHNOLOGY
correctly, it is not possible to proceed to the next one. The high simplicity of management has therefore solved our initial doubts. It also saves our coating staff’s time, because thanks to the scanner system they no longer have to re-set the spraying programs every time according to the different products on the line.” The high coating quality level has been guaranteed by replacing the old guns with new ones featuring a Venturi system and it has been further improved thanks to the high application efficiency of the dynamic reciprocator (Fig. 10). “The system settings were defined by Gema to obtain the best coating efficiency based on the conveyor speed, the guns’ application capacity, and the workpiece size: therefore, we can now be certain that the booth is working in the best way possible. Moreover, despite the transition
9 1
from a 6-gun to an 8-gun system, i.e. 14 guns in total, and despite
Figure 9: The control panel of the powder coating booth.
changed: this is a further advantage of our new system (Fig. 11).”
Conclusions
© ipcm ®
ease of handling a different
the greater production capacity, the consumption of powder has not
“We are very pleased with our choice,” states Bianchi. “Gema has
process than the one they
always been a guarantee of quality for us, so much so that when we
were used to. However,
decided to replace our old coating plant we contacted their team
Gema’s staff was willing to
directly, without assessing any alternative solution. Thanks to the
understand our concerns
installed system, we have managed to improve our productivity level
and look for a solution
for those workpieces that forced us to slow down our line; at the same
able to reassure us: their
time, we have simplified the management of the powder application
system is easy to use, not
process also for components with which we could maintain a good
only in terms of process
productivity level, but with the constant presence of an operator.
management but also of
However, what pleased us the most was Gema’s ability to train our staff
cleaning operations. With
quickly: for us, seeing our coating operators happy with the results
frequent colour changes
of their work is an extra incentive to strive for the optimisation of our
(even every 30 minutes),
production processes through technological innovation.”
the cleanliness of the system The operator performs this process following each step on the control panel (Fig. 9); if a stage is not performed
© Gema Europe
is very important for us. 10 1
Figure 10: A product detail highlighting the high quality level of the coating.
The Gema’s system is easy to use, not only in terms of process management but also of cleaning operations. With frequent colour changes (even every 30 minutes), the cleanliness of the system is very important. The operator performs this process following each step on the control panel; if a stage is not performed correctly, it is not possible to proceed to the next one.”
11 1
Figure 11: The 14 guns for the application of powder coatings.
international PAINT&COATING magazine - JANUARY/FEBRUARY 2019 - N. 55
21
HIGHLIGHT OF THE MONTH
The New ADAPTA APP, a Pioneer in the Powder Coatings Market as for Sustainability and Efficiency David Pellicer
W
e live in the era of the fourth industrial revolution, of the digital revolution, of Industry 4.0. Yet,
© Adapta Color SL
adaptacolor@adaptacolor.com
© Adapta Color SL
Adapta Color SL, Peñíscola - Spain
companies are still required to produce mountains of paper. Be it to comply with the new privacy regulation or to perform a quality audit, it seems impossible to avoid generating a huge amount of paper documentation. Nowadays everything is just a click, scroll, or swipe away. Billions of pieces of information are available on our mobile devices: knowing the basics of keyword or hashtag searches is enough to find anything in a few seconds. Yet, classifying the coated products of a warehouse can still be a time-consuming and burdensome operation. Getting the data you need at the right time, always having the updated version of a document available while avoiding to
2 1
3 1
© Adapta Color SL
Figure 2 and 3: With ADAPTA APP powder coatings users will have all the necessary information at their disposal at any time in order to pass a quality audit or an inspection, fill out a technical specification, or respond to a dispute.
produce further paper documentation and
key elements for achieving these goals. The
to flood your suppliers with requests, or
new ADAPTA APP for mobile devices is the
simply choosing the product you want with
result of Adapta’s efforts to comply with
one click is now possible with the brand
all the requirements established by the
new APP of Adapta for all powder coating
Regulation (EC) No. 1907/20061 concerning
users.
the Registration, Evaluation, Authorisation, and Restriction of Chemicals (REACH) and
Adapta Color SL is very attentive to all safety and prevention-related issues
1
as tools to protect the integrity and Figure 1: The new ADAPTA APP makes the latest versions of safety data sheets (SDS) and product analysis bulletins available in real time.
22
the Regulation (EC) No. 1272/20082 Council
health of people interacting towards the sustainable development of their business. Information and training are
N. 55 - JANUARY/FEBRUARY 2019 - international PAINT&COATING magazine
1
Regulation (EC) No. 1907/2006 of the European Parliament and of the Council concerning the Registration, Evaluation, Authorisation, and Restriction of Chemicals (REACH).
2
Regulation (EC) No. 1272/2008 of the European Parliament and of the Council on Classification, Labelling and Packaging of substances and mixtures (CLP).
on Classification, Labelling and Packaging of
© Adapta Color SL
HIGHLIGHT OF THE MONTH
Finally, the “My products” section allows the users to create a digital
Your Leaders in Zero Liquid Discharge
archive of all Adapta products
substances and
available in their warehouse. By
mixtures (CLP) and
scanning the barcode on the
its subsequent
powder boxes, the APP creates a
amendments (Fig. 1).
record with the related technical
This tool, a pioneer in
data and an icon corresponding to
the powder coatings
the colour of the scanned product.
market, makes the
This amount of information available
latest versions of
in real time on mobile devices will
safety data sheets
enable users to find the information
(SDS) and product
needed at the right time, saving
analysis bulletins
paper and archiving times.
Industrial Wastewater Treatment
available in real time. The user simply has
Complete and continuous
to scan the barcode
traceability of powders, simplified
of the box containing
warehouse management, and
a product and select
real-time availability of technical
a language. In this
information on products: these are
way, powder coatings users will have all the necessary information at their
the key advantages of ADAPTA APP,
4 1
without forgetting accessibility –
Figure 4: The APP offers an overview of Adapta’s smart coating catalogues.
because, nowadays, being
Simple Principle
user-friendly is a must.
in order to pass a quality audit or an inspection, fill out a technical specification, or respond to a dispute (Figs. 2 and 3).
© Adapta Color SL
disposal at any time
The application has a wide range of additional features, such as the calculation of the theoretical yield of
Effective Result
specific coating products, the coding scheme of all products available for sale, and the list of Adapta’s licenses and (business, product, and environmental) certifications. The APP also offers an overview of Adapta’s activities and products: colour ranges, smart coating catalogues, flagship projects with the description of the finishes used, latest news, and much more (Fig. 4). The “RAL Classic” section enables the user to click on a colour code to verify its name in 5 languages, its RGB composition, and the list of Adapta products available for that tint (Fig. 5).
5 1
Figure 5: The “RAL Classic” section enables the user to click on a colour code to verify its name in 5 languages, its RGB composition, and the list of Adapta products available for that tint.
Leading companies rely on vacuum distillation systems for the sustainable treatment of industrial wastewater. Do you want to benefit from a zero liquid production with VACUDEST aswell?
info@h2o-de.com www.h2o-de.com
BRAND-NEW
C
ondoroil Stainless offers complete and automatic
Š Condoroil
Giunone, the New Ultrafiltration Automatic Plant for E-coat ultrafiltration plants, such as
the Giunone model for e-coat (Fig. 1).
Ultrafiltration is a technique that allows the separation of molecules having different dimensions and, for this reason, it can be, as a first approximation, equated with a very thorough filtration process that uses special filters named membranes. Membranes have different construction configurations and, for economic reasons and flexibility, to process paints of e-coat systems the standard are the spiral membranes. The main use is to produce, starting from the painting bath itself, the first rinse water (or better the mixture water and solvent). However it is becoming always more frequent the use of reverse osmosis systems to get a more thorough purification of the permeate for the last rinse step. Membranes are made of modified
1
Figure 1: Giunone is the ultrafiltration automatic plant designed by Condoroil Stainless.
e-coat paints, both anaphoresis and
are collected as permeate
cataphoresis.
while the largest substances
Standard 4, 7.6 and 8 inches elements
are retained by the membrane
are available, as well as valid and
and recovered back to the
competitive spare parts for each
paint bath (Fig. 2).
ultrafiltration system.
The permeate is used in the
The plant consists of a monobloc unit
rinse ramps. This closed loop
assembled on a AISI 304 stainless steel
cycle is used to recover paint
skid.
solids (drag-out).
Ultrafiltration is a membrane process
The permeate can be deviated
able to separate components in
to purge to reduce paint
the solution based on molecular
conductivity.
measurements and shapes. Solvents and other small dissolved particles pass
For further information:
through an ultrafiltration membrane and
www.condoroil.com
24
N. 55 - JANUARY/FEBRUARY 2019 - international PAINT&COATING magazine
Š Condoroil
PVDF and have a proven efficacy on
2 1
Figure 2: Ultrafiltration is a membrane process able to separate components in the solution based on molecular measurements and shapes.
SUSTAINABILITY
BASF is Most Sustainable Innovation Partner for BMW Š BASF
B
ASF was honoured with a BMW Supplier Innovation Award 2018 as the winner in the Sustainability
category. BMW Group said BASF achieved the best performance in CO2
emissions in the report published by the non-governmental organization CDP. BASF’s anchoring of the fight against climate change within the company were cited as another reason for the decision. In addition, BASF develops solutions that help its customers reduce CO2 emissions. One example for the
automotive industry is the innovative integrated coating process, which considerably reduces energy
1
consumption by eliminating one entire coating and curing step.
Figure 1: Dr. Martin BrudermĂźller (middle), Chairman of the Board of Executive Directors of BASF SE, at the awards ceremony with JĂśrg Willimayer (left) and JĂźrgen Westermeier of BMW Group.
“For more than 50 years, BMW and BASF have shared a common goal: sustainable mobility,â€? said Dr. Martin BrudermĂźller, Chairman of the Board
sustainability. As such, we have set ourselves
achievements and exceptional collaboration
of Executive Directors of BASF SE, at
the target of CO2-neutral growth until 2030.�
and named five winners in the categories
The awards ceremony took place on
Productivity, Sustainability, Efficient Dynamics,
award as both recognition of our
November 21 at the BMW plant in Landshut,
Digitalization and Emotional Experience.
longstanding collaborative partnership
Germany. BMW Group presented the BMW
as well as motivation to continue to be
Supplier Innovation Award for the fifth time.
For further information:
a pioneer and a trendsetter in terms of
It recognized a total of 15 suppliers for their
www.basf.com
the awards ceremony. “We see this
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SUCCESS STORIES
Ding Dong Merrily on High after 18 months
Figure 1: After 18 months, the Petersglocke of Cologne cathedral is ringing again.
© Dörken MKS
R
inging out again of silence: the bell
“Petersglocke” of Cologne cathedral (Fig. 1). Traditional bell technology meets state-of-the-art construction and coating techniques. In the summer of 2016 an investigation by the European competence centre for bells ECC-ProBell revealed that uneven © Dörken MKS
striking of the clapper – as a result of the offset hole in the bell cover – meant that the “Dicke Pitter” was no longer emitting its
1
Figure 2: The even zinc flake coating protects the mount of the bell clapper as well as the clamping nut against corrosion. © Dörken MKS
customary sound. It was subsequently discovered that a repositioning of the bell clapper could not only result in an improved sound, but also contribute to the long-lasting protection of the Petersglocke. In collaboration with the Cologne University of Applied Sciences, the cathedral construction authority developed a new mount, to be realised by the company Dirostahl. The special feature of this mount? It is milled from a single forged piece and can be moved horizontally to the millimetre via two double eccentric components. In addition, it is also
2 1
equipped with a HEICO-TEC® clamping nut that guarantees a defined torque
Working together with inhouse
A particular benefit of the new product:
in the rod that carries the clapper and
and contract coater Lisi Automotive
The protective coat has a thickness
secures the bell. This mount is unique
BETEO Oberflächentechnik GmbH & Co. KG,
of just 4–20μm and dries at room
of its kind worldwide.
the company applied the newly-developed
temperature, eliminating the need for
It is all the more important that this
product DELTA-PROTEKT® KL 170 RT
a curing oven. This meant that it could
bearing element is protected against
to coat the mount. The sacrificial behaviour
be applied to the 780 kg component on
corrosion. This is where the corrosion
of the zinc flake coating delivers cathodic
site, in the belfry of Cologne cathedral,
experts from Dörken MKS came in.
corrosion protection (Fig. 2).
via spray application (Fig. 3).
26
N. 55 - JANUARY/FEBRUARY 2019 - international PAINT&COATING magazine
Efficient
SUCCESS STORIES © Dörken MKS
and reliable solutions for surface coating since 1988.
3 1
Figure 3: The ultra-thin protective layer was applied on-site via spray application.
The clamping nut is also securely protected against corrosion. After the mount and the approximately 600kg clapper were brought back into position, the nearly 100-year-old bell was able to ring out again to
electrostatic systems for liquid painting
mark All Saints. Equipped with a highly-efficient corrosion protection solution from Dörken MKS (Fig. 4). For further information:
electrostatic systems and spraying booths for powder coating
www.doerken-mks.de/en
© Dörken MKS
pneumatic systems for high-, medium-, and low-pressure painting
IR and UV drying systems
robot and reciprocators
4 1
CM SPRAY s.r.l. www.cmspray.it
eosmarketing.it
Figure 4: From left to right: Prof. Dr. Klöcker (TH Köln), Alexander Kreicker (Dörken MKS), Jens-Paul Hänig (Lisi Automotive BETEO Oberflächentechnik GmbH & Co. KG), Thomas Schuhmacher (Kölner Dombauhütte), Pascal Jung (Dörken MKS) and Tobias Kleyer (Dörken MKS).
© ipcm ®
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N. 55 - JANUARY/FEBRUARY 2019 - international PAINT&COATING magazine
HIGHLIGHT OF THE MONTH
Euromask® Increases Its Hook Packaging Automation Level Simeone Maitan Finishing Group Srl, Lainate – Italy
info@euromask.com
© ipcm ®
E
uromask®, belonging
Euromask® manufactures
to the Finishing Group,
hooks with 1.5 to 5 mm-
is one of the most
diameter metal wire,
widely known brands for the
but it can provide other
production and distribution
cross-sections on
of masking systems for
request (Fig. 1).
all surface treatments,
The standard hooks with
such as powder and liquid
C and V bends (in their
coating, anodising, galvanic
3 versions: HV, Tipo5,
cataphoresis, and chrome-
and Tipo6) meet most
plating. For several years
operating requirements,
now, it has distributed a
but this company can
wide range of plugs, caps,
also create custom
coating hooks, tapes,
hooks with numerically
discs, tubes, and special
controlled wire benders
moulded products all over
in order to meet every
the world. Resulting from of Euromask products, the ®
company’s growth has led to
need and shape or size
1
the rapid market success
specification.
Figure 1: Euromask® manufactures hooks with 1.5 to 5 mm-diameter metal wire, but it can provide other cross-sections on request.
The manufacturing of Euromask® hooks
frequent changes of location
has always been
to solve the problems of
characterised by great
lack of space for machinery
rapidity and delivery
and operators: the current plant covers an area of 1600 m2 and it is the firm’s third headquarters in twelve years. One of the departments that have been further developed in the new factory is devoted to the production of iron and steel hooks for coating systems, which have always stood out in the market for their robustness and durability. The hooks are manufactured based on the designs of customers, which can select diameters, bends, bend rotation, and lengths.
speed. The latter is now even more efficient
Euromask®, belonging to the Finishing Group, is one of the most widely known brands for the production and distribution of masking systems for all surface treatments, such as powder and liquid coating, anodising, galvanic cataphoresis, and chrome-plating.”
thanks to the implementation of a second machine and a robot linked to it, which picks up the hooks and places them in the box, ready for shipping (ref. Opening photo). In the past, the most critical phase was the insertion of hooks with a length exceeding 300 mm inside the box: the operator was forced to stop production to take the components and place them manually in the container. Now, thanks to the installation of the robot, this is no longer necessary and it is even possible to continue producing at night (Fig. 2).
Opening photo: The robot’s arm picks up a hook to be placed in the shipping box.
international PAINT&COATING magazine - JANUARY/FEBRUARY 2019 - N. 55
29
© ipcm ®
The new machine has a more advanced technological level than the one already existing in the plant. It has also solved the straightening issues found on hooks with a length of 400 mm or more, thanks to a torsion system that enables to produce straight workpieces with an extended length.” as that of aluminium profile vertical coating, where it is now competitive in terms of volumes produced and value for money. Italy remains the company’s target market, but there has been a significant increase in trade relations with foreign countries thanks to the opening of branches in Mexico, Poland,
2 1
Slovakia, and Romania, including the
The manufacturing of Euromask® hooks has always been characterised by great rapidity and delivery speed. The latter is now even more efficient thanks to the implementation of a second machine and a robot linked to it, which picks up the hooks and places them in the box, ready for shipping.”
soon-to-open one in Germany.
© ipcm ®
Figure 2: The new automatic system can work 24/7.
The new machine has a more advanced technological level than the one already existing in the plant. It has also solved the straightening issues found on hooks with a length of 400 mm or more, thanks to a torsion system that enables to produce straight workpieces with an extended length (Fig. 3). This additional production capacity is allowing Euromask® to enter new markets, such
30
3 1
Figure 3: The new machine has solved the straightening issues found on hooks with a length of 400 mm or more.
N. 55 - JANUARY/FEBRUARY 2019 - international PAINT&COATING magazine
Oops...
FASTRIP, for the easy, effective and rapid paint stripping of metals.
ALIT Technologies, the chemical paint stripping specialist. Products, machines, processes and consultancy.
www.alit-tech.com San Bonifacio â&#x20AC;&#x201C; Verona - ITALY
INTERNATIONAL PATENT
NITROROBOT Eurosider, a company with vast experience of using various fluid carriers for liquid painting, has developed a new system to produce a high density carrier in order to obtain better atomization which brings the advantages listed below. Nitrorobot can keep all day long the same settings and guarantee the best working conditions, independently from the conditions of the environment. The equipment, in Touch Screen version, is provided with the system of control of various settings, possible to monitor from any coating system control panel. Ideal application for Nitrorobot is on automatic coating systems with rotary bells, or it can be applied on conventional pneumatic guns, HVLP or electrostatic guns.
NITROTHERM The performance is reffered to fluid enriched in nitrogen with concentration of 93% ¹ 1%, at environment temperature of 20 °C and atmospheric pressure of 1013 mbar. Inlet compressed air must be free from impurities (water, oil, solid particles). We advise to use filter elements supplied by Eurosider. All the data and images are merely approximate and can be changed; the performance vary in accordance with environment and working process pressure and temperature. Eurosider reserves a right to make modifications, even without advanced notice.
EUROSIDER Piazzale Thailandia 6 | 58100 GROSSETO | ITALY ph. +39 0564 425117 | fax +39 0564 418833 www.eurosider.com | info@eurosider.com
S PECI A L O N R AW MAT E R I A L S , P I G ME NTS , PA I N T & C O AT I N G T E C H N O LO G I E S
34
BRAND NEW
38
SUSTAINABILITY - 5 ON 5
46
INNOVATIONS: PRESENT&FUTURE
54
HIGHLIGHT OF THE MONTH
Five on Five Interview: Sustainability According to the Industry Players
Multi-Curing Waterbased PU Dispersion: Faster Drying, Robustness and Improved Performance Even Under Poor UV-Curing Conditions
Chemtec Expands its Plant and Develops a Laboratory Test Contracting Service
58
HIGHLIGHT OF THE MONTH Novaresine: The Sustainable Approach of a Chemical Company Open to Everyone
66
INNOVATIONS: PRESENT&FUTURE
70
HIGHLIGHT OF THE MONTH
76
INNOVATIONS: PRESENT&FUTURE
80
INNOVATIONS: PRESENT&FUTURE
VOC-compliant Coating: Ultra-high-solid Platform Technologies
Research and Technological Innovation as the Cornerstones of Industrias Titan’s Philosophy
Lacquering Before Polishing: Technical Coatings for Additive Manufacturing
© Sinhyu_fotolia
The Evolution from Single Component to Plural Component Paint
S P E C I A L O N RAW M ATE RI A L S , PIGMENTS, PA I NT & C O ATI NG TE CHNOLOGIES
BRAND-NEW
European Coatings Show 2019: BASF to Present New Solutions Covering the Needs of Customers
T
he broad range of products
fulfilling latest regulations and technical
that has been specifically designed
offered by BASF includes
properties. It does not contain
for classical ternary SLUs. This new
dispersions, resins, additives,
stenomeric monomers and Bisphenol
superplasticizer in powder form
light stabilizers, antioxidants, pigments,
A (BPA), offers immediate chemical
enables longer slump retention and
hardeners, cross-linking agents,
and scratch resistance and is very
improved temperature robustness as
reactive diluents and solvents.
compatible with mixing components
well as compatibility with all kinds of
(e.g. acrylic combination partners).
fruit-based acids. Due to a reduced
More durable waterborne coatings for white pigmented furniture
retarder dosage customer benefit
White coated furniture is becoming
Non-reactive but highly protective industrial floor coatings
more and more popular, especially in
The screeds used in industrial buildings
living rooms and kitchens. However,
such as warehouses and cellars must
in everyday life it can easily happen
withstand high levels of abrasion stress.
Adhesion all-rounder for 1K and 2K polyurethane primer applications
that coloured liquids such as coffee
Therefore, they are often coated with
Universal adhesion performance
or red wine leave irreversible stains
epoxy floor coating systems.
on various substrates, low solvent
on bright furniture surfaces – a major
From now on, there will be a
demand and formulation robustness
problem particularly for waterborne
waterborne alternative to conventional
combined all in one solution offers
coatings. This does not have to be:
reactive systems: The new dispersion
Basonol PU 1035 W. This very
Due to the new, physically drying
Acronal 5522 for mineral surface
flexible OH-functional aliphatic
resins, the recently launched Joncryl®
protection combines the required
polyurethane dispersion (PUD) is
95XX series, furniture coatings end up
performance with sustainability
suitable for 2K polyurethane (PUR)
with high levels of chemical resistance
features. Floor coatings based on
primer applications ideal for plastic
against aqueous stains even after
this acrylic composite polymer do not
and 1K melamine w/wo blocked
16 hours of exposure (according to
require labelling and can be applied
polyisocyanate crosslinking primer
DIN 68861-1B); they are also suitable
easily.
applications on metal substrates.
for DIY-applications. Furthermore,
®
from cost savings and achieve better hardening properties.
It does not contain any organic
agent for water-based systems,
Classical ternary self-levelling underlayments
supports excellent chemical resistance
Self-levelling underlayments (SLUs)
and can be used as universal blending
and leads to greatly improved storage
gain increasing acceptance, when
partner for acrylic dispersions.
stability and anti-sedimentation
it comes to ensuring smooth and
behaviour. For industrial UV
crater-free surfaces for subsequent
applications, where immediate
floor installations. No wonder, as they
Strong protective shield for coating surfaces
availability of properties is necessary,
can be applied easily and offer good
With regard to many coating
BASF developed Laromer® UA 9135
mechanical properties compared
applications customers increasingly
Aqua. The UV curable dispersion
with conventional methods.
require products that combine
is designed for the formulation of
Melflux® SELECT 4411 F constitutes
aesthetics with additional coating
highly resistant furniture coatings,
a new PCE based superplasticizer
functionalities such as improved
Dispex® Ultra PX 4575, a dispersing
34
N. 55 - JANUARY/FEBRUARY 2019 - international PAINT&COATING magazine
solvents e.g. N-Methyl-2-pyrrolidon (NMP) or N-Ethyl-2-pyrrolidon (NEP)
SP E C I A L O N RAW M ATE RI A L S , P I G M E NTS , PA I NT & C O ATI NG TE C HNO LO G I E S
© BASF
BRAND-NEW
1
Figure 1: Classical ternary self-levelling underlayment.
durability, reduced dirt pick-up and
such as new consumer requirements
easy-to-clean features. Hence, BASF
and environmental standards.
enhanced its Formulation Additives
The ECS trade fair is a welcome
portfolio with a novel concept of coating
opportunity for us to continue
surface modification: It is based on
the close ongoing dialog with our
fluoro-modified block copolymers
customers on market needs and drive
that crosslink with the binder matrix.
innovations,” says Christoph Hansen,
The block copolymers align at the top
head of the Dispersions & Resins
surface layers via self-organization and
Europe business unit.
are fixed in the right place, which leads to improved durability and weathering
BASF offers the broadest global range
resistance of the surface as well as
of raw materials for the formulation
additional functionalities such as an
of coatings and paints in the field of
easy-to-clean effect. The new concept is
architectural coatings, construction,
suitable for various types of applications
automotive, industrial coatings, furniture
such as automotive clearcoats or
and flooring as well as raw materials for
industrial top coats.
powder coating resins.
“Our customers in the coatings sector are facing diverse challenges resulting
For further information:
from ever-changing overall conditions
www.basf.com/ecs2019
S P E C I A L O N RAW M ATE RI A L S , PIGMENTS, PA I NT & C O ATI NG TE CHNOLOGIES
BRAND-NEW
B
YK-Gardner - worldwide partner of the automotive, paint and plastic
© BYK-Gardner
Next Generation of BYK-Gardner’s Data Analysis Software smart-chart industries for quality control
of colour, appearance and physical properties - is announcing the next generation of their data analysis software smart-chart. In order to guarantee uniformity over time and be able to proactively take measures before colour or appearance start to drift, process stability has to be controlled. Therefore, a representative number of readings have to be taken and large data sets need to be analysed. The next generation of smart-chart software is built on a new state-of-the-art platform and offers advanced graphics and printout functionality as well as a streamlined user interface.
Dive into the new advanced graphical functionality of smart-chart
1
Figure 1: The new drill-in function shows history trend of the last 20 measurements of the same model, colour and painting line.
A new pan & zoom functionality allows to
Communication to the point with dynamic print layout
first enlarge the graph and then move it
Taste differs – not only in the case of food!
to the area of interest. For line graph, the
Which data is needed on the printout
zooming is even done simultaneously for
depends on the requirements. Therefore,
all charted parameters allowing to always
smart-chart 5 offers a dynamic print layout
smart-chart 5 – one software solution for all BYK-Gardner colour & appearance products
see the data for exactly the same day or
so that you can create your own template.
It can’t get any more efficient in organizing
individual.
The order of data table and graphs can
your QC system. Set-up of instruments, central
Brand new is the display of red and
be defined, line and page breaks can be
data storage and data analysis is streamlined
green tolerance lines. They are based on
inserted and it can even implement a
and the same for BYK-maci, cloud-runner,
your product specifications in standard
company logo, a footer and a comment.
wave-scan, micro-gloss and the recently
management and can easily indicate
set in Trend Report without the need to move to another report.
launched spectro2guide.
proactively take measures to avoid costly
Data analysis streamlined with new reports
rejects.
To make the software more user-friendly
available 1st quarter of 2019. Software
The new drill-in function shows history
reports are combined without losing the
smart-lab to follow approx. 2 months later.
trend of the last 20 measurements of the
functionality of previous software versions.
same model, colour and painting line: just
As an example, to compare data of different
For further information:
click on any point in the scatter plot.
check zones only a checkmark needs to be
www.byk.com
a quality drift so that you are able to
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N. 55 - JANUARY/FEBRUARY 2019 - international PAINT&COATING magazine
The software package smart-process including the new features mentioned above will be
S P E C I A L O N RAW M ATE RI A L S , PIGMENTS, PA I NT & C O ATI NG TE CHNOLOGIES
BRAND-NEW
S
has organised its 13 Parts Cleaning
Experts answer all questions
Day, focussing on recycling and
How do we achieve the longest
urface treatment specialist SurTec th
media treatment, on March 13, 2019
bath life possible? What does
at its headquarters in Zwingenberg
optimal processing mean? How
(Germany, Fig. 1). All interested players,
does modern particle filtration
such as planners, cleaning system
work and what methods are
procurers, and plant operators are invited
available? SurTec’s professionals
to exchange ideas and make contacts.
will answer to this kind of questions
This event is not free.
during the event. Other experts
A guided tour will also offer the opportunity
from the industry will also be
to gain interesting insights into the company.
available to talk.
© SurTec
Parts Cleaning Day 2019 at SurTec: Focus on Recycling and Media Treatment
2 1 © SurTec
Figure 2: SurTec’s recycling process.
Legal requirements: achieving a long bath life In the framework of legal requirements on waste water discharge (AbwVO), it is increasingly important to tackle the issue of stable cleaning baths. Indeed, this German regulation requires plant operators to treat their process baths with methods that can guarantee their longest service life possible. If suitable, bath ingredients should to be recirculated from rinsing baths to process baths (Fig. 2). Actually, stable baths offer several advantages in terms of parts cleaning: they enable to save resources and they guarantee a consistent cleaning quality level and the required component cleanliness degree. 1
Figure 1: The key visual of the Parts Cleaning Day 2019.
For more information: www.surtec.com
international PAINT&COATING magazine - JANUARY/FEBRUARY 2019 - N. 55
37
S P E C I A L O N RAW M ATE RI A L S , PIGMENTS, PA I NT & C O ATI NG TE CHNOLOGIES
SUSTAINABILITY
Hel en
HMG er, ld
W
lenius, Tekn Ca o ik
Joel Sv
a, Tikkurila kul ar
elcome to the first of a series of interviews on the role of sustainability within the coatings industry. Ever more present in almost every press release or corporate communication, we wanted to dig deep to understand sustainability and what it represents to our sector. The most popular definition of sustainability is that from the Brundtland Report of 1987, which stated: “Sustainable development is development that meets the needs of the present without compromising the ability of future generations to meet their own needs”. Ever more important, environmental sustainability within all industries is set to have a fundamental role if we are to slow or reverse the environmental
, DSM ets M
s
Fred er
John Fa
Five on Five Interview: Sustainability According to the Industry Players
Elis aM
5 ON 5
impacts of global warming. The late eighties and early nineties saw companies eager to promote the “greenness” of their products as a marketing lever. From the mid-nineties until recently, green issues, while not forgotten, seemed no longer to be a priority for most industries. While there are some very notable exceptions, most green initiatives during this time were truly probably only financed as they were cost savings. Fast forward to the current decade and you cannot miss companies screaming out from the rooftops regarding their sustainability credentials. But is this the real deal? Are companies finally taking the issue seriously? ipcm®, in a series of interviews with senior figures from within the coatings industry, found everyone
to be very open and sincere on the topic: each company may be at a different point in their sustainability journey, but we happily found that the topic was a very high priority for everyone. Below, in the first of a three-part interview, you can find the answers to the first five questions from five senior industry contacts. There is no wrong or right answer and we believe the comparison makes for a great read as well as being thought provoking. A new feature within the ipcm® magazines, this section aims to provide an interesting read with the long-term hope that if we can showcase sustainability best practices then maybe, one day, one of these will be the inspiration for another organisation to make a difference.
For this first interview we were delighted to work with the following sector leaders: Joel Svendsen - President of Belzona Helen Mets - President of DSM 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
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N. 55 - JANUARY/FEBRUARY 2019 - international PAINT&COATING magazine
n, Belzona dse en
SUSTAINABILITY
1
How does your company define sustainability today?
Joel Svendsen, Belzona - If you look at sustainability as minimising damage to the environment, you can tackle it from a few different angles. The more traditional routes include using less energy, trying to reduce waste and improving recycling. We’re kind of in a fourth column. How can we preserve the life of machinery, equipment, buildings and structures? If you go back in Belzona’s history, we used to have the tagline “Conservation of Man-Made Resources”. Essentially, this is where we see ourselves. If we can extend the lifespan of these assets, replacement can be avoided and we’re able to reduce the environmental cost associated with replacing large pieces of machinery or structures. Helen Mets, DSM - DSM believes that sustainability involves the absolute responsibility and clear actions that must be put in place to address some of the major environmental and societal issues the world faces today. Our strategy is closely linked to the sustainable development goals and we are setting ambitious goals as business under 3 pillars: “Health” (creating healthy living environments), “Climate & Energy” (reducing impact on climate change) and “Circularity and Resources” (eliminating waste and enabling a circular economy). To achieve our goals and to push the industry forward we need to work in conjunction with organisations and companies across the entire value chain, as well as end consumers, to develop science-based and scalable solutions which make a positive impact on society without a negative one to our planet. It also involves delivering these goals while remaining a profitable, performance-focused and growth-oriented company, for which we do
S P E C I A L O N RAW M ATE RI A L S , PIGMENTS, PA I NT & C O ATI NG TE CHNOLOGIES
not see any contradiction. In short, we want to deliver business excellence providing we can adhere to our core sustainability values which are at the heart of everything we do. As President of DSM Functional Materials and Resins, I personally have an intrinsic motivation to change the world, so sustainability for us is not a nice to have. It’s a must have. John Falder, HMG - Decent, Worthwhile and Secure are key HMG values and underpin everything the company does. The HMG mission statement reads: “To supply coatings that protect and enhance. Bought by customers who want to use it, produced by staff that want to make it and doing so in a sustainable, innovative and fair manner”. In this instance, it makes sustainability an integral part of the HMG business strategy and we are committed in being a socially responsible company. Fredrik Calenius, TEKNOS - For Teknos sustainability is a mindset and an integrated part of our strategy and business model. Teknos is highly committed to protecting the planet and making the world last longer. We constantly strive to create sustainable long-term value for society, our customers, employees and suppliers by both protecting the environment and the safety and health of our employees and others, while also using resources as efficiently as possible. Minna Avellan, Tikkurila - Sustainability is simply the way we conduct our business; it is the foundation of our values and brands. Sustainable development is a very material part of our strategy, deployment is strongly integrated in everything we do. Sustainability provides genuine business opportunities at the same time as it enables us to affect on what kind of planet we want to leave to the next generations. It benefits economically, reduces costs and minimizes risks.
2
What have been the biggest issues encountered in bringing theory into practice?
Joel Svendsen, Belzona - I would say that, if there is a challenge, it’s that you can make materials cheaper but at the expense of making them nastier. It’s not that difficult to make an inexpensive coating, at the expense of adding in lots of nasty solvents. You could look at it from a certain point of view and say, “That’s great, I’ve got this protective coating and it is a lot cheaper”. But it brings with it two problems: solvent systems generally don’t perform well compared to a non-solvent system; secondly, solvent systems have an environmental cost. With these chemicals evaporating into the air, they’re potentially harmful to the people breathing it in. Helen Mets, DSM - It’s easy to talk a good game on sustainability, but far harder to actually make it a commercial reality. From our perspective we encounter two main obstacles: firstly, there is still a lot of education and communication that needs to be done to convince industry sector customers that truly sustainable products can be high performance and available at the right price point. There is still significant miscomprehension around sustainable products and they can sometimes be a hard sell. This is evident by the fact that solvent-based paints are still dominant in certain parts of the world where an effective and cost comparable alternative is available. Secondly, the necessary conditions for sustainable product development need to be in place – so not only an open-minded market, but the right supply chain partnerships that share your vision and are prepared to take on the myriad of issues involved, from supply of sustainable resources and materials to energy efficiency and high performance. DSM uses its passion and energy every day to overcome these challenges.
international PAINT&COATING magazine - JANUARY/FEBRUARY 2019 - N. 55
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S P E C I A L O N RAW M ATE RI A L S , PIGMENTS, PA I NT & C O ATI NG TE CHNOLOGIES
SUSTAINABILITY
John Falder, HMG - Like any initiative, the initial rollout can generate issues, especially if it changes existing business practices. Thankfully though, the HMG staff is very engaged and understands the wider impacts and eventual benefits that introducing new practices can bring. Fredrik Calenius, TEKNOS - People involvement has been crucial. We had to first understand what our true sustainability goals were and translate these into a strategy that can be measured. Only once this was complete could we move to ensure the buy-in from all stakeholders at every level, from the ground up to the boardroom. We had to have this buy-in to ensure that sustainability became a truly integrated part of corporate policy. Minna Avellan, Tikkurila – Depending on the readiness of our stakeholders, we have seen differences both in people awareness and country practices. In order to get all relevant stakeholders to join your journey, the company needs to bring sustainability into practice – sustainability requires concrete actions. Furthermore, tightening legislation has a great impact on our operations.
3
players seem to be doing a reasonably conscientious job at “trying to do the right thing”. In third place, there is government regulation and you have be in compliance with the rules that are out there. Helen Mets, DSM - Without doubt, the key driver for sustainability in coatings must be volatile organic compounds (VOCs). The clue is in the name – these materials are “volatile”. They are being emitted as gases from the thousands of every day products that form part of our daily lives. The long-term negative health effects are now well understood and what is so alarming is that concentrations of many VOCs are consistently and very significantly higher indoors where coatings of all descriptions are used from wall paint to varnishes to adhesives (Fig. 1). This is where one of the key pillars of our sustainability strategy comes in – to positively impact the health of the population. The more we understand about VOCs, the greater the urgency becomes to take action, which is why DSM has worked so hard to help the industry migrate from solvent-borne to waterborne technologies.
What do you see as the key drivers of sustainability in industry today?
Joel Svendsen, Belzona - The biggest drivers are the natural drivers throughout industry: companies want to save money. If they can save energy and prolong the life of their equipment at the same time as saving money, that’s great. So, it’s a virtual circle. Since companies want to be more efficient, they want to behave in a more sustainable fashion. Second to that, companies don’t want to be seen as evil, but a force for good. The bigger
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N. 55 - JANUARY/FEBRUARY 2019 - international PAINT&COATING magazine
John Falder, HMG - Companies are now responding to pressure from regulators and the wider community to drive the sustainable conversation, which is fantastic. Social responsibility, commercial factors and perhaps, most significantly, simply doing the right thing for local and wider stakeholders are the key drivers. Fredrik Calenius, TEKNOS - Driving growth – sustainability can contribute to growth by improving our brand values and opening up new market opportunities (e.g. markets for low VOC or bio-based paints/coatings). Lowering costs – efficient use of raw materials and resources (e.g. energy, water) can reduce costs and improve profitability. Employees are easier to motivate to save resources when arguing about sustainability. Reducing risks – sustainable business practices can help us reduce risks. These include risks from increasing emissions taxes (energy, transportation), pollutants and toxic releases (energy, VOCs, various chemical compounds), shipment of hazardous materials (reagents, intermediates, raw materials, solvents), new and increasingly restrictive regulations, climate change, disruptions in supply chains, etc. Financial benefits – better risk
© DSM
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1
S P E C I A L O N RAW M ATE RI A L S , PIGMENTS, PA I NT & C O ATI NG TE CHNOLOGIES
SUSTAINABILITY
© Teknos
Minna Avellan, Tikkurila - The key drivers for our sustainability work are the expectations of our stakeholders and changing regulations as well as global and business environment trends, which are impacting on our operations considerably. Customer awareness – we are listening and work with our
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© Tikkurila
management through sustainability can help us to receive better loan interest rates from financial institutes. Attracting talents – employees, especially young generations, want to work for more sustainable and responsible companies. Strong sustainability commitment can help us attract and retain the best talents. For future generations – at Teknos we want to build the company which the next generations will be proud to lead and be part of in the future. Teknos wants to make choices, which bear to all the generations to come (Fig. 2).
3
customers with the aim to meet their changing demand. Customers want to choose products that cause a minimal environmental impact in production and in use and that are safe to use. People are increasingly concerned about well-being and health, as well as the state of the environment (Fig. 3). Changing legislation – we actively monitor the legislative development of our industry and meet the legal requirements regarding our operations and products. Megatrends – trends affecting particularly the paint industry and consumer-focused business operations include urbanization, the rise of the middle class, changes in consumption behaviour, aging of the population, exhausting natural resources, and climate change. Digitalization brings new opportunities for eco-innovation and service design, for instance.
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2
What business value have you seen?
Joel Svendsen, Belzona - In the end, it means to save money over the life of that structure/ equipment, if you made it suitable in the first place. These third-party energy certifications help to drive this forward. If you take that approach further, looking at the smaller details of the industry,
they make people invest a little bit more up front, so you can save money, energy and time in the long run. Which falls nicely in line with how Belzona looks at things. Helen Mets, DSM - We have been the leader to transform the market from solvent based to water-based coatings, drastically lower the VOC emission and improving the health of, for example, workers. As a result, we have grown our business with high single digits y/y over the last decade. John Falder, HMG - Hard to quantify, as it’s been part of the business since it was founded. It’s evident though that throughout the years the culture has meant we’ve constantly improved our process and build long term relationships that have a fundamental foundation in sustainability. Fredrik Calenius, TEKNOS - With our program we aim to add value to our customers and customers’ customers. A few of our customers are now beginning to ask for more sustainable options, for example using less solvents, so it’s important that we adapt to be ahead of the curve even if it’s just a trickle of requests today (Fig. 4). Another very important value is that sustainability is becoming an ever more important factor in attracting new talent, particularly for the younger age groups. Elisa Markula, Tikkurila - There is a growing business case for sustainability, and thus, in our company it is embedded in everything we do
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SUSTAINABILITY
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as a part of our business strategy. We want design business models that create value for all stakeholders, including employees, shareholders and supply chains, also the planet. Sustainability as a part of our company DNA helps us mitigate risks, drive for more innovations and significantly reduce costs, like energy and water consumption, i.e. improve our operational efficiency. On top of this, there is a growing demand from our customers for more environmentally friendly solutions which will grow our sales. Also, investors are now tracking the high performers on ESG (environmental, social and governance factors) and are correlating better financial performance with better ESG performance.
5
How do you compare to the competition?
Joel Svendsen, Belzona - I would say we do more than our competition. You maybe pay a little bit more for a Belzona
product, but what you get is a solution for the long term. Helen Mets, DSM - A lot of development is not open to public scrutiny, so it can be hard to assess what is going on and determine exactly who our competitive peers are, although we debate this regularly. One thing I would say is that we have the same attitude as elite sports men and women, in that while we are aware there is competition, our focus is on ourselves and being the best, we can without needing to constantly look at who is beside us or coming up from behind. Sustainability redefines what competition means. It takes industries and value chains to work together to make the changes required to address the issue we face. John Falder, HMG - As a company we feel we fair favourably to competition, this is perhaps reflected in the fact HMG Paints was the first paint company to win the BCF Coatings Care award twice
along with Northwest Business Environment, Granada Waterwatch and Environmental Education awards and our links to the Red Rose urban woodland project. Fredrik Calenius, TEKNOS - Compared to some of the bigger players in our sector we have started our journey later, however we have the advantage of being a family run business, which allows us to be very flexible and to move quickly. So, we believe we will catch up very quickly and hope to be very shortly at the forefront, adding value for our customers and differentiating ourselves in the market. Minna Avellan, Tikkurila – Tikkurila has sustainability deep in its DNA. Responsibility and sustainability have been part of our business already for decades. We started training our customers in the late 1920s. We introduced the first water-borne products in the early 50s and met the stringent eco-label requirements already 20 years ago – just to mention a few strategic milestones. To move forward, our focus is on finding our own competitive advantages.
© Teknos
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N. 55 - JANUARY/FEBRUARY 2019 - international PAINT&COATING magazine
Automatic SEASIDE endorsement
*Fully integrated in SATâ&#x20AC;&#x2122;s vertical coating plants
sataluminium.com
26 â&#x20AC;&#x201C; 28 February 2019 DWTC, Dubai, UAE
Where the market meets See the latest products
5000+ attendees Unrivalled networking
Senior decision makers in 1 place
www.coatingsgroup.com/mecs
300+ exhibitors
WELCOME TO THE INDUSTRY’S LEADING TRADE SHOW NUREMBERG // GERMANY European Coatings Show: 19 – 21 March 2019 European Coatings Show Conference: 18 –19 March 2019
Most recently over 1,100 international exhibitors and over 30,000 visitors Accompanied by Europe’s largest and most important industry conference w Plan your visit online: european-coatings-show.com/shownavigator Organisation: NürnbergMesse european-coatings-show.com
Organiser: Vincentz Network european-coatings.com
© Dariusz Jarzabek
Opening photo: The UV-curing waterborne PU dispersion enhaces the efficiency of the coating process even on difficult geometries and in shadow areas.
INNOVATIONS: PRESENT&FUTURE
S P E C I A L O N RAW M ATE RI ALS, PIGMENTS, PA I NT & C O ATI NG TECHNOLOGIES
Multi-Curing Waterbased PU Dispersion: Faster Drying, Robustness and Improved Performance Even Under Poor UV-Curing Conditions Eva Tejada Rosales, Berta Vega Sánchez, Michael Ludewig and Matthias Wintermantel Covestro Deutschland AG – Leverkusen, Germany
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www.coatings.covestro.com
N. 55 - JANUARY/FEBRUARY 2019 - international PAINT&COATING magazine
U
V-curing waterborne polyurethane (PU) coatings
© Covestro
INNOVATIONS: PRESENT&FUTURE
bring clear benefits. But they
also have their disadvantages, e.g. inadequate UV curing in shadow areas or for pigmented paints, and a long water evaporation phase before UV curing. A newly developed multi-curing waterborne PU dispersion has been shown to overcome these problems and also offer important benefits. Evidence of the positive feedback, Covestro’s innovative technology has received came from the 2018 European Technical Coatings Congress in Amsterdam where it won the Alain Clause Award.
1
Figure 1: Limitations and pain points of UV systems.
Drawbacks defeated The ultra-fast curing properties and high productivity of UV curing technology are well-known. But up to now, the applicability of this technology has been limited by some drawbacks, e.g. insufficient curing in shadow areas (e.g. on complex furniture geometries) or difficulties in pigmented paints, and a longer drying period due to slow water evaporation in case of UV-curable waterborne systems (Fig. 1). Covestro overcame these challenges by integrating a second curing mechanism into a UV-curable PU dispersion to create a multi-curing technology (Fig. 2). The combination of an oxidative and a UV-curing mechanism leads to a
UV-curing waterborne polyurethane (PU) coatings bring clear benefits. But they also have their disadvantages, e.g. inadequate UV curing in shadow areas or for pigmented paints, and a long water evaporation phase before UV curing. A newly developed multi-curing waterborne PU dispersion has been shown to overcome these problems and also offer important benefits.”
Thanks to the excellent coating performance achieved with low UV energy this technology can be used even without UV curing or with less photoinitiator input. As a uniformly high coating performance is now possible – even on difficult geometries and in shadow areas – there are no coating-related limitations on the design creativity of furniture manufacturers, for example. What’s more, this UV-curing waterborne PU dispersion is manufactured in part from renewable sources and does not contain a reactive diluent (oligomer),
higher crosslinking density (Fig. 3).
resulting in a more environmentally
This multi-curing technology brings a
friendly solution with no hazard
performance, especially under low UV
Efficiency and effectivity enhanced
dosage conditions. And even without
The technological breakthrough
less photoinitiator, it also requires
UV curing, it ensures sufficient coating
achieved by Covestro enhances the
less UV and drying energy. Last but
performance, though the properties
efficiency of coating processes in
not least, this dispersion is suitable
can be clearly enhanced when UV light
multiple ways. Speedy water release
for a wide range of applications,
is applied. It is the inherent crosslinking
enables to shorten the drying time up
e.g. clear and pigmented coatings,
of the polymer that offsets any lack of
to 50%, compared to other standard
exterior applications, and on-site
light, while the chemical constitution
UV-curable dispersions. Crosslinking
parquet (ref. Opening photo).
of Covestro’s multi-curing technology
the polymer chain improves the
So what chemistry makes this new
speeds up water release.
coating’s chemical resistance properties.
technology possible?
marked improvement in the coating
pictogram on the product label. This technology not only needs
international PAINT&COATING magazine - JANUARY/FEBRUARY 2019 - N. 55
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S P E C I A L ON RAW M AT E RI A L S , P I G M E NT S , PA I NT & C OAT I NG T E C HNOLOG I E S
Secondary crosslinking chemistry Oxidative crosslinking is one of the oldest and well-established curing technologies for coatings. This is particularly true for applications where the requirements are relatively basic. Oxidative crosslinking is a generally low-cost, easy-to-use solution as the curing agent oxygen is instantly available once a surface has been coated. But the curing on its own does not produce a very high crosslinking density. In other words, it cannot be seen as an adequate replacement for an isocyanate-based or UV-crosslinking system in demanding applications. As oxidative crosslinking is also a slow-reacting curing method, the final properties are only obtained after a post-application delay of several days.
Covestro integrated a second curing mechanism into a UV-curable PU dispersion to create a multi-curing technology. The combination of an oxidative and a UV-curing mechanism leads to a higher crosslinking density. This multi-curing technology brings a marked improvement in the coating performance, especially under low UV dosage conditions.â&#x20AC;?
The solution the Covestro specialists came up with involves a combination of UV radiation and oxidative curing. The benefits of both technologies are thus incorporated into a single system: high productivity, very high crosslinking densities leading to good chemical and mechanical resistances in areas where UV curing is possible; and relatively good properties in areas where the effect of radiation is inhibited by a complex geometry or UV-absorbing pigments. Covestroâ&#x20AC;&#x2122;s innovative PU dispersion technology is highly flexible and gives resin developers much more freedom in designing products best suited to the application in question. What this means in practice is that extra weight can be given to the oxidative curing step for systems in need of a post-curing via UV radiation, for example. Alternatively, an applicator may want to give UV radiation a greater weight in order to achieve more robustness and excellent properties even in shadow areas. Whatever weighting is chosen, this mixture of oxidative and UV curing leads to an advantageous outcome, as tests have proved.
INNOVATIONS: PRESENT&FUTURE
The technological breakthrough achieved by Covestro enhances the efficiency of coating processes in multiple ways. Speedy water release enables to shorten the drying time up to 50%, compared to other standard UV-curable dispersions. Crosslinking the polymer chain improves the coating’s chemical resistance properties.” Shorter drying time The introduction of a second crosslinking mechanism enables the drying time for conventional water-borne UV-curing coatings to be reduced by up to 50%. Coating formulations based on Covestro’s multi-curing PU dispersion are dry enough to be exposed to UV radiation just 2 - 5 minutes after application at an oven temperature of 50° C. Other factors such as line speed, air flux, substrate and the application amount naturally influence the overall drying time. However, this multi-curing PU dispersion has been shown in tests to deliver an impressive physical drying performance and enable fast water evaporation. If a coating with the double crosslinking mechanism is compared with a conventional water-borne UV-curing coating – both applied at 100 g/m2 and oven-dried at 50° C – the coating featuring the double crosslinking mechanism is dry in about 3 minutes, whereas the conventional product needs some 6 minutes to be dry enough to avoid white pore effect, due to water remaining in the dried film.
Lower costs The improved drying behaviour of formulations based on the new Covestro dispersion is due to the dual curing mechanisms: conventional radical polymerisation as the basis of all UV-curing coating systems, and alkyd modification resulting from oxidative crosslinking in the presence of air. The secondary crosslinking
Oxidative crosslinking is one of the oldest and well-established curing technologies for coatings. This is particularly true for applications where the requirements are relatively basic. Oxidative crosslinking is a generally low-cost, easy-to-use solution as the curing agent oxygen is instantly available once a surface has been coated.”
HIGH
PERFORMANCE POWDER COATINGS
© Covestro
SP ECIAL ON RAW MATE R IALS, PIGMEN TS, PAINT & COATING TECH N O LO GIES
The introduction of a second crosslinking mechanism enables the drying time for conventional water-borne UV-curing coatings to be reduced by up to 50%. Coating formulations based on Covestro’s multi-curing PU dispersion are dry enough to be exposed to UV radiation just 2 - 5 minutes after application at an oven temperature of 50° C. Other factors such as line speed, air flux, substrate and the application amount naturally influence the overall drying time.”
2 1
Figure 2: Multi-curing possibilities.
With a coating based on Covestro’s
efficient coating process than with
water evaporates and continues for
new multi-curing technology, the cost
standard waterborne UV-curing PU
several days. A coating reaches its
of the coating process can be reduced
dispersions.
final properties after 3-7 days at room
for several reasons: a lower oven
temperature. As well as improving
temperature for water evaporation, less
coating properties, alkyd modification
UV source energy consumed, a longer
Previously unattainable robustness
also increases the hydrophobicity of the
UV lamp lifetime and less photoinitiator
Incomplete UV curing can negatively
coating, which in turn improves water
required. Generally speaking, the
impact the quality of wood coatings
release during drying.
outcome is a more cost-effective and
on complex furniture geometries
© Covestro
mechanism starts as soon as the first
Covestro’s innovative PU dispersion technology is highly flexible and gives resin developers much more freedom in designing products best suited to the application in question. What this means in practice is that extra weight can be given to the oxidative curing step for systems in need of a post-curing via UV radiation, for example.”
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3 1
Figure 3: Idealized chemical structure of UV-curable polyurethane dispersions.
N. 55 - JANUARY/FEBRUARY 2019 - international PAINT&COATING magazine
With a coating based on Covestro’s new multi-curing technology, the cost of the coating process can be reduced for several reasons: a lower oven temperature for water evaporation, less UV source energy consumed, a longer UV lamp lifetime and less photoinitiator required.”
© Covestro
INNOVATIONS: PRESENT&FUTURE
4 1
Figure 4: Multi-curing UV-curing polyurethane dispersions for clear coatings.
or parquet coatings applied on site.
for resistance to a 48% ethanol solution during
shown to perform just as well as an
Coatings based on this new multi-curing
a one-hour exposure period. The coatings were
identical formulation with a more typical
dispersion, in contrast, have been shown
applied at 100 g/m2 on melamine, dried for
1% photoinitiator. Another advantage
to display a previously unattainable
10 minutes at 50° C and cured using an
for furniture manufacturers (and
robustness, as the oxidative crosslinking
80 W/cm UV Hg lamp (256 mJ/cm2). A clear
users) is that clear coats based on the
mechanism offsets any deficiencies in the
coat formulation based on the new dispersion
new dispersion are highly resistant to
UV-curing process. Tests were conducted
and containing only 0.5% photoinitiator was
everyday ‘threats’ such as water, red
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SP ECIAL ON RAW MATE R IALS, PIGMEN TS, PAINT & COATING TECH N O LO GIES
Complex furniture geometries
wine, coffee and hand cream – even if the
Bayhydrol® eco UV 2877, a Covestro product featuring the new multi-curing PU dispersion technology, is particularly suitable for coatings intended for industrial wood applications with complex geometries. The properties shown by Bayhydrol® eco UV 2877 include good chemical resistance without UV and very good resistance after UV curing, good hardness at a low UV dosage (shadow curing), and very good final hardness. Moreover, only 2 min 30 sec are required for the water release phase at 50° C. and 0.5% photoinitiator is sufficient. 40% solid content, 38% bio-based content (Fig. 6): Bayhydrol® eco UV 2877 is not only a high-performing solution for excellent wood coatings; it is also a more
Bayhydrol® eco UV 2877, a Covestro product featuring the new multi-curing PU dispersion technology, is particularly suitable for coatings intended for industrial wood applications with complex geometries. The properties shown by Bayhydrol® eco UV 2877 include good chemical resistance without UV and very good resistance after UV curing, good hardness at a low UV dosage (shadow curing), and very good final hardness.”
environment-friendly one.
© Covestro
Incomplete UV curing can negatively impact the quality of wood coatings on complex furniture geometries or parquet coatings applied on site. Coatings based on this new multicuring dispersion, in contrast, have been shown to display a previously unattainable robustness, as the oxidative crosslinking mechanism offsets any deficiencies in the UV-curing process.”
As Dr. Matthias Wintermantel, Covestro’s Head of
coating has not been
Application Development
UV-cured (Fig. 4).
for Building & Infrastructure
The superiority of this
Coatings, points out,
multi-curing PU dispersion
secondary crosslinking
technology is also evident
does make a significant
in critical coloured
practical difference:
pigmented coatings, e.g.
“If a coating formulation
white or yellow: yellow
is based on our new
pigments are highly absorbent of UV radiation; white pigments are the most critical for good
multi-curing PU dispersion,
5 1
water is released faster so UV curing can
Figure 5: Performance of pigmented wood coatings.
commence earlier. As our © Covestro
chemical stain resistance. All the tests conducted
secondary cross-linking mechanism is based on
so far have shown that
fatty acid modification, our
formulations based on the
Bayhydrol® eco UV 2877
new dispersion perform
has over 38% bio-based
better than ones using
content. Alkyd modification
established products
raises the system’s
for pigmented coatings
hydrophobicity, which leads
(Fig. 5). Furthermore, the
to faster water release
product has also shown
and speeds up the overall
good weather stability, making it considerable for exterior applications.
52
6 1
Figure 6: Properties of self-crosslinking UV-curable polyurethane dispersions.
N. 55 - JANUARY/FEBRUARY 2019 - international PAINT&COATING magazine
process. The outcome is improved productivity with less energy required.”
© ipcm ®
Opening photo: Chemtec’s new laboratory has started a test contracting service.
HIGHLIGHT OF THE MONTH
S P E C I A L O N RAW M ATE RI ALS, PIGMENTS, PA I NT & C O ATI NG TECHNOLOGIES
Chemtec Expands its Plant and Develops a Laboratory Test Contracting Service From an interview with Carlo Guidetti Chemtec Srl, Corbetta (Milan) – Italy
c.guidetti@chemtec.it
“U
pdated tradition” is not
“The technologies developed by
products that comply with the increasingly
just a slogan for Chemtec,
Chemtec are advanced, revolutionary,
restrictive safety regulations. Our
a company established in
and characterised by a very limited
corporate philosophy has always been
2010 and specialising in the formulation,
environmental impact,” states Carlo
oriented to our customers. This is not
production, and distribution of complete
Guidetti, the owner of this firm
limited to the peculiar relationship created
products and technologies for the
located in Corbetta (Milan, Italy). “They
during commercial negotiations, but it is
pre-treatment and waste water treatment
are designed to bring new solutions
understood as a deep collaboration that
processes intended for the coating sector.
into a traditionally difficult sector
includes the analysis and understanding
It also reflects the mission of a business
with little innovation. We constantly
of the production environment in which
that, although recently established, can
develop new formulations in order
our technologies will be installed, in order
rely on thirty years of experience in terms
to improve the toxicological profile
to formulate products that are often
of formulations and expertise.
of existing technologies and launch
tailor-made.”
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N. 55 - JANUARY/FEBRUARY 2019 - international PAINT&COATING magazine
HIGHLIGHT OF THE MONTH
The company is currently expanding its
area in future. The laboratory, our greatest
corrosion resistance tests, but also
factory in order to provide its customers
pride, will be located on the upper floor. Its
provide information on the causes of
with a complete service. The aim is
team will continue to research and develop
corrosion: in this way, we can define
insourcing some processes, such as
new custom formulations, but it will also start
targeted actions to solve any problems
production and logistics, installing new
a new test contracting service (ref. Opening
or improve the finishing performance
machines, and making the laboratory
photo and Fig. 1).”
level.”
even more efficient through the
“Thanks to impedance spectroscopy,
that gives us more control on our
The development of formulations in Chemtec’s laboratory
production. Currently, we have an about
In addition to the complete management
sheet among those offered by different
1000 m2-wide area that houses our
of the water cycle from pre-treatment to
suppliers or the most oxidation
production department, laboratory,
discharge, the services offered by Chemtec
resistant powder coating among
offices, and warehouse and that will be
include coating quality control.
different products with the same nature
implementation of the most innovative tools. “We want to create a structure
specific studies to identify, for example, the most corrosion resistant metal
© ipcm ®
integrated with an additional
on the other hand, we can conduct
production department for
but manufactured by different firms. This is
water-based products (which
the kind of tests that
now account for half of
our laboratory has
Chemtec’s entire production)
recently performed
and a logistics department.
for our customers,
“We will continue to outsource
thus helping them to
the manufacturing of
improve the quality
solvent-based and powder
of their products in a
products, but we will ship
very short time and
them from our factory.
without drastically
Although these are not
changing their coating
solvents with high VOC
processes.”
contents, flammable, or
The laboratory tools
dangerous, we have chosen not to insource their production. As for water-based products, on
1
Figure 1: The technical staff of the laboratory.
the other hand, we opted for
In addition to the devices used for salt spray resistance
an integrated production flow, from
“We perform a complete inspection of
analyses, Chemtec’s lab is equipped
the research and development of
coatings’ quality level, measuring the
with a cleaning machine for industrial
new solutions up to the formulation,
conventional parameters of adhesion,
tests and a 200 litre/hour reverse
production, packaging, and shipping of
impact, bending, etc. on the products treated
osmosis system with UV filters, entirely
end products.”
and coated by our clients. We also carry
conceived by the company’s technical
out neutral and acetic salt spray corrosion
staff (Fig. 2). “We are starting to
resistance tests and accelerated corrosion
offer our Chemtec-branded reverse
A new structure for a complete service
resistance tests with electrochemical
osmosis and demineralisation plants
By connecting two buildings, Chemtec’s
methods such as impedance spectroscopy
to the market (Fig. 3). We install these
factory will take a horseshoe shape.
and the ACET method.”
machines as a part of pre-treatment
“On one side, we will create a
“The latter technique enables us to quickly
and water treatment systems. In the
warehouse for raw materials, whereas
obtain objective and repeatable numerical
former case, these are devices for lines
the end product logistics department
data and to understand the causes of
not produced by Chemtec, whereas
will be located on the other side. We
corrosion. Indeed, in just 24 hours it is
in the latter they become accessories
will keep an empty area where we will
possible to obtain results that not only
or integral parts of physical-chemical
arrange a partly automated packaging
allow to predict the progress of salt spray
systems designed and installed by us.”
international PAINT&COATING magazine - JANUARY/FEBRUARY 2019 - N. 55
55
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© ipcm ®
© ipcm ®
SP EC IAL ON RAW MATE R IALS, PIGMEN TS, PAIN T & COATING TECH N O LO GIES
3 1
Figure 2: Analysis tools.
Figure 3: The Chemtec-branded 200 litre/hour reverse osmosis system with UV filters has been presented to the market recently.
For its analyses, the laboratory employs
Conclusions
- dynamic surface tensiometer: it
different techniques, as follows:
measures the dynamic surface tension
“We have chosen to invest in order to
- high performance liquid chromatography:
of a liquid to determine the exact
expand our plant and equip our company
it enables to detect the concentration of
concentration of a surfactant in a
with tools guaranteeing scientific,
oils and polymers in the baths of both
degreasing bath.
measurable results,” says Guidetti. “Such
Toran 3®, the one-stage cold pre-treatment
“Finally, our laboratory is equipped with
scientific approach obviously involves
system developed by Chemtec, and
a coating room including two 1 m -wide
high costs in terms of both tools and staff
conventional degreasing plants;
booths (one for liquids and the other for
training. However, although the hardest
2
powders) to coat samples and one drying
one, Chemtec has chosen this road to
technique is used to detect the
oven. Here, we can both formulate new
counteract the increasing spread of
cleanliness degree of surfaces.
products to be offered on the market
superficial solutions found in the
By measuring the surface tension, it is
and perform any coating quality control
pre-treatment and cleaning fields.
possible to detect the concentration
requested by our customers.”
Appropriate tools were necessary to achieve
- UV spectrophotometry: this analysis
this goal: the following
obtain scientific data related to the cleaning
© ipcm ®
of surfactants and thus
step was putting them at the service of any user requiring equally
level of the workpiece; - impedance spectroscopy:
accurate results for
analysis method used for
their tests. The aim
electrochemical systems,
is creating a more
including ACET;
scientific approach to the problems
- gas chromatography: employed for the control
that can arise in the
of raw materials and some
manufacturing industry
products (Fig. 4);
and, in particular,
- Fourier Transform Infrared
in the coating sector.
Spectroscopy (FTIR): used
The way is still long to
for the quality control of
“update tradition”,
some raw materials and to perform analyses for customer assistance;
56
4 1
Figure 4: The gas chromatograph for the control of raw materials.
N. 55 - JANUARY/FEBRUARY 2019 - international PAINT&COATING magazine
but it is based on well-established premises.”
© ipcm ®
Opening photo: Novaresine specialises in the formulation and production of alkyd resins and polyesters.
S P E C I A L O N RAW M ATE RI ALS, PIGMENTS, PA I NT & C O ATI NG TECHNOLOGIES
HIGHLIGHT OF THE MONTH
Novaresine: The Sustainable Approach of a Chemical Company Open to Everyone Interview to Bruno Franceschini and Francesco Tamburrino Novaresine Srl, Colà di Lazise, Verona – Italy
info@novaresine.com
N
ovaresine’s history started about
including can and coil coating, architecture
developing its manufacturing processes
forty years ago. With time, the
and decorations, transport, wood, and
in order to maintain the high quality level
company has specialised in the
natural stone, and they can meet any
of its truly Italian-made products.
formulation and production of alkyd
specific need (ref. Opening photo and
Last year, significant resources were
resins and polyesters, thus becoming a
Fig. 1).
invested in the R&D department, where
point of reference in the Italian chemical
Novaresine’s production plant covers an
the most qualified professionals work
market. Initially a part of the Tenax Group,
80,000 m area in Colà di Lazise (Italy), a
with sophisticated tools and cutting-edge
Novaresine is now an independent
stone’s throw from Lake Garda.
research techniques inside the Nova
high-tech company. Its products are
Over the years, the company has
Lab, the firm’s brand new quality
intended for the most diverse sectors,
focussed on strengthening and
control, research and development,
58
2
N. 55 - JANUARY/FEBRUARY 2019 - international PAINT&COATING magazine
© ipcm ®
HIGHLIGHT OF THE MONTH
1
Figure 1: A bird’s eye view of the production site.
and instrumental analysis
complied with safety
laboratory inaugurated in
and environmental
2018. ipcm®’s staff has asked a few questions to Novaresine CEO Bruno Franceschini and Foreign Sales Manager Francesco Tamburrino to understand the current dynamics of the Italian chemical industry and the developments expected for
regulations to be
Novaresine’s history started about forty years ago. With time, the company has specialised in the formulation and production of alkyd resins and polyesters, thus becoming a point of reference in the Italian chemical market. Initially a part of the Tenax Group, Novaresine is now an independent high-tech company. Its products are intended for the most diverse sectors, including can and coil coating, architecture and decorations, transport, wood, and natural stone, and they can meet any specific need.
accused of the opposite. That is why Novaresine has chosen to adopt a policy of complete transparency and openness. Recently, we have organised an Open Day while the plant was in full production. We took the opportunity
coating (Fig. 2).
to explain the details of
© ipcm ®
the raw materials used in
ipcm®: What does it mean
our new co-incinerator project, which includes
to be a chemical company,
the installation of a
nowadays?
highly technological
Bruno Franceschini: For a
system for the thermal
firm, defining itself a chemical
destruction of reaction
company has a different
water and exhaust
weight and value than in
solvents produced by our
the past. Nowadays, more
resins’ manufacturing
and more attention is paid
process. The institutions
not only by customers and
and municipalities of
competitors, but also by
our neighbouring towns
public opinion. Thanks to
were invited, as well as
the new media, information
all people interested
communicated in the wrong way is enough to spread wrong beliefs and lead a company that has always
in understanding our
2 1
production processes
Figure 2: CEO Bruno Franceschini (right) and Sales Manager Francesco Tamburrino.
and their impact on the environment.
international PAINT&COATING magazine - JANUARY/FEBRUARY 2019 - N. 55
59
© Novaresine
SP ECIAL ON RAW MATE R IALS, PIGMEN TS, PAINT & COATING TECH N O LO GIES
ipcm®: Did you invest a lot in
awards, such as the Certificate of
environmental safety?
Excellence that Certiquality assigns
BF: In the past six years, half
exclusively to companies awarded with
of the investments made by
the three certifications ISO 9001:2015
Novaresine have been aimed at
(quality), ISO 14001:2015 (environment),
optimising the safety level and
and OHSAS 18001:2007 (health and safety
reducing the environmental
of workers) and the EcoVadis certification
impact of our processes (Fig. 3).
obtained through the evaluation platform
These two aspects are a part
of Corporate Social Responsibility used
of our code of ethics and
worldwide by the largest companies to
they represent an added
assess the social, ethical, and ecological
value for our products on the
aspects of partners and suppliers, on which
market. Nowadays, if different
we aim at getting the Gold medal.
chemicals have the same
3 1
For a firm, defining itself a chemical company has a different weight and value than in the past. Nowadays, more and more attention is paid not only by customers and competitors, but also by public opinion. Thanks to the new media, information communicated in the wrong way is enough to spread wrong beliefs and lead a company that has always complied with safety and environmental regulations to be accused of the opposite. That is why Novaresine has chosen to adopt a policy of complete transparency and openness.”
60
ipcm®: How was this change
their manufacturers’ attention
implemented at the production level?
to environmental sustainability
Francesco Tamburrino: Over these
can make the difference
six years, we have made significant
and lead the customers to
improvements, our production volume has
choose one supplier rather
reached 26,000 tonnes, and turnover has
than another. Over the last
almost doubled. Thanks to the collaboration
ten years, Novaresine has
with some client companies, in particular
made a radical change in
from the can coating sector, we have
terms of environmental
increased the volume of water-based
policy, considering process
chemicals from 1% to 15%. In other words,
sustainability as its first goal.
saturated polyesters account for 12,000
Thanks to this project, we have
tonnes (of which 4,000 are water-based
obtained several international
products and 8,000 solvent-based, since
© ipcm ®
Figure 3: The new reactor is a part of the sustainable renovation project of Novaresine’s factory.
performance and quality level,
4 1
Figure 4: The Nova Lab.
N. 55 - JANUARY/FEBRUARY 2019 - international PAINT&COATING magazine
these are still often required, especially in
© ipcm ®
HIGHLIGHT OF THE MONTH
the coil coating sector) out of the 26,000 tonnes of products we manufacture. We still produce a good percentage of alkyd resins, mainly intended for the Italian wood and decorative market, and of unsaturated polyesters, used to treat natural stone. ipcm®: What is the characteristic that distinguishes the Novaresine products? FT: Certainly, our strength is our R&D department’s ability to timely and accurately develop and formulate tailor-made products by working side by side with customers. Our laboratory is the other element that characterises us: our factory renovation project will
5 1
end precisely with the updating of its tools.
Figure 5: The laboratory area devoted to quality control.
© ipcm ®
SP ECIAL ON RAW MATE R IALS, PIGMEN TS, PAINT & COATING TECH N O LO GIES
and instrumental analysis for application tests and test results. We are now equipping our 400 m2-wide lab with new machinery and equipment, not necessarily related to the formulation and analysis of resins. The goal is to obtain products that are as suitable as possible for their intended use through the results of our tests. In the quality control area (Fig. 5), we analyse raw materials, which are subjected to our internal controls to confirm their characteristics even if they are already certified, and finished resins, of which we verify the parameters included in the technical data sheet, such
6 1
as dry residue, solid residue,
Figure 6: The differential scanning calorimeter.
© ipcm ®
In the past six years, half of the investments made by Novaresine have been aimed at optimising the safety level and reducing the environmental impact of the processes. These two aspects are a part of the company’s code of ethics and they represent an added value for its products on the market.” BF: The ultimate goal is that our customers use the equipment made available by our lab as if it were theirs. We have decided to open the doors of our Nova Lab to all those wanting to collaborate with us for the creation of new chemical products. Previously, our activity was aimed at a niche target and limited to the formulation of resins (Fig. 4). Now, we have understood that the more the sectors involved in our projects, the higher the chances to learn useful skills from the mutual exchange of expertise: both our lab technicians and our customers can benefit from it. ipcm®: How is Nova Lab organised? FT: The laboratory is divided into three areas: quality control of raw materials and products, research and development,
62
7 1
Figure 7: The gas chromatograph for the purity and quali-quantitative analysis of raw materials and end products.
N. 55 - JANUARY/FEBRUARY 2019 - international PAINT&COATING magazine
© ipcm ®
HIGHLIGHT OF THE MONTH
8 1
Figure 8: The curtain coater for the paint application.
colour, viscosity, acid value, and all that
and coil coating sectors. For saturated
is required to check the products’ quality
polyesters, we have tools available to
level (Fig. 6).
determine the isothermal peaks of
The instrumental analysis area is the
reactions with a thermocouple system,
most innovative and sophisticated
devices for the optical evaluation of films
one in terms of equipment, including
applied on sheets, and a colourimeter
The ultimate goal is that Novaresine’s customers use the equipment made available by the company’s lab as if it were theirs. Novaresine has decided to open the doors of its Nova Lab to all those wanting to collaborate for the creation of new chemical products. Previously, its activity was aimed at a niche target and limited to the formulation of resins. Now, Novaresine has understood that the more the sectors involved in the projects, the higher the chances to learn useful skills from the mutual exchange of expertise: both the lab technicians and the customers can benefit from it.”
acquisition system and an ATR device with its related software package, centrifuges
© ipcm ®
a spectrophotometer with a data
for the separation of particles in solution, a gas chromatograph to determine the distribution of molecular masses through thermal analyses, and a classic gas chromatograph (Fig. 7). Finally, the synthesis area is equipped with two 2 kg stations and three 5 kg stations to produce resin prototypes in appropriate flasks. Here, production conditions are reproduced on a laboratory scale. ipcm®: How are coating resins analysed in your laboratory? FT: The application test area specialises in coating resins, especially for the can
Figure 9: The infrared spectrometer.
9 1
international PAINT&COATING magazine - JANUARY/FEBRUARY 2019 - N. 55
63
© ipcm ®
SP ECIAL ON RAW MATE R IALS, PIGMEN TS, PAINT & COATING TECH N O LO GIES
to determine
ipcm®: How does the
the colours’
investment for your
components,
laboratory fit into the
aging process,
context of your factory
hardness and gloss
renovation project?
levels, and all the
BF: The lab’s renovation
characteristics
was the last step of the
useful for assessing
development project of
the aesthetic
Novaresine, although
and functional
the most important one:
characteristics of
our laboratory is the tool
resins.
with which we gain our
Our lab is also
customers’ trust and
equipped with a
loyalise them. It must be
curtain coater to detect the coating layers’ grammage (Fig. 8),
equipped with the most 10 1
advanced devices and our technicians must be ready
Figure 10: The Aalborg control system.
to perform tests of any
a spectrometer
kind for the most diverse
for UV colour analyses (Fig. 9) now also used for wood, an Aalborg
industries. We would like the Nova Lab to be known in our sector
control system to assess curing processes in an oven able to reach
for its ability to meet any request, its willingness to help customers develop and formulate suitable products, and the effectiveness of its results – with a focus on environmental sustainability, which
metal sheets and carrying out stress tests on substrates.
Novaresine has and will always advocate.
© ipcm ®
very high temperatures (250-260 °C, Fig. 10), a König pendulum to detect surface hardness (Fig. 11), and different tools for pressing
The lab’s renovation was the last step of the development project of Novaresine, although the most important one: the laboratory is the tool with which Novaresine gains its customers’ trust and loyalise them. It must be equipped with the most advanced devices and its technicians must be ready to perform tests of any kind for the most diverse industries.”
64
11 1
Figure 11: The pendulum for performing hardness tests with the König method.
N. 55 - JANUARY/FEBRUARY 2019 - international PAINT&COATING magazine
© Emil Frei GmbH & Co. KG
Opening photo: Cost savings with significantly reduced solvent consumption.
INNOVATIONS: PRESENT&FUTURE
S P E C I A L O N RAW M ATE RI ALS, PIGMENTS, PA I NT & C O ATI NG TECHNOLOGIES
VOC-compliant Coating: Ultra-high-solid Platform Technologies Oliver Zanner Emil Frei GmbH & Co. KG – Bräunlingen, Germany
info@freilacke.de
T
he conversion from solvent-based to
coatings, multi-layer structures are almost
costly ventilation and filter technology.
water-borne coating systems is often
always used – such as cathodic EC or 2C epoxy
FreiLacke, on the other hand, is now using
linked with high investment costs. The
primers which are combined with 2C-PU top
its new ultra-high-solid systems (or UHS for
new ultra-high-solid platform technologies
coats. These coating systems score in terms of
short) which entirely meet the demands for
from FreiLacke can significantly reduce
adhesive strength and corrosion protection as
a reduction in the VOC content in paints and
solvent consumption, even without system
well as very good UV and chemical resistances.
coatings. With a solids content of up to 80
conversions.
Their disadvantage: A high VOC content which
percent by weight, they have a VOC value of
In order to produce high-quality and efficient
has to be compensated with laborious and
less than 350 g/l.
66
N. 55 - JANUARY/FEBRUARY 2019 - international PAINT&COATING magazine
INNOVATIONS: PRESENT&FUTURE
The conversion from solvent-based to water-borne coating systems is often linked with high investment costs. The new ultra-high-solid platform technologies from FreiLacke can significantly reduce solvent consumption, even without system conversions.” High stability, fast drying The UHS systems also include two new primers and a high-gloss top coat. “Our new 2C polyurethane primer UR1937H is used wherever rapid recoating with a wide range of top coat systems is required,” explained Andreas Morlock, head of the Development and Application Technology Industrial Coatings group at the Baden-based coating manufacturer. The primer is characterised by high stability and fast drying; despite the high solids content, it can be applied by means of conventional air atomisation or the Airmix process. Adhesion is good on many substrates and the use of a single curing agent for both the primer and the top coat provides users with simple handling as well as appreciable savings in time and money (Fig. 1).
Use of renewable raw materials If very high corrosion protection is required, the new 2C epoxy UHS primer ER1936H demonstrates its strengths: “We were able to formulate the curing agent component HE0016 using renewable raw materials in such a way that the irritation typical of amine curing agents is very low. The primer and curing agent were brought to series production completely without reactive thinners,” explained the group leader. Besides fast recoating, the system also scores with its high stability and a sufficiently long pot life. And the new 2C polyurethane UHS top coat UR1409G – a high-gloss top coat system that boasts excellent flow properties and rapid drying – is now also available to coating companies. Together with the UHS primers UR1937H and ER1936H, it ensures a reduction in emissions, short cycle times as well as balanced application and surface properties (Fig. 2).
Total layer thickness in only one step Those who want to accelerate their coating processes even further can make use of the new single-layer UHS system UR1422 from the Black Forest coating experts (ref. Opening photo): FreiLacke has also formulated this 2C system with a solids content of around 80 percent by weight and employs the latest generation of raw material components. “The system meets the
© Emil Frei GmbH & Co. KG
SP ECIAL ON RAW MATE R IALS, PIGMEN TS, PAINT & COATING TECH N O LO GIES
A quarter less VOCs The values of the total emissions per coated surface indicate a reduction in the VOC content of around 25 percent. “Particularly worthy of mention is the very good corrosion protection of the single-layer systems as well as the popping limit of the single-layer system,” said the developer. The system is particularly suitable for industries such as vehicle construction because it resists deformation of the substrate without forming cracks. “Our new single-layer system boasts outstanding values with respect to deformation and stone-chip resistance. When performing the Erichsen cupping test (DIN EN ISO 1520), a deformation value of more than six millimetres is reached before initial cracks appear in the coating,” concluded Andreas Morlock.
1
Figure 1: UHS coatings for agricultural machinery.
highest requirements for high, popping-free
reduced and throughput increased with
layer thicknesses, drying that meets the
the new single-layer system. Additional
needs of real-life situations, good surface
application systems can be omitted
properties and high resistance levels to
and solvents – especially for cleaning
corrosion,” said developer Philipp Butkus.
purposes – can be saved. In addition, the
“The VOC content of the coating system is
handling of the coating materials is much
significantly below the limit value of 420 g/l.
easier with regard to logistics and storage;
The application of the entire layer thickness
mix-ups of the individual coating materials
up to a dry layer thickness of 150 μm
are ruled out.
is possible in just one operation. The thickness depends greatly on the type of application, but even with the airless method, which is often critical with regard to popping formation, a popping limit of more than 200 μm dry layer thickness is reached,”
© Emil Frei GmbH & Co. KG
maximum possible popping-free layer
explained Butkus.
Improved cycle times, simplified handling By eliminating intermediate flash-off and forced intermediate drying of the primer, the cycle times can be considerably
Figure 2: UHS coatings for use on motors, gears and pumps.
68
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N. 55 - JANUARY/FEBRUARY 2019 - international PAINT&COATING magazine
The system is particularly suitable for industries such as vehicle construction because it resists deformation of the substrate without forming cracks. The new single-layer system boasts outstanding values with respect to deformation and stone-chip resistance.”
© ipcm ®
Opening photo: A detail of a laboratory in the Titan’s R&D Centre in El Prat de Llobregat near Barcelona.
HIGHLIGHT OF THE MONTH
S P E C I A L O N RAW M ATE RI ALS, PIGMENTS, PA I NT & C O ATI NG TECHNOLOGIES
Research and Technological Innovation as the Cornerstones of Industrias Titan’s Philosophy Ilaria Paolomelo ipcm®
T
he coating market is constantly evolving.
have an R&D department focussing on
of the Spanish company since its
It requires increasingly advanced
innovation, in terms of both products and
establishment in 1917. Thanks to the
solutions in terms of both aesthetics
manufacturing processes.
choices and investments implemented
and performance, which also comply with
For Industrias Titan, technological
in about a century of history, Industrias
ever-stricter environmental regulations.
innovation has always been synonymous
Titan has become a leading company
In order to meet market needs, therefore,
with constant research and development:
in the Spanish market of industrial and
for a coating manufacturer it is crucial to
this has been the corporate philosophy
decorative paints. In addition to its
70
N. 55 - JANUARY/FEBRUARY 2019 - international PAINT&COATING magazine
© ipcm ®
HIGHLIGHT OF THE MONTH
company has three laboratories located within a single building and a staff of 40 specialised technicians who share tools, knowledge, experience, and skills to create synergies and operational efficiencies in a stimulating environment. Industrias Titan’s R&D centre is arranged on three floors, each devoted to a different sector as follows: • research and development of powder coatings (Fig. 1); • research and development of decorative and industrial liquid coatings (Fig. 2); • quality control, product analysis, and colourimetry (Fig. 3).
The powder coating R&D laboratory “In order to produce high quality coating solutions, as well as
1
conventional tools such as colourimeters and glossmeters, our lab
Figure 1: The laboratory’s department for powder coatings.
the reactivity of products, a dustmeter for measuring the size of the powder particles of all the
© ipcm ®
production facilities in Spain and
is equipped with more sophisticated tools such as DSC for analysing
products formulated by us,
Portugal, the firm has a modern
and a reduced-scale system
and innovative R&D centre in
for wood effect sublimation,
El Prat de Llobregat – a strategic
which also includes a vacuum
location near the airport and port
press (Fig. 4),” says Powder
of Barcelona, the Alta Velocidad
Coating Technical Director
Española (AVE) rail network,
José Antonio Arrieta. “Titan
and the largest waste water
is one of the companies that
treatment plant in Spain
has most focussed on the
(ref. Opening photo).
wood effect market and our
Industrias Titan has decided to
sublimation bases are among
further expand its research centre
the most performing ones
of Powder Coating R&D unit located in El Prat de Llobregat. Here, the powder products of the Titan range are reproduced on a
on the market. Moreover,
2 1
in the so-called “dirty area”
Figure 2: The R&D laboratory for liquid coatings.
of our laboratory, we have © ipcm ®
laboratory scale and numerous tests are performed to check the quality of coating systems and products and prevent post-production defects. Currently, the
The coating market is constantly evolving. It requires increasingly advanced solutions in terms of both aesthetics and performance, which also comply with ever-stricter environmental regulations. In order to meet market needs, therefore, for a coating manufacturer it is crucial to have an R&D department focussing on innovation, in terms of both products and manufacturing processes.”
3 1
Figure 3: The Quality control, product analysis, and colourimetry laboratory.
international PAINT&COATING magazine - JANUARY/FEBRUARY 2019 - N. 55
71
© ipcm ®
SP ECIAL ON RAW MATE R IALS, PIGMEN TS, PAINT & COATING TECH N O LO GIES
For Industrias Titan, technological innovation has always been synonymous with constant research and development: this has been the corporate philosophy of the Spanish company since its establishment in 1917. Thanks to the choices and investments implemented in about a century of history, Industrias Titan has become a leading company in the Spanish market of industrial and decorative paints.”
4 1
Figure 4: A differential scanning colourimeter in use by the powder coatings laboratory.
R&D Project Manager Jaume Solá. “In
says Solá, “and we carry out some
our liquid coating R&D lab, we design
application tests with different tools, such
not only industrial solutions but
as roller, brush, and gun, to check the
also, and above all, decorative liquid
aesthetic properties of the applied film.”
paints, which are our core business.
“In the near future, Titan intends to
At the end of the laboratory-scale
expand its range of liquid paints for
production cycle, a liquid product is
industrial use. Currently, these are mainly
subjected to numerous tests aimed
used for the industrial maintenance of
at checking both its optical properties
large structures. However, we will expand
a reduced-scale powder production line
and performance level. As for the latter, we
their range by the end of 2019 with the
composed of a mixer, a mill, and an extruder.
assess the film’s flexibility and weathering
addition of the OXIRON line, which will
Here, our staff takes care of the selection and
resistance with an impact meter and we
include both industrial and decorative
processing of raw materials, reproducing real
measure the paint’s viscosity with different
water-based formulations. In the
industrial manufacturing conditions to
types of viscometer. Finally, our products
decorative paint sector, this will not be
fine-tune the formulations (Fig. 5). Finally,
undergo salt spray corrosion tests (Fig. 7),”
a big change, as water-based products
customer’s curing conditions and analyse the behaviour of our paints in their ovens.
© ipcm ®
we have a gradient oven to simulate our
We can make an accurate evaluation of different characteristics like: such as degassing, mechanicals properties that our products will achieve in their installation (Fig. 6).” “In line with its corporate philosophy, Titan is constantly looking for innovative coating systems to be launched on the market. In particular, we are investing in two projects for the powder sector: a range of hyper-durable coatings to be Qualicoat Class 3 certified and graphene as an additive to create powders with an increased barrier effect, thus offering high performance coatings even in the most corrosive environments,” explains Arrieta.
The liquid coating R&D laboratory “The liquid paint range of Industrias Titan is very wide: for our formulations, we use about 2000 raw materials, which are all catalogued and stored in our dedicated laboratory,” says
72
5 1
Figure 5: The powder coatings laboratory has a reduced-scale powder production line composed of a mixer, a mill, and an extruder.
N. 55 - JANUARY/FEBRUARY 2019 - international PAINT&COATING magazine
© ipcm ®
HIGHLIGHT OF THE MONTH
6 1
Figure 6: The gradient oven to simulate customers’ curing conditions and analyse the mechanical resistance of the applied films.
are now widespread; however, the OXIRON line will certainly be an important innovation for the industrial sector, where solvent-based coatings generally prevail due to their ease of application and drying speed.”
The quality control, product analysis, and colourimetry laboratory “The third lab is mainly devoted to three services: colourimetry, quality control, and product analysis. In addition to checking the quality of both raw materials and end products, we carry out tests to verify that the products comply with current regulations. These include the control of emissions of volatile organic compounds. We use liquid chromatography tools to perform qualitative and quantitative analyses and infrared and mass spectrophotometry tools to separate the components contained in the liquid paint mixtures in order to detect and analyse the amount of VOCs in the formulation. Finally, a further research topic we are working on is the
Industrias Titan has decided to further expand its research centre of Powder Coating R&D unit located in El Prat de Llobregat. Here, the powder products of the Titan range are reproduced on a laboratory scale and numerous tests are performed to check the quality of coating systems and products and prevent post-production defects.”
© ipcm ®
SP ECIAL ON RAW MATE R IALS, PIGMEN TS, PAINT & COATING TECH N O LO GIES
7 1
Figure 7: Some instruments to analyse the physical, mechanical and chemical resistance of the film.
Titan performs bacteriological checks on all water-based products and makes sure that the coatings come out of the manufacturing cycle completely free of contamination. The production water cycle is monitored carefully: the water is purified, filtered, and only recirculated after a careful bacteriological analysis. Spain has very strict regulations concerning the percentage of biocidal additive that can be added to formulations.”
control of biocides contained in
is why it is crucial to monitor the quality
skills among our resources and the
liquid coatings, which must not
of water, especially in a warm climate like
company’s inclination towards the
exceed certain limits according
ours.”
continuous search for innovative solutions have enabled Industrias
to current law. We work closely with the bacteriological analysis
“In Titan’s R&D centre, each lab
Titan to position itself on the Iberian
laboratory in order to find the
collaborates closely with the other two.
market as a leader in its sector,” states
correct formulation of a product
The sharing of knowledge and technical
José Antonio Arrieta.
“Titan performs bacteriological checks on
© ipcm ®
(Fig. 8).”
all water-based products and makes sure that the coatings come out of the manufacturing cycle completely free of contamination. The production water cycle is monitored carefully: the water is purified, filtered, and only recirculated after a careful bacteriological analysis. Spain has very strict regulations concerning the percentage of biocidal additive that can be added to formulations. These additives cannot be used freely: that
74
8 1
N. 55 - JANUARY/FEBRUARY 2019 - international PAINT&COATING magazine
Figure 8: Bacteriological analysis of the water-based coatings.
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)
Š Fraunhofer IAP
Opening photo: Complex AM-fabricated parts dry after their metallization.
INNOVATIONS: PRESENT&FUTURE
S P E C I A L O N RAW M ATE RI ALS, PIGMENTS, PA I NT & C O ATI NG TECHNOLOGIES
Lacquering Before Polishing: Technical Coatings for Additive Manufacturing Sandra Mehlhase Fraunhofer IAP, Potsdam-Golm â&#x20AC;&#x201C; Germany
info@iap.fraunhofer.de
A
dditive Manufacturing (AM)
In a joint project, researchers from the
stereolithography (SLA) or material
has many advantages: custom
Belgian NPO Sirris and the Fraunhofer
jetting (MJ) play important roles in the AM
manufacturing, flexible production
Institute for Applied Polymer Research
market. While the first AM technologies
and easy customization, for example.
IAP have investigated technical coatings
were developed for rapid prototyping,
Yet many products have a high surface
for additive manufacturing (TCAM) with
today, AM is taking the leap into industrial
roughness and porosity. The post
promising results.
production. It is one of the important
processing of the thus fabricated parts is
AM describes the construction of
future technologies that will influence
time consuming and often a significant cost
an object layer by layer using a
the manufacturing market and beyond.
factor for manufacturers. Technical coatings
3D-model. The technologies vary but
The industry can profit from AM with its
open up new possibilities for the AM
3D printing is probably the best known.
production on-demand capabilities, its and
market, especially in industrial production.
However, selective laser sintering (SLS),
flexible adaptability and the possibility to
76
N. 55 - JANUARY/FEBRUARY 2019 - international PAINT&COATING magazine
INNOVATIONS: PRESENT&FUTURE
produce small quantities. However, the surface of the fabricated components is usually very rough and porous. To meet this challenge, two partners investigated technical coatings for additive manufacturing in a joint project: Sirris is an organization focused on finding solutions for technological challenges, usually in projects with universities, research centers, companies, associations and other institutions. Researchers at the Fraunhofer IAP,
Additive Manufacturing (AM) has many advantages: custom manufacturing, flexible production and easy customization, for example. Yet many products have a high surface roughness and porosity. The post processing of the thus fabricated parts is time consuming and often a significant cost factor for manufacturers.”
Technical Coatings enable smooth and sealed surfaces with specific functions With technical coatings, the Sirris and Fraunhofer researchers were able to significantly improve AM-produced parts regarding surface roughness and porosity. It turned out that the combination of lacquering and polishing is the most efficient technique for surface optimization in AM. In addition, components can be functionalized further by using special lacquers or
among other areas of expertise, have
surface treatments. In the current
long years of experience in
project, the scientists metallized the
technical coatings.
smoothed components. The metal
“Today, with the transition from rapid
quality is essential for industry producers.
coating is a visible example for the
prototyping to industrial production,
In addition, demands on the surface quality
functionalization process. Improved
the demands on AM-manufactured
are growing”, says Dr. Andreas Holländer,
scratch resistance, antimicrobial
components are growing (Fig. 1). Being
expert in surface technology at the
properties and many more features are
able to warrant consistent material
Fraunhofer IAP.
applicable.
EcoDose
Electronic dosing system for higher application efficiency The EcoDose 2K can be used in manual and automatic processes. Optimized for quick color changes and easy flushing, it enhances resource utilization and contributes to higher application efficiency. Fluids like 1 or 2K materials, water and solvent based paints, varnishes, lacquers and monolayer paints are measured consistently and precisely, even media with different viscosities.
www.verind.it
SP ECIAL ON RAW MATE R IALS, PIGMEN TS, PAINT & COATING TECH N O LO GIES
AM describes the construction of an object layer by layer using a 3D-model. The technologies vary but 3D printing is probably the best known. However, selective laser sintering (SLS), stereolithography (SLA) or material jetting (MJ) play important roles in the AM market.”
Patrick Cosemans from Sirris Flanders adds:
faster and more cost-efficiently. With AM, a
“If we only polish our finished components,
component that would conventionally consist
it takes a long time, and especially with fine,
of many individual parts and would have to
detailed features, we change their shape.
be assembled can be created in one step.
It comes to abrasion, which we want to avoid.
“It is important”, says Dr. Holländer, “that
With the Fraunhofer IAP we have developed
every part of the component’s surface
possibilities to overcome the current
has the required quality. In complicated
problems, especially the porous and rough
parts, some surfaces are difficult to reach.
surface, in additive manufacturing.”
With the appropriate surface treatment
Is combining AM with established technologies the future?
technology, which in future will even be integrated into the AM machines, we are able to functionalize even complex components
Conventional production methods often reach
completely.”
their limits with complex components.
Finishing the project both partners conclude
The more complex a component, the
that AM in combination with established
more difficult and expensive it becomes
technologies provides even better
Sirris provided different components
in conventional production. AM opens up
capabilities and more possible applications
made with SLS, SLA, MJ, and FDM (fused
possibilities to produce complex components
than AM alone.
deposition modeling = 3D printing). All methods pose different challenges to surface treatment. “With years of expertise in surface treatment, we are able to meet a wide range of requirements. We analyzed each part in the first step to determine the specific properties. Afterwards we were able to activate, paint, and polish and, in this case, metallize the respective surface with the appropriate method”, says Holländer, who leads the research group at
With technical coatings, the Sirris and Fraunhofer researchers were able to significantly improve AM-produced parts regarding surface roughness and porosity. It turned out that the combination of lacquering and polishing is the most efficient technique for surface optimization in AM.
78
© Fraunhofer IAP
the Fraunhofer IAP.
1
Figure 1: Today, with the transition from rapid prototyping to industrial production, the demands on AM-manufactured components are growing.
N. 55 - JANUARY/FEBRUARY 2019 - international PAINT&COATING magazine
© Graco
Opening photo: Graco offers products that are suitable for all three mixing common methods to mix plural component paint: sequential dosing, dynamic dosing and continuous flow.
INNOVATIONS: PRESENT&FUTURE
S P E C I A L O N RAW M ATE RI ALS, PIGMENTS, PA I NT & C O ATI NG TECHNOLOGIES
The Evolution from Single Component to Plural Component Paint Cristiano Giancola Graco Distribution BVBA, Maasmechelen – Belgium
cristiano.giancola@graco.com
W
hat advantages does plural
as multi component or 2K) paint. Single
In the last 20-25 years there has
component paint offer, what is
component paint consists of only one
been a very strong migration towards
the most optimal method to mix
material that reacts with various factors
plural component paint. Unlike single
it, and what mixing equipment do you need?
such as heat, evaporation, moisture in the
component paint, plural component paint
In the finishing business there are
air, UV etc. Plural component paint involves
has a potlife, which is the period of time
numerous types of paint, but the two most
at least two components – a resin and a
during which the paint is usable after
commonly found are single component
catalyst – mixed together in a certain ratio to
being mixed. Plural component paints can
(or 1K) and plural component (also known
start a reaction.
be solvent-based or waterborne.
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N. 55 - JANUARY/FEBRUARY 2019 - international PAINT&COATING magazine
INNOVATIONS: PRESENT&FUTURE
Epoxies are common plural component
the environmental benefits of plural
paints that are usually applied at high
component paint due to lower VOC’s
Ways to mix plural component paint
pressure as base coats to provide a
because you don’t have to evaporate
There are three common methods
protective layer; they typically contain
solvent.
to mix plural component paint:
a lot of fillers. Other common plural
Finally, plural component paints can have
sequential dosing, dynamic dosing and
component paints are polyurethanes,
a higher solid content, which leads to
continuous flow. Before describing
which are usually applied at low
better surface coverage.
them, it’s first necessary to understand © Graco
pressure as thin top coats to obtain a good quality
what are the different
finish. It is important to
components
note that epoxies and
being mixed.
polyurethanes use two
These are shown
completely different and
in Figure 1.
incompatible catalysts.
Component A
So if you are spraying
is the resin or
both epoxies and
base material.
polyurethanes you need
It can also be
two different mixing
a prepolymer,
machines.
polyol or lacquer. Component B
Benefits of plural component paint There are many advantages to using plural component paint. Compared to single component paint, plural
is the catalyst, which is also called the
1
accelerator,
Figure 1: The two (or sometimes three) components to be mixed to make a plural component paint.
mechanical strength which allows it to withstand abusive conditions better than other paints. It also has better chemical resistance, so can better withstand exposure to a wide range of abrasive chemicals. Plural component paint demonstrates increased flexibility. This means that painted polymeric substrates such as a car bumper are less likely to crack on impact. Another benefit is that less energy is required to cure the paint. Ovens can therefore be run at lower temperatures, which reduces cost. Faster cure times are possible with plural component paints, and curing is much easier to control. Increasingly important these days, especially with companies keen to enhance their green credentials, are
activator or hardener. In some plural
component paint displays improved durability. It has a higher
promoter,
In the finishing business there are numerous types of paint, but the two most commonly found are single component (or 1K) and plural component (also known as multi component or 2K) paint. In the last 20-25 years there has been a very strong migration towards plural component paint. Unlike single component paint, plural component paint has a potlife, which is the period of time during which the paint is usable after being mixed. Plural component paints can be solvent-based or waterborne.”
component paints, a third component (C) is added, such as a reducing agent. Mixing used to occur manually (and still does in some regions) but nowadays mainly occurs via mechanical or electronic mixers, also called proportioners. In the following diagrams, blue is the resin and yellow is the catalyst, which come together to form the green final paint product. The sequential dosing method of mixing In sequential dosing (Fig. 2), both resin and catalyst go through a flow meter with a metering valve, but never both at the same time. Either the resin valve or the catalyst valve is opened; never both together. This means that catalyst is shot into the resin in a sequential way. The mixed paint then enters an
international PAINT&COATING magazine - JANUARY/FEBRUARY 2019 - N. 55
81
integrator, a static mixer and then
© Graco
SP ECIAL ON RAW MATE R IALS, PIGMEN TS, PAINT & COATING TECH N O LO GIES
In other words, the resin flows
exits along the hose and through the
continuously and the catalyst
gun.
is given in shots at regular
Figure 3 illustrates the machine
intervals and in different
opening the resin valve A for a certain
quantities, depending on your
amount of time and then closing it,
mix ratio (Fig. 5).
when catalyst valve B opens to give a
With dynamic dosing you
certain amount or shot of catalyst.
remove all the disadvantages
A key feature of sequential dosing
of the sequential dosing’s
is the use of an integrator, which
integrator. Dynamic dosing
has advantages and disadvantages.
is suitable for a wider range
One advantage is that you can easily
of paints, including
change the size of the integrator:
shear-sensitive paints,
50 cc is often a standard size, but you
primers with high amounts
can choose smaller (10 or 25 cc) or
of solids and/or abrasives,
larger (100 cc) integrators. This means
high gloss wood applications,
that with sequential dosing a large
and polyurethane and Iso
range of mixing ratios is possible. Sequential dosing is easy to control via a regulator, and is particularly suitable for solvent-borne paints
applications. The absence of
2 1
an integrator that needs to be
Figure 2: Sequential dosing.
flushed means it’s a very good method if you have multiple
with a low viscosity that are relatively
colour changes, and consequently you
straightforward to mix.
use less solvent to flush. It also means
The disadvantage of an integrator is that
that it’s much easier to handle material
if you have an application that requires
with different viscosities.
a lot of colour changes, for every new
However, dynamic dosing is not a perfect mixing method. You need to
colour you use you need to flush the integrator, which leads to a lot of waste
Epoxies are common plural component paints that are usually applied at high pressure as base coats to provide a protective layer; they typically contain a lot of fillers. Other common plural component paints are polyurethanes, which are usually applied at low pressure as thin top coats to obtain a good quality finish.”
material and high solvent use. This is particularly so with a 50 or 100 cc integrator; slightly less with a 10 or 25 cc integrator. In general, sequential dosing is fine for up to eight colour changes per day; more than that and it becomes less cost-effective. A further disadvantage of sequential dosing is that it is not suitable for high viscous fluids or shear-sensitive fluids such as water-borne polyurethanes because the integrator creates turbulence which can damage the paint.
carefully control the pressure of the resin and catalyst. In fact, the catalyst has to be at a pressure that is at least 10-15% higher than that of the resin. If the catalyst pressure is lower than this, it will not penetrate the resin. If the catalyst pressure is too high, it will block the flow of resin. This means that you need a resin pressure regulator and a catalyst pressure regulator. And also you need a regulator for the final mixed material. You also need a restrictor, which comes in a number of sizes depending on the mix ratio and the flow.
The most obvious difference with dynamic dosing compared to sequential dosing is the absence of an integrator; the catalyst is injected directly into the stream of resin (Fig. 4).
82
© Graco
The dynamic dosing method of mixing
3 1
Figure 3: The mixing sequence of the two components during sequential dosing.
N. 55 - JANUARY/FEBRUARY 2019 - international PAINT&COATING magazine
© Graco
INNOVATIONS: PRESENT&FUTURE
4 1
Figure 4: Dynamic dosing.
© Graco
There are many advantages to using plural component paint. Compared to single component paint, plural component paint displays improved durability. It has a higher mechanical strength which allows it to withstand abusive conditions better than other paints. It also has better chemical resistance, so can better withstand exposure to a wide range of abrasive chemicals.”
5 1
Figure 5: The mixing sequence of the two components during dynamic dosing.
© Graco
SP ECIAL ON RAW MATE R IALS, PIGMEN TS, PAINT & COATING TECH N O LO GIES
The most obvious difference with dynamic dosing compared to sequential dosing is the absence of an integrator; the catalyst is injected directly into the stream of resin. In other words, the resin flows continuously and the catalyst is given in shots at regular intervals and in different quantities, depending on your mix ratio.”
6 1
Figure 6: Continuous flow.
Graco’s plural component paint mixers Graco offers products that are suitable for all three mixing methods (ref. Opening smooth mixing process that does not
photo). For sequential dosing, Graco offers
With the continuous flow method of mixing
damage the paint. It’s therefore ideal
two products. One is the Graco ProMix® 2KS,
plural component paint, you have a pump
for shear-sensitive fluids. It’s also highly
which offers precise and reliable electronic
and two lowers. Depending on the volume
suitable for high solids/abrasive primers,
proportioning for a broad range of
of your lowers you create a mix ratio that is
and for applications with multiple colour
solvent-borne, water-borne and acid catalyzed
defined by the displacement of the piston
changes as less solvent is required for
materials. From entry level to upgraded
(Fig. 6).
flushing. Another important advantage
applications, the ProMix 2KS provides
With continuous flow, the components
is that it allows you to mix at the gun if
flexibility and increased efficiency – including
– the resin and the catalyst – are mixed
your gun is a specially designed 2K gun.
optimized flushing sequences and an optional
continuously and smoothly. Figure 7
This minimizes waste and flushing and
third purge valve to properly manage
displays the mixing sequence of a 2:1 mix.
optimizes your return on investment.
water-borne urethanes for manual and
As with dynamic dosing, no integrator is
A challenge with continuous flow is that
automatic operation.
necessary. Continuous flow leads to a very
you have to balance the pressures of
The second product for sequential dosing is
your resin and catalyst very carefully,
the Graco ProMix 2KE flow meter system which
depending on your flow rate. You also
provides precise fluid volume measurements
need to size the hosing depending
to enable you to efficiently meet your target
on the hose length. Paint viscosity
mix ratios (Fig. 8). Designed to handle most
differences can also cause problems.
water-borne and solvent-borne materials, a
Volumes also tend to be lower due
neat feature of this product is that you can
to the need to clean the system,
automatically flush the exact amount of solvent
particularly during colour changes.
required, reducing waste and disposal costs.
In sequential dosing, both resin and catalyst go through a flow meter with a metering valve, but never both at the same time. Either the resin valve or the catalyst valve is opened; never both together. This means that catalyst is shot into the resin in a sequential way.”
84
© Graco
The continuous flow method of mixing
7 1
Figure 7: The mixing sequence of the two components during continuous flow mixing.
N. 55 - JANUARY/FEBRUARY 2019 - international PAINT&COATING magazine
© Graco
INNOVATIONS: PRESENT&FUTURE
8 1
Figure 8: The Graco ProMix 2KE flow meter system for sequential dosing provides precise fluid volume measurements to efficiently meet the target mix ratios.
For dynamic dosing the same ProMix 2KS is available, but with additional proportioning technology to meet the needs of unique applications. Also for dynamic dosing, the Graco ProMix 2KE Pump-Based System is designed with reliable Merkur® pumps. It’s easy to run and comes ready to spray. For continuous flow, the Graco ProMix M2K is an easy-to-use plural component proportioning system that has all you need in one small package (Fig. 9). This fixed ratio machine keeps your mix ratio consistent while only mixing what you use. Plus it eliminates all of the wasted material and clean-up associated with hand mixing – saving you precious time and money. An exciting new addition to Graco’s plural component proportioning line is the ProMix PD2K which is designed for continuous flow mixing (Fig. 10). It allows you to mix
SP ECIAL ON RAW MATE R IALS, PIGMEN TS, PAINT & COATING TECH N O LO GIES
close to the gun, greatly reducing
of the main parameters to consider are:
mixed material waste and flush
• The type of material.
solvent waste generated during
• The viscosity of material.
the flush sequence. 100% positive
• Is there a viscosity difference between the
© Graco
displacement technology allows for
resin and the catalyst?
accurate mix ratios and consistent,
• What is the solid content of the paint?
accurate performance.
• Is the material shear-sensitive?
Which method is best for my specific application?
• Are you using a low viscous fluid? • Do you want a long pot lifetime? • Is ease of control important?
There are many parameters Graco is able to satisfy each specific application
sequential dosing, dynamic dosing
requirements and suggest the most optimal
or continuous flow, and which Graco
mixing method and plural component
plural component mixer to use. Some
proportioner.
© Graco
that influence whether to use
9 1
Figure 9: For continuous flow, the Graco ProMix M2K is an easy-to-use plural component proportioning system.
Graco offers products that are suitable for all three mixing methods. For sequential dosing, Graco offers two products: the Graco ProMix® 2KS and the Graco ProMix 2KE. For dynamic dosing the same ProMix 2KS is available, but with additional proportioning technology to meet the needs of unique applications. For continuous flow, the Graco ProMix M2K is an easy-to-use plural component proportioning system that has all needed in one small package.
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10 1
Figure 10: The ProMix PD2K is designed for continuous flow mixing.
®
Š Nordson Deutschland GmbH
Opening photo: It is often the coating that contributes to fulfill specific customer requirements of an enclosure. Those requirements arise, for example, from the installation site of an enclosure for photovoltaic or wind turbine systems, in the production halls of automotive suppliers, in the food and beverage industry, or in a data center.
FOCUS ON TECHNOLOGY
Electrical Cabinet Manufacturer Rittal Offers Insight into Their Production Mario Hahn Nordson Deutschland GmbH, Erkrath â&#x20AC;&#x201C; Deutschland
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ics.eu@nordson.com
N. 55 - JANUARY/FEBRUARY 2019 - international PAINT&COATING magazine
FOCUS ON TECHNOLOGY
R
leading system suppliers for
Millions of square meters and intelligent standardization
enclosures, power distribution,
“Our goal is to use standardized products
ittal is one of the world‘s
Rittal’s goal is to use standardized products to meet customer-specific requirements faster and on a more timely basis. It is in the process of creating the conditions to achieve this, especially in the coating systems area and it is doing so despite the fact that the total number of square meters of powder coated surface area per year measures in the millions!”
climate control, IT infrastructure
to meet customer-specific requirements
and software & services. This global
faster and on a more timely basis. We are
player based in Herborn, Germany,
in the process of creating the conditions
offers insights into the configuration
to achieve this, especially in the coating
and processes of its state-of-the-art
systems area,” admits Heiko Denner,
powder coating systems.
Project Manager for Surface Finishing
In all markets, in countless industries,
Technology at Rittal, during the meeting
and in nearly every company,
in the company’s own Rittal Innovation
“Industry 4.0” is the next big thing:
Center, “and we’re doing so despite the
but does the investment in new
fact that the total number of square
equipment really pay off? What
meters of powder coated surface area per
conditions have to be met and what
year measures in the millions!”.
changes must be made in order to
In addition to Rittal’s standard Light Gray
manufacture high-quality products
RAL 7035, many other colours approved
that satisfy customer requirements
by Quality Assurance are available as
hygiene requirements in all areas.
cost-effectively today?
serial production to satisfy customer
Here the right housing design can help
Machinery and equipment from
wishes.
save cleaning and disinfectant agents,
Germany are a calling card of local
“For anyone offering such a broad variety
improve cleaning results and reduce the
industry and in high demand the
of colours, an intelligent, extremely flexible
risk of contamination. Other examples
world over. Wherever electronics
booth concept is absolutely vital.” Rittal
include wind turbine and photovoltaic
have to be protected, the chances
relies here on the highest standards of
systems, whose outdoor housings must
are good that the enclosures for the
Nordson ColorMax booth technology,
withstand wind and weather to protect
equipment control system, power
with special booth floor material and
sensitive control technology from extreme
distribution or climate control come
highly automated cleaning cycles that
temperature fluctuations and moisture.
from Rittal. Headquartered in the
enable extremely fast colour changes.
In much the same way, applications in
German state of Hesse, Rittal is a
“ColorMax booths are ideally suited for
IT, transportation technology, and – in
genuine global player employing
all our applications, no matter whether
extreme cases – machinery construction
over 9,300 people and operating 13
we run a single colour in a shift or have to
and process industries also impose
production facilities worldwide.
change colours frequently,” says Denner
special requirements.
(Fig. 1).
Once installed, an enclosure usually
It is often the coating that contributes to
then stays in its place for many years
fulfill specific customer requirements of
– where aggressive environments are
an enclosure. Those requirements arise,
not uncommon. That means a powder
for example, from the installation site of
coating must function reliably – and also
an enclosure for photovoltaic or wind
look good – for a long period and under
turbine systems, in the production halls
adverse conditions. “Our products can
of automotive suppliers, in the food and
achieve that only because we consistently
beverage industry, or in a data center (ref.
apply the highest quality coatings,” says
Opening photo).
Heiko Denner, returning to the subject
Along with the design possibilities of
of surface finishing. What matters to
Rittal enclosures, the company started
him here is not only the quality of the
already from an early stage to develop
finished surface, but also the efficiency
specific solutions for an extremely wide
of the coating process. “To enable us
range of applications. For the food
to deliver uniformly high quality – shift
and beverage industry, for example,
after shift, day in and day out, and totally
which is subject to uncompromising
independent of personnel – we defined
In all markets, in countless industries, and in nearly every company, “Industry 4.0” is the next big thing: but does the investment in new equipment really pay off? What conditions have to be met and what changes must be made in order to manufacture high-quality products that satisfy customer requirements cost-effectively today?”
3
3
international PAINT&COATING magazine - JANUARY/FEBRUARY 2019 - N. 55
89
© Nordson Deutschland GmbH
our processes precisely and they are continuously monitored and adjusted.” And nothing is left to chance.
Maximizing process control by means of dense phase technology “We measure and record our powder consumption very precisely, of course – but the same also goes for air and energy consumption, as well. All consumption parameters are then calculated not just for the batch, but rather right down to the individual part – which enables us to achieve an extremely high level of transparency.” The data collected in this way helps us adjust the system efficiently using key parameters. At the same time, however, they also serve as the basis for further process optimization measures: large quantities amplify even the smallest potential savings. “We have already been relying on dense-phase technology for years now,” says the Project Manager. “Today the very consistent operation of the HDLV pumps provides ideal conditions for uniform processes, transporting the powder with extreme care from our 400 kg big bags to the powder feed center and to the guns and then returning the overspray back to the system again – thereby keeping the
1
quality of the material stable over an
Figure 1: ColorMax3 powder booths are ideally suited for all our applications, no matter whether we run a single colour in a shift or have to change colors frequently.
extended period (Fig. 2).” “Moreover, the low flow velocity and high powder content generate a ‘soft cloud’ that allows the powder gun to work very close to the workpiece. Together with low back
For anyone offering such a broad variety of colours, an intelligent, extremely flexible booth concept is absolutely vital. Rittal relies here on the highest standards of Nordson ColorMax3 booth technology, with special booth floor material and highly automated cleaning cycles that enable extremely fast colour changes. ColorMax3 booths are ideally suited for all applications, no matter whether we run a single colour in a shift or have to change colours frequently.”
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N. 55 - JANUARY/FEBRUARY 2019 - international PAINT&COATING magazine
corona discharge, that significantly increases the application efficiency while also providing the benefits of deep penetration, even with more complicated housing geometries.” The uniformity with which this technology distributes powder across the coated surface is apparent even
FOCUS ON TECHNOLOGY
Rittal has already been relying on dense-phase technology for years now. Today the very consistent operation of the HDLV pumps provides ideal conditions for uniform processes, transporting the powder with extreme care from our 400 kg big bags to the powder feed center and to the guns and then returning the overspray back to the system again – thereby keeping the quality of the material stable over an extended period.”
PAINTING ROBOTS & SYSTEM INTEGRATOR We are able to provide the full range of articulated and cartesian robots for every painting need! LeBot MV A5-A6: 5 and 6 axis articulated robot with self-learning, point to point and 3D offline programming, also available in chariot, carriage and carousel configuration with 3D Lesta shape acquisition system.
to the naked eye. “Sometimes in the past we used to see the so-called ‘picture frame’ effect,” recalls Denner. “That was a small border right next to an edge. Today with the low powder consumption, the coating layer distribution is so uniform that this no longer happens, so now we meet Rittal QA standards.”
LeBot C5: 5 axis cartesian robot with 3D Lesta shape acquisition system. acqui ystem.
Achieving that level of uniformity takes great care. Even the fresh powder is sieved into the Spectrum® HD powder feed center, for example, because after extended storage or transport time, freshly supplied powder has been observed to form extremely fine clumps on occasion. “That could cause our sensitive processes to malfunction – and sieving eliminates the possibility of this happening.”
The “human factor” still matters! “Anyone who imagines that the highly automated systems of a state-of-the-art powder coating plant reduce production operators to mere extras couldn’t be more wrong,” assures Project Manager
LeBot IA6: articulated 6-axis industrial robots with jointed-arm kinematics for all point-to-point and continuous-path tasks, controlled by our LeCRob K-Manager software. LeBot IA6 robots can work with 3D Lesta shape system. aacquisition ac qu tem.
Denner, comparing their situation with that of a pilot in a modern cockpit. “Even the slightest anomaly demands a fast reaction – and the right one!” Consistently high-quality, efficient production therefore not only requires machine operators to be extremely vigilant and reliable, but also necessitates continuous advanced training. “It might sound like a contradiction,” explains Denner, “but the simpler a system’s operation looks, the more complex the processes behind it. And our operators must have a clear understanding of those processes in order to be able to take the
WWW.LESTA.IT
right action when necessary.” Experience shows the importance of informing the employees early about changes and bringing them on board right from the start – an approach followed systematically by the Friedhelm Loh Group, to which Rittal belongs. Recognized in 2018 as one of Germany’s Top Employers for the tenth consecutive time, this family-run business places a strong emphasis on continuing education.
LESTA S.r.l.
Via D. Chiesa, 42 - 20020 Dairago (MI) - Italy +39 0331.430817 +39 0331.1581053 0331.158 info@lesta.it
“When we need specialized knowledge
immediately cites yet another benefit of this
concerning coating, we’re glad to
system: “Especially for our situation, the icon-
take advantage of training courses at
based user interface has also proven very
Nordson’s technical center,” reports the
convenient. With an international workforce
Project Manager. “Our employees enjoy
made up of employees from more than 100
training under real conditions like that
countries, language-independent system
because it’s so much better than a dry
operation is clearly the most intelligent solution!”
classroom seminar.”
And when the system guides operators through
Operators also get a fortuitous
even complex procedures like colour changes
motivational boost from a completely
clearly and safely, their enthusiastic feedback
different source, however: from the
comes as no surprise.
coating system’s PowderPilot® HD
Rittal has a 50-year tradition of success, and
touchscreen control. “Many of the
customers have long valued the quality of the
employees today experience a
products. “Our industrial coatings meet their
full-blown enhancement of their job
specifications – on land, in the air and on the
when they use these modern terminals
water. Some of our enclosures are installed on
to perform their monitoring and control
super-yachts,” grins Denner, “that not only look
functions,” knows Heiko Denner, who
great, but also withstand harsh sea air.”
© Nordson Deutschland GmbH
The uniformity with which this technology distributes powder across the coated surface is apparent even to the naked eye. Sometimes in the past Rittal used to see the so-called ‘picture frame’ effect. That was a small border right next to an edge. Today with the low powder consumption, the coating layer distribution is so uniform that this no longer happens, so now Rittal QA standards have been met.”
Figure 2: The very consistent operation of the HDLV® pumps provides ideal conditions for uniform processes.
2 1
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N. 55 - JANUARY/FEBRUARY 2019 - international PAINT&COATING magazine
One App to manage all the big data of your coating plant
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Watch the video IMEL SpA - Via Divisione Julia 10 - 33033 Codroipo, UD - Italy - T +39 0432 908578 - info@imelspa.com - www.imelspa.com
SUCCESS STORIES
Turning a Vision into a Reality: Eisenmann Builds First Skidless Paint Shop for Electric Vehicles
I
n Shaoxing, in China’s eastern Zhejiang province, Eisenmann is
Moreover, a range of other Eisenmann technologies are to
constructing a turnkey paint shop for electric-vehicle startup DEARCC.
be deployed at DEARCC. The Shaoxing facility will feature a
The carmaker employs highly flexible, state-of-the-art manufacturing
pretreatment and electrocoating zone equipped with compact,
technologies – and ordered a skidless paint shop from plant engineering
cost-saving E-Shuttle 200 conveyors (Fig. 4). Additionally, Eisenmann © Eisenmann
expert Eisenmann, headquartered in southern Germany. The solution
will supply spray booths and dryers complete with energyefficient E-Cubes for paint
uses VarioLoc conveyors
overspray removal – plus work
to link individual process
decks, and the ventilation
steps. The project will be
and exhaust air purification
completed in record time:
systems.
Eisenmann was tasked in the summer of 2018, and
The brain of the paint shop is
installation has already
the E-MES production control
begun. The first electric
system from Eisenmann
vehicles are expected to roll
Industrial Software Company
off the line from late 2019.
(Enisco). It supports intelligent
Eisenmann’s modular
management in the shape
VarioLoc conveyors are the
of online planning, material
heart of the highly efficient, agile smart paint shop for DEARCC (Fig. 1). Eliminating the need for heavy skids revolutionizes the
flows control and integrated
1
digital worker guidance –
Figure 1: Eisenmann’s modular VarioLoc conveyors are the heart of the highly efficient, agile smart paint shop for DEARCC.
enabling diverse car body types, materials and © Eisenmann
movement of car bodies.
customer-specific
The individual shuttles (dubbed “Locs”) travel along a rail in the floor (Fig. 2).
surfaces to be painted within a single facility.
Removing skids lays the foundation for far greater
“That is Industry 4.0
flexibility in production – in terms of cycle times,
in action: connected
throughput, capacity and vehicle architectures.
manufacturing,
In the Shaoxing factory, DEARCC will produce a new
where our flexible
E-SUV model named ME7 (Fig. 3). The new car is the
hardware and
first model under the high-end brand Enovate which
intelligent software
was released by DEARCC this November. Enovate
solutions are
ME7 uses a wide-body design while shrinking the
seamlessly linked,”
window section as much as possible to form an
explains Bruno
aerodynamic Gulfstream shoulder, lowering the drag coefficient and making the vehicle visually very dynamic.
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N. 55 - JANUARY/FEBRUARY 2019 - international PAINT&COATING magazine
2 1
Figure 2: The individual “Locs” travel along a rail in the floor.
Casorati, Senior Vice President, Automotive
© Eisenmann
SUCCESS STORIES
1
Figure 3: The E-SUV ME7 is the first model under the high-end brand Enovate from DEARCC.
Systems at Eisenmann. “Eisenmann’s integrated, end-to-end approach for a highly flexible and efficient, smart paint shop has proved very popular with our customers. We offer them advanced, market-ready technologies that support Industry 4.0 imperatives. These not only deliver exceptional versatility in manufacturing, but also cut costs and save energy.” DEARCC is the second carmaker, after Mercedes-Benz in Kecskemét, Hungary, to take delivery of Eisenmann’s rapidly implemented, one-stop, smart and skidless solution for the paint shop of the
© Eisenmann
future.
3 1
Figure 4: The Shaoxing facility will feature a pretreatment and electrocoating zone equipped with compact, cost-saving E-Shuttle 200 conveyors.
BRAND-NEW
BENSELER Acquires BETEO
E
ffective January 1, 2019, the BENSELER
and bent parts as well as turned
“The company has many years of
group acquired LISI Automotive
parts. The customers are leading
know-how in the field of screw locking
BETEO GmbH & Co. KG, Gummersbach.
manufacturers of fasteners in Europe;
and the processes used there are an ideal
The surface specialists, headquartered
a large proportion of the corrosion
complement to what we already offer our
in Markgröningen (Germany), are thus
and safety coatings are intended for
customers as one of the largest contract
expanding their portfolio in the field of zinc
the automotive sector. As of January 1,
coaters.” The new BENSELER subsidiary
flake processes and screw locking systems.
2019, the new BENSELER subsidiary
rounds out the surface specialists’ service
The company LISI Automotive BETEO GmbH
will operate under the name
portfolio with zinc flake coating for
& Co. KG was founded in Gummersbach
Benseler BETEO GmbH & Co. KG.
components with smaller dimensions
(North Rhine-Westphalia) in 1982 and
“We are delighted that BETEO is
and/or complex geometries such as small
belonged to the French LISI Group until
part of the BENSELER group and
internal drive screws.
December 31, 2018. The company produces
represents an important building
“BETEO fits very well into the BENSELER
high-quality thread locking coatings,
block in our growth strategy,” says
group” says Jens-Paul Hänig, Managing
corrosion protection coatings and lubricant
Thomas Müller, Managing Director of
Director of Benseler BETEO GmbH & Co. KG.
coatings for threaded parts, stamped
BENSELER Holding GmbH + Co. KG.
“We agree that only excellent quality as well as an absolute
© Benseler / J. Zimmermann
and flexible delivery capability in conjunction with best service form the basis for a reliable, customer- and future-oriented company.” Müller adds: “Just like BENSELER, BETEO is constantly adapting its production range to the growing demands of the market.” Jens-Paul Hänig will continue to be responsible for the development of the location as Managing Director. For further
1
information: Figure 1: BETEO has a lot of know-how in the field of screw locking - an ideal complement to the portfolio of BENSELER.
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N. 55 - JANUARY/FEBRUARY 2019 - international PAINT&COATING magazine
www.benseler.de
eosmarketing.it
do you need a CHAIN CONVEYOR?
BRAND NEW HOOK! loading capacity > 1,500 kg, it allows the rotation with an integrated lock system
TRAS-MEC iW XLI ǻVWX GSQTER] to safeguard your system and contractually guarantee a downtime free production.
www.tras-mec.it
BRAND-NEW
Mobile and Fast Quality Control of Cleaning and Coating Baths
A
t parts2clean 2018, KRÜSS
at a glance. Moreover, the tendency
required or the bath will have to be
presented a novel solution
of the surfactant content becomes
renewed instead of having to react
for quality control of
immediately obvious thanks to the
quickly when a critical SFT value was
industrial baths that contain cleaning
automatic graphical representation
reached. Using measurements in the
or wetting agents. The new Bubble
of the course over any given time
Continuous mode of the instrument, it is
Pressure Tensiometer – BPT Mobile
period. Thus, predictions can be made
even possible to monitor the change in
is an instrument for determining the
about when further dispensing will be
SFT while dispensing a surfactant.
surfactant content by means the solution. Working independently from
Error-free quality control using reference values
a computer or the power grid and
How the SFT correlates with the
providing results within a few seconds, it
concentration and at which surface age
is particularly suitable for regular quality
© KRÜSS
dynamic surface tension (SFT) of a
the bubble pressure method works in
checks.
the most sensitive way depends on the
Whether an industrial bath obtains
kind of surfactant used.
the required cleaning or wetting
The BPT Mobile supports the important
effect depends on the concentration
preparation step of defining the analysis
of free surfactant, which decreases
parameters for the subsequent, quick
over time due to contamination of the
quality routine. For this purpose, the
bath or adsorption at the workpiece.
instrument has a mode for measuring
The dynamic SFT reacts particularly sensitively to changes of the surfactant concentration so that bubble pressure measurements with the BPT Mobile quickly and reliably reflect the bath’s quality.
Time-saving measurements and ergonomic use The BPT Mobile is equipped with a colour touch display for especially simple operation and ensures that every desired function is accurately triggered thanks to the comfortable size of 5’’. The display also responds to the touch with lab gloves without any problems. The instrument saves time particularly due to the ad-hoc analysis of the results. Whether the measured value lies within a defined quality range is visible
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N. 55 - JANUARY/FEBRUARY 2019 - international PAINT&COATING magazine
Figure 1: Bubble Pressure Tensiometer – BPT Mobile for quality control of industrial baths containing cleaning or wetting agents.
BRAND-NEW
the dynamic SFT as a function of the
for strongly contaminating samples.
necessary, the instrument can be
surface age over a wide range between
Thanks to intelligent control and
connected to a computer, behaving
10 and 30.000 ms.
precise measurement of the
like a mass storage device, to export
The parameters determined in this way
pressure, the instrument works
measurements to Excel with one click
can also be used for easy-to-create
independently from the immersion
in order to carry out customized data
templates in order to reliably measure
depth to the greatest possible
analyses. The user interface of the BPT
always under the same conditions â&#x20AC;&#x201C; also
extent and thus also accurately
Mobile orients itself towards the familiar
with optimized parameters for different
performs when held in oneâ&#x20AC;&#x2122;s hand.
control logic of smartphones so that
baths independently from each other.
Deviations when used by different
false measurements due to operating
persons are therefore virtually ruled
errors are practically excluded.
Technical solutions for precise, simple, and robust measurements
out. Moreover, the temperature for each data point can be documented
For further information:
thanks to the removable temperature
www.kruss-scientific.com
For creating the air bubbles in
sensor.
the course of bubble pressure
The internal memory of the
measurements, the instrument uses
grid-independent instrument has
disposable capillaries which are
room for more than two million
inexpensive and easily exchangeable.
measurements, which can be tidily
This feature is particularly advantageous
sorted into folders. Whenever
Dynamic contour detection Sophisticated coating solution
- High level automation of the application process - Automated recognition of complex geometries for both the front and rear of the object - Optimized coating quality - Powder savings and reduction in overspray - Drastic reduction of the manual coating operation - Automated programming of U-axes. No time consuming axes adjustments Gema Europe Srl | Via Goldoni, 29 Via Carlo Goldoni 29 | 20090 Trezzano Sul Naviglio (MI) | ITALY | T. +39 02 48 400 486 | F. +39 02 48 400 874
Industry 4.0 Ready
www.gemapowdercoating.com
BRAND-NEW
WACKER Cooperates with Dynaplak on Producing Sustainable Binders © WACKER
W
ACKER is to collaborate with Dynaplak, the
Dutch manufacturer of biobased raw materials for agricultural and industrial applications. Together, the two companies want to develop hybrid binders based on starch and polymers. The first products for interior wall paints are scheduled for market launch in the first quarter of 2019. WACKER is thereby responding to the growing demand for sustainable binders in the paint and coatings industry. “Our partnership with Dynaplak lays the foundations for increasing our
Koos Slor, managing director of
customers outstanding product quality,”
contribution to more sustainability in the
Dynaplak, says: “In our production
explains Nely. The new binders will be
binders market. We will be one of the
process, we utilize starch that would
manufactured at the Dynaplak site in
first chemical companies to expand our
otherwise be lost. Our innovative
Veendam in the Netherlands and are
portfolio with products based partially
technology increases the functionality
part of WACKER’s new VINNECO® line.
on renewable raw materials,” explains
of conventional starch, enhancing
It will present the first products from
Dominique Nely, who manages WACKER’s
its performance.” In an emulsified
this line at the European Coatings Show
binders for consumer goods and
form, starch reveals its properties
2019.
industrial applications in western Europe.
and helps to tie together components
“In the first phase, we will focus on interior
of a paint, such as pigments and
For further information:
paints - where demand for ecological
fillers. “By partnering with WACKER,
www.wacker.com
alternatives to petroleum-based binders
our sustainable products will also be
is growing strongly.”
available to customers from the paints
Dynaplak’s biobased technology together
and coatings industry,” Slor continues.
with WACKER’s decades of experience in
In technical terms, hybrid binders
manufacturing polymer-based binders will
meet the high-quality standards
result in hybrid starch and polymer-based
for WACKER products. “We want to
binders. The starch is a side-stream
act in an ecologically responsible
product from potato processing.
way, while continuing to offer our
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N. 55 - JANUARY/FEBRUARY 2019 - international PAINT&COATING magazine
© Karl Bubenhofer AG
Opening photo: The POLYFLEX® PAC-140-SD powder coating system is specifically designed for outdoor use.
HIGHLIGHT OF THE MONTH
Deep Matt Powder Coatings with no Hazardous Substances Karl Bubenhofer AG, Gossau – Switzerland
102
pulver@kabe-farben.ch
N. 55 - JANUARY/FEBRUARY 2019 - international PAINT&COATING magazine
HIGHLIGHT OF THE MONTH
D
eep matt powder coatings are currently
employees and no mandatory training or special
very popular for both outdoor and
safety equipment is needed.
indoor use. Karl Bubenhofer AG has
The POLYFLEX® PAC-140-SD powder coating
developed a special formulation for these
system is specifically designed for outdoor use.
powder coatings using
It is highly resistant
no substances that are
to weathering, has
categorised as hazardous.
excellent colour
The ongoing process of reclassifying chemicals presents paint and powder coating manufacturers with new challenges. In particular in the case of deep matt coatings, it has become difficult to create formulations containing no hazardous substances. Karl Bubenhofer AG began its search for alternatives at
Karl Bubenhofer AG began its search for alternatives at an early stage and can now offer deep matt powder coatings for outdoor and indoor use with no constituents that are classified as hazardous. Users no longer have to take additional measures to protect their employees and no mandatory training or special safety equipment is needed.”
an early stage and can now
stability and is certified to Qualicoat Class 2. These factors are particularly important for architectural applications, because the long-lasting coatings help to maintain the value of the property (ref. Opening photo and Fig. 1). A special “anodised” range
consists of high-quality metallic coatings that
and indoor use with no constituents that are
are bonded and can therefore be processed
classified as hazardous. Users no longer have
reliably (Fig. 2). The POLYFLEX® PAC-135 system
to take additional measures to protect their
includes a selection of brightly coloured coatings
© Karl Bubenhofer AG
offer deep matt powder coatings for outdoor
1
Figure 1: The POLYFLEX® PAC-140-SD system is highly resistant to weathering, has excellent colour stability and is certified to Qualicoat Class 2. These factors are particularly important for architectural applications.
© Karl Bubenhofer AG
The aim of Karl Bubenhofer AG is to provide its users with modern, safe and sustainable solutions through its entire supply chain. They provide a simple, future-proof solution that meets the requirements of a variety of different users and is ideal for a wide range of applications.”
2 1
Figure 2: A special “anodised” range consists of high-quality metallic coatings that are bonded and can therefore be processed reliably.
with a standard level of weather
This makes cleaning easier, in particular for
The coatings have very high
resistance. The key advantages of
indoor applications, which is an additional
resistance to overbaking, with
this system include its consistent
advantage of this system over exterior
no reduction in their gloss
gloss level across components
powder coatings. The curing time is 10
level and no yellowing.
of different thicknesses and the
minutes at an object temperature of 180°C.
They also have good
option of curing it for 15 minutes
mechanical properties.
at an object temperature of only
The aim of Karl Bubenhofer AG
180°C. This combination of factors
is to provide its users with
is unique and keeps the cost of the application process to a minimum. The ideal solution for interior use is the POLYFLEX PES-50 Matt hybrid ®
powder coating system. It produces deep matt, velvety surfaces that feel pleasant to the touch. The coatings have good levelling properties and are available in plain colours and bonded metallic shades. The benefits of this cost-effective coating system include reliable processing and resistance to chemicals.
104
The ideal solution for interior use is the POLYFLEX® PES-50 Matt hybrid powder coating system. It produces deep matt, velvety surfaces that feel pleasant to the touch. The coatings have good levelling properties and are available in plain colours and bonded metallic shades. The benefits of this cost-effective coating system include reliable processing and resistance to chemicals.”
N. 55 - JANUARY/FEBRUARY 2019 - international PAINT&COATING magazine
modern, safe and sustainable solutions through its entire supply chain. The comprehensive POLYFLEX® PAC-140-SD and PES-50 product ranges consist of smooth flowing, deep matt powder coatings containing no hazardous substances. They provide a simple, future-proof solution that meets the requirements of a variety of different users and is ideal for a wide range of applications.
SUCCESS STORIES
World Market Leader Kässbohrer Automates Production of its PistenBully with Painting Robot from Dürr
K
the process means greater efficiency in
the harsh environmental influences, two
groomers are now being painted
production and less exposure to paints
primer coats as well as the base coat are
by a Dürr robot. This halves
and solvents for workers.
applied – by an EcoRP L033 painting robot
the duration of the painting process,
Temperatures below freezing, sharp
from Dürr, which coats the metal frames
because application by robot is much
ice crystals, strong UV radiation: when
from the outside and inside (Fig. 1). “The
faster than manual application by a
used on slopes and cross-country skiing
most the robot needs to paint a cab is an
worker. For the internationally leading
trails, the surfaces of the PistenBully
hour. Compared to previous painting by
manufacturer of specialist vehicles
cabs are subjected to the most extreme
hand, this saves us so much time that we
for slope preparation, automating
conditions. To provide protection against
have been able to significantly increase our
© Dürr
ässbohrer PistenBully snow
1
Figure 1: The Dürr EcoRP L033 robot delivers an automated painting process at Kässbohrer Geländefahrzeug AG.
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© Dürr
SUCCESS STORIES
2 1
Figure 2: An automatic turning and tilting frame moves the body into the correct position for painting.
output to 600 cabs per year,” says Uwe
solvent consumption. This is followed by
Thierer, Plant Manager at Kässbohrer
the intermediate drying stage before the
Geländefahrzeug AG’s Laupheim site.
third painting stage, the base coat as colour
Automation of painting increases occupational safety
Apart from the speed, the robot’s
application.
Health protection is another important
uniform and reproducible quality
Dürr’s scope of delivery also includes the
argument in favour of automating the
ensures a high efficiency gain in the
skid conveyor technology with turntable
painting process. When this is done
process. The paint layers are applied
and tilt function (Fig. 2). This ensures
by hand, the workers are exposed
in a combination booth. First, the
reproducible cab adjustment and correct
to paint and solvent fumes. When a
EcoRP L033 applies two primer layers
positioning of the cab for the painting
robot is used, this burden is removed
as a bonding agent and corrosion
process. The robot paints the cab body
from the workers. As part of the
protection wet-in-wet without drying
fully and by applying two primer layers also
automation process, Kässbohrer also
in-between. The colour changing and
looks after the corrosion protection, which
switched to chromate-free paint for the
dosing technology integrated in the
in automotive painting takes place in the
manufacture of the PistenBully.
front robot arm ensures minimal paint
tank. Five pressure pots for main colour,
losses when changing colour as well
hardener, and thinner are provided for the
For further information:
as short rinsing times with minimal
paint supply.
www.durr.com
international PAINT&COATING magazine - JANUARY/FEBRUARY 2019 - N. 55
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© ipcm ®
Opening photo: The new compact coating line installed by Solintellysys at the premises of Prifer.
FOCUS ON TECHNOLOGY
Prifer and Solintellysys Develop an Innovative Compact Coating Line that Applies both Liquids and Powders Ilaria Paolomelo - Alessia Venturi ipcm®
T
he long and deep economic
sectors had to cope with the economic
companies choose to be the first to
recession occurred worldwide
crisis and adapt to new market needs; many
install a new technology or to rely on
during the first years of the
companies were forced to renew themselves
a new technological concept, because,
twenty-first century hit in particular the
in terms of both organisation and production.
although aware of the initial technical
Eurozone, and especially some countries
Such transformation calls sometimes
and management difficulties, they
such as Portugal. Several economic
for daring technological choices: some
also know that this will give them an
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© ipcm ®
FOCUS ON TECHNOLOGY
important competitive advantage
installing new technologies, and
on the market.
creating a new quality department
As John D. Rockefeller said, “The
to conquer new markets and
secret of success is to do the
expand internationally. Now, the
common things uncommonly well.”
Prifer Group exports 80% of its
That is what the Portuguese
production. From next year, it will
Group Prifer seems to have
also produce components for the
done when choosing to install a
automotive sector.
cutting edge plant supplied by
“Surface treatments play a key
the Portuguese plant engineering
role in our company,” says Group
company Solintellysys. Thanks to
CEO João Prior (Fig. 1), “because
the implementation of a robot
they both increase the added
at the centre of the line, this
value offered to our clients
1
compact line enables to apply both liquid and powder coatings
and enable us to distinguish
Figure 1: Group CEO João Prior (left) and Solintellysys Sales Manager Luís Rodrigues.
on metal workpieces with different sizes, while using one
ourselves on the market. Within our Group, we possess both the technologies and human
pre-treatment tunnel, one curing
resources to perform a wide
oven, and one double-circuit
range of finishes: from coating
one-rail conveyor (ref. Opening
Prifer decided to install a cutting edge plant supplied by the Portuguese plant engineering company Solintellysys. Thanks to the implementation of a robot at the centre of the line, this compact line enables to apply both liquid and powder coatings on metal workpieces with different sizes, while using one pre-treatment tunnel, one curing oven, and one double-circuit one-rail conveyor.”
photo).
The Prifer Group In 1978, Fundifás was established as a family business located in the Aveiro district; it specialised in the supply of die-cast non-ferrous alloys for the
to galvanic and PVD coatings, from polishing and cleaning to vibrofinishing and shot blasting.” The latest technologies installed by Prifer include a new compact coating line supplied by Solintellysys, a Portuguese company specialising in the design, development, and
surface treatment and finishing, and component assembly.
© ipcm ®
sectors of civil construction,
Over the years, Fundifás has heavily invested in technological innovation, thus becoming a learning organisation focussing on training, human capital development, and production process quality in order to constantly improve its activity and the added value offered to its customers. In 2012, after a deep crisis in the national market, especially in the civil construction sector, Fundifás was acquired by the Prifer Group. The Portuguese company thus began a long process of updating its already existing production plants,
2 1
Figure 2: The loading area of metal components.
international PAINT&COATING magazine - JANUARY/FEBRUARY 2019 - N. 55
109
© ipcm ®
installation of surface treatment plants. “Solintellysys and Prifer are tied by a long-standing collaboration. This has led us to develop a hybrid coating line, able to apply both powder and liquid products without any problems of part contamination,” states João Prior. “We have worked together with Solintellysys to come up with a solution perfectly suited to both our production needs and the space available in our factory.”
Plant features “This hybrid system features two conveyor circuits, a blue one (the main conveyor, devoted to the workpieces to be powder coated) and a red one (devoted to parts requiring a liquid painting process),” explains Solintellysys
© ipcm ®
Sales Manager Luís Rodrigues. “The line is completely
3 1
Figure 3: The pre-treatment tunnel.
Surface treatments play a key role in Prifer because they both increase the added value offered to clients and enable it to distinguish itself on the market. Within the Group, Prifer possesses both the technologies and human resources to perform a wide range of finishes: from coating to galvanic and PVD coatings, from polishing and cleaning to vibrofinishing and shot blasting.”
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4 1
Figure 4: The inside of the pre-treatment tunnel.
© ipcm ®
FOCUS ON TECHNOLOGY
5 1
Figure 5: The robot managing the load bars depending on whether they must be powder or liquid coated.
with demineralised water, a surface
automated and it has a speed of 2 m/min. Its core is a robot that interfaces with the system software package and has the task to move the workpieces from one circuit to another. In order to keep the plant compact, the conveyor path has been designed in such a way that it does not directly enter the pre-treatment tunnel, but rather it runs clockwise around the machine and enters the pre-treatment tunnel on the opposite side to the loading station (Fig. 2 and 3). The pre-treatment cycle uses multi-metal chemicals provided by Chemetall and it consists of two degreasing phases, a rinse with mains water, a rinse
The latest technologies installed by Prifer include a new compact coating line supplied by Solintellysys, a Portuguese company specialising in the design, development, and installation of surface treatment plants. Solintellysys and Prifer are tied by a long-standing collaboration. This has led Prifer to develop a hybrid coating line, able to apply both powder and liquid products without any problems of part contamination.”
conversion phase, and a final rinse with demineralised water (Fig. 4).” “After drying in the oven, the conveyor proceeds towards the robot station (Fig. 5): its task is to transfer the parts assigned to the liquid process by the management system onto the red circuit and leave only the workpieces to be powder coated on the blue chain, working with a continuous flow. The coating areas are equipped, respectively, with a Solintellysys water veil booth (Fig. 6) featuring a Dürr EcoDose paint mixing and dosing system and two manual application stations and with a Wagner
international PAINT&COATING magazine - JANUARY/FEBRUARY 2019 - N. 55
111
Š ipcm Ž
6 1
Figure 6: The water veil booth for the application of liquid paints.
The line is completely automated and it has a speed of 2 m/min. Its core is a robot that interfaces with the system software package and has the task to move the workpieces from one circuit to another. In order to keep the plant compact, the conveyor path has been designed in such a way that it does not directly enter the pre-treatment tunnel, but rather it runs clockwise around the machine and enters the pre-treatment tunnel on the opposite side to the loading station.â&#x20AC;?
FOCUS ON TECHNOLOGY
The powder coating booth is contained in a dust free chamber with a controlled suction system, in order to avoid any contamination between the application areas of the two different coating products. The entrance and exit of the curing oven are the only areas in which the two circuits, the red one for liquid coating and the blue one for powder coating, meet.”
powder application booth linked to a last generation SuperCenter powder management unit (Fig. 7 and 8),” says Luís Rodrigues. “The powder coating booth is contained in a dust free chamber with a controlled suction system, in order to avoid any contamination between the application areas of the two different coating products. The entrance and exit of the curing oven are the only areas in which the two circuits, the red one for liquid coating and the blue one for powder coating, meet (Fig. 9). In order to keep the plant compact, we placed the drying oven at the bottom of the line, while the curing oven occupies the upper part,” says
© ipcm ®
Luís Rodrigues.
7 1
Figure 7: Wagner’s powder booth.
© ipcm ®
Figure 8: The powder management unit.
© ipcm ®
8 1
An unexpected solution Prifer produces a very diversified range of parts
The Group needed to install a system complete with both technologies in a very small space, which was not enough for two separate lines. The solution designed by Solintellysys entrusts the sorting of the workpieces to the two coating circuits to a robot and it features all the technical measures needed to avoid contamination among components painted with different technologies.”
for a wide variety of industrial sectors, some of which require a powder finish while others call for one-coat liquid systems. Therefore, the Group needed to install a system complete with both technologies in a very small space, which was not enough for two separate lines. The solution designed by Solintellysys entrusts the sorting of the workpieces to the two coating circuits to a robot and it features all the technical measures needed to avoid contamination among components painted with different technologies. Certainly, it will not be exempt from problems during start-up and industrialisation, but it could be a solution for any company looking for
Figure 9: The exit of the curing oven with the two parallel conveyors.
114
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N. 55 - JANUARY/FEBRUARY 2019 - international PAINT&COATING magazine
extreme technological flexibility with a limited investment.
Zaniolo CdA - 1.18
QUALITÀ QUALITY QUALITÀ
PRIORITÀ ASSOLUTA
Europolveri, offre una diversificata varietà di Vernici in Polvere caratterizzate da elevato standard qualitativo, ottime performances ed un basso impatto ambientale. Un'ampia gamma di prodotti standard disponibili in più di 1800 toni cromatici ed una serie di 240 effetti speciali formulati per garantire un plus in termini di valore estetico e durabilità. Cinque linee di prodotti innovativi formulati ad hoc per rispondere ad esigenze ed applicazioni specifiche. Europolveri: Esperienza, Efficienza, Evoluzione. QUALITY AS ABSOLUTE
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© BASF
Opening photo: BASF unveiled the Color Report 2018 for Automotive OEM Coatings.
HIGHLIGHT OF THE MONTH
BASF Analyses the 2018 Automotive Colour Distribution By BASF’s Coatings Division Münster - Germany
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HIGHLIGHT OF THE MONTH
W
Effects create new colour variations in Europe
significantly contributes to the unique look
for Automotive OEM Coatings”, BASF’s Coatings
Nearly every fifth car in Europe is painted
were finished with an effect coating. The
division provides a global analysis of
grey (Fig. 2). The colour replaced black
larger the car, the more likely it was painted
the colour distribution in the 2018
as the second most popular colour.
with an effect. Dark colours such as black
automotive market (Fig. 1).
Buyers can choose from more than 110
and grey are mostly formulated to have
The achromatic colours – white,
variations ranging from light grey to dark
a metallic effect, whereby lighter colours
ith the “BASF Color Report
of a car. In 2018, two thirds of all vehicles
black, grey and silver – still dominate
are primarily solid shades. “The
the roads. They cover almost 80%
landscape of automotive coatings
of cars produced worldwide. White
effects evolves continuously and is shaped by new and inspiring
is the most popular colour among them. More than every fourth car in North America and nearly every third vehicle in Europe is painted white, while in Asia Pacific it is more than every second car. Silver’s popularity decreased slightly in comparison to the previous year. Among the diverse range of colour shades, blue is the most popular,
The achromatic colours – white, black, grey and silver – still dominate the roads. They cover almost 80% of cars produced worldwide. White is the most popular colour among them. More than every fourth car in North America and nearly every third vehicle in Europe is painted white, while in Asia Pacific it is more than every second car.”
followed by red. These chromatic
ideas,” said Mark Gutjahr, head of Automotive Color Design Europe at BASF’s Coatings division.
White is most popular in Asia Pacific but chromatic colours gain importance White is more popular in Asia Pacific than in any other region
colours tend to be more popular
(Fig. 3). 53% of all new cars are white. The colour’s popularity grew
such as compact and subcompact
more options. Approximately 140 shades
significantly in comparison to the previous
cars. The overall amount of chromatic
make blue the region’s most diverse
year. Among chromatic colours, red is still
hues drops off significantly in the
colour space. With a share of 11%, it
the most popular choice. Blue, however, is
larger segments. Here, there was a
overtook silver in 2018, becoming the
closing the gap. An interesting observation
considerable increase in black and
fourth most desired colour in Europe.
is that brown remains especially popular
white compared to the previous year.
A metallic or pearlescent effect also
with SUVs but has shown signs of slowing
1
Figure 1: Global analysis of the colour distribution in the 2018 automotive market.
© BASF
metallic anthracites. Blue offers even
© BASF
within the smaller vehicle segments,
2 1
Figure 2: Automotive chromatic colours popularity in 2018 in Europe.
international PAINT&COATING magazine - JANUARY/FEBRUARY 2019 - N. 55
117
© BASF
© BASF
3 1
4 1
Figure 3: Automotive chromatic colours popularity in 2018 in Asia Pacific.
Figure 4: Automotive chromatic colours popularity in 2018 in North America.
down, indicating that its importance in this
Among the achromatic colours, white
segment may have passed.
maintains its leading position. Besides
Trend competence and innovative colour concepts
Car buyers in Asia Pacific are increasingly
the achromatic shades, consumers
BASF’s Coatings division has an excellent
connecting their colour preferences to
continued to demonstrate a growing
understanding of what is trending in materials
their attitudes and lifestyles. For example,
affinity for red, specifically within the
and colours, and uses this to predict which
metallic and sparkling blacks have risen in
pickup and sports car segments. The
colours will play a key role in the future
demand across several body segments.
diverse blue colour space remained
automotive market. Every year, the Coatings
Even in subcompact cars, silvers and
nearly the same compared to the prior
division’s designers create Automotive Color
greys with dazzling effects are becoming
year.
Trends, an innovative collection of 65 new
more common. This can be seen in the
Over the last ten years, Crossover
colours based on extensive research and
Chinese market, where a broader palette
Utility Vehicles (CUV) have emerged as
in-depth analysis of global trends and cultural
of colours has emerged. “The diversity
a dominant vehicle segment in North
shifts that will influence automotive colours
of chromatic colours is evident, with
America. CUVs combine the qualities
three to five years into the future.
red, blue, yellow, brown and gold hues
of Sport Utility Vehicles (SUVs), like
appearing in almost every segment.
safety and driving convenience, with
Colour and Sustainability
Chinese consumers readily display their
other benefits such as fuel efficiency
Integrated into its colour design innovations,
coloristic tastes more so than in the
and therefore offer appealing features
BASF offers a range of sustainable coatings
past”, said Chiharu Matsuhara, head of
to a wide array of drivers. White is the
solutions for the automotive industry. Among
Automotive Color Design Asia Pacific.
most popular colour in this segment,
these are coatings that enable a shortened
followed by black and grey. Blues and
application and curing process, which can
Diversity in today’s achromatic colours in North America offers a look into the future
reds are almost equally desired by car
reduce CO2 emissions by up to 20 percent,
buyers. “In coating large surfaces for
waterborne basecoats that meet strict global
the CUV segment, the industry looks to
regulations to minimize the volatile organic
bring a suitable visual expression of the
compound (VOC) content, and coatings with
In 2018, the achromatics remained the
vehicle’s perceived use and link it to the
a temperature management functionality
most popular automotive colours for
brand image,” said Paul Czornij, head of
whereby the car surface does not heat up as
North America, accounting for roughly
Automotive Color Design for BASF North
much as conventional coatings, minimizing the
75% of market production (Fig. 4).
America.
heat build-up in interiors.
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SUSTAINABILITY
Pine Needles from Old Christmas Trees Could Be Turned into Paint and Food Sweeteners in the Future
A
bandoned Christmas trees could
friendly, the chemical structure of pine
Christmas trees during the festive period
be saved from landfill and turned
needles is broken down into a liquid
every year and sadly, about 7 million trees end
into paint and food sweeteners
product (bio-oil) and a solid by-product
up in landfill.
according to new research by the University
(bio-char).
If pine needles were collected after Christmas
of Sheffield (UK).
The bio-oil typically contains glucose,
and processed in this way, the chemicals
Christmas trees have hundreds of
acetic acid and phenol. These chemicals
could be used to replace less sustainable
thousands of pine needles which take a
are used in many industries - glucose in
chemicals currently used in industry.
long time to decompose compared to other
the production of sweeteners for food,
This could lead to a decrease in the
tree leaves. When they rot, they emit huge
acetic acid for making paint, adhesives
UK’s carbon footprint by reducing the UK’s
quantities of greenhouse gases which then
and even vinegar.
dependence on imported artificial
contribute to the carbon footprint of the UK.
The process is sustainable and creates
plastic-based Christmas trees and a reduction in the amount of biomass waste © University of Sheffield
Cynthia Kartey, a PhD student from the University of Sheffield’s Department of Chemical and Biological Engineering, has found that useful products can
going to landfill. Dr James McGregor, Senior Lecturer in the Department of Chemical and Biological
be made from the chemicals
Engineering said: “The use of
extracted from pine needles
biomass – materials derived
when processed.
from plants – to produce
The major component (up
fuels and chemicals currently
to 85%) of pine needles is a
manufactured from fossil
complex polymer known as
resources will play a key role in
lignocellulose. The complexity
the future global economy.”
of this polymer makes using pine needles as a product for biomass energy unattractive and useless to most industrial processes.
“If we can utilise materials that
1
would otherwise go to waste
Figure 1: Abandoned Christmas trees could be saved from landfill and turned into paint and food sweeteners according to new research by the University of Sheffield (UK).
Cynthia said: “My research
in such processes, thereby recycling them, then there are further benefits.” “In our research group we
has been focused on the breakdown of
zero waste as the solid by-product can
are currently investigating the production of
this complex structure into simple, high-
be useful too in other industrial chemical
valuable products from a variety of organic
valued industrial chemical feedstocks such
processes. Fresh trees and older,
wastes, including forestry sources, spent
as sugars and phenolics, which are used
abandoned Christmas trees can both be
grain from the brewing industry and food
in products like household cleaners and
used.
waste; alongside investigating processes for
mouthwash.b“Biorefineries would be able
Cynthia continued: “In the future, the
the conversion on carbon dioxide into useful
to use a relatively simple but unexplored
tree that decorated your house over the
hydrocarbon compounds.”
process to break down the pine needles.”
festive period could be turned into paint
With the aid of heat and solvents such as
to decorate your house once again.”
For further information:
glycerol, which is cheap and environmentally
The UK uses as many as 8 million natural
www.sheffield.ac.uk
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SUSTAINABILITY
An Alliance Between Major Global Companies to Manage Plastic Waste
I
n January 2019, about thirty major
to join us”, explains David Taylor, CEO of
river systems all over the world and
global companies belonging to the
Procter&Gamble and President of AEPW.
found that just ten rivers transport
petrochemical and plastic sector signed
AEPW is a not-for-profit organization,
more than 90% of plastics to the ocean.
a collective agreement to take action
partnering with the finance community,
The rivers all have two common traits:
against the pollution caused by plastic
government and civil society, including
a generally high population living
waste, founding the Alliance To End Plastic
environmental and economic development
in the surrounding region, in some
Waste (AEPW).
NGOs.
cases hundreds of millions, and a lack © Alliance To End Plastic Waste
In modern society, plastic is a matter of global interest and its use is often the focus of heated debates. It is a true modern dichotomy: if on the one hand it brings several advantages
of adequate waste management systems and infrastructure. The problem comes from the Asia, where billions of people
- a lower production and
have finally had the
usage costs, it is light and
possibility of using
hygienic, it preserves food
previously inaccessible
without contaminating it and
goods. However, this
can be used in various fields
has produced a large
and sectors – on the other, it
quantity of plastic waste
causes one of the most serious pollution. To counter the global issue
such as containers,
1
and widespread forms of
packages and bottles
Figure 1: Origin by country of unmanaged plastic waste in 2010 (metric tones).
that are dispersed in the environment. In fact, while developed
arising from the dispersion of plastic in the environment, especially in
“History has shown us that collective
countries have waste collection
the marine one, about thirty corporations,
action and partnerships between
and recycling services, the newly-
including BASF, Covestro, Clariant, Dow
industry, governments and NGOs can
industrialized countries have not yet
and DSM, have joined under the aegis of
deliver innovative solutions to a global
adopted waste management systems.
Alliance To End Plastic Waste, investing
challenge like this. The issue of plastic
Plastics provide many critical sanitary,
more than $ 1 billion with the goal of
waste is seen and felt all over the world.
safety, health preservation and
allocating $ 1.5 billion over the next five
It must be addressed and we believe the
convenience benefits. Even as we work
years to fight against plastic waste.
time for action is now”, says Bob Patel
aggressively to reduce plastic waste in
“Everyone agrees that plastic waste does
(LyondellBasell), vice-president of AEPW.
the environment, we must maintain the
not belong in our oceans or anywhere in
critical benefits that plastics bring to
the environment. This is a complex and
Facts about plastic waste
serious global challenge that calls for
Research conducted by Ocean Conservancy
world. With a thoughtful, comprehensive
swift action and strong leadership. This
shows that almost 80% of plastics that
and strategic approach, Alliance To End
new alliance is the most comprehensive
end up in the sea comes from land-based
Plastic Waste aims to do both.
effort to date to end plastic waste in the
sources and is transported by rivers.
environment. I urge all companies, big and
Scientists of the Center Helmholtz for
For further information:
small and from all regions and sectors,
environmental research have studied 57
www.endplasticwaste.org
people and communities around the
international PAINT&COATING magazine - JANUARY/FEBRUARY 2019 - N. 55
121
BRAND-NEW
RoDip® E Impresses in China
T
he joint venture FAW-VW is
In addition to exchanging the conveyor
Reiner Schmid, CEO of Dürr in China,
revamping a Chinese paint shop.
technology in the pretreatment and
on this modification: “In addition to the
Plant engineering firm Dürr has
electrocoating areas, Dürr is also modernizing
increase in capacity, this modernization
been chosen as a competent partner for
the conveyor technology in the adjacent
will benefit the customer through lower
this task. Once the paint shop is put into
areas. The oven and cooling zones as well as
maintenance costs, simpler operation,
operation in September 2019, it will be
the PVC workstations are also being extended.
and higher plant availability.”
the first time that the RoDip® E rotational
The aim is to increase the capacity to 65 units
dip process with electric drive has been
per hour and to integrate a new, larger vehicle
For further information:
used in China.
model into the production process.
www.durr.com
Well over 10 million bodies per year tried-and-tested technology from Dürr.
© Dürr
worldwide are already coated with this It does away with the need for entry and exit inclines, which reduces the dip tank length by up to 6 meters and as a result saves water and chemicals. The smaller tank volumes also reduce the amount of energy required for tank conditioning. RoDip® not only reduces the unit costs, but at the same time offers outstanding corrosion protection through an optimized immersion, flooding, and draining process. Up to now, customers in the Chinese market have preferred the mechanical RoDip® M variant. The electric RoDip® E version is now being used for the first time in China, replacing an existing rival product. RoDip® E impresses with its electric drive, in which each of the freely programmable trolleys contains not only the conveying drive, but also a separate drive for the rotation. The individually programmable trolleys enable optimized dip curves for the respective body. This in turn results in even better coating quality and increased energy efficiency, and thus enables a further reduction in unit costs.
Figure 1: RoDip® E rotational dip process saves space, material, and energy and increases the quality of the corrosion protection.
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8TH INTERNATIONAL EXHIBITION FOR THE FASTENER AND FIXING INDUSTRY 19 â&#x20AC;&#x201C; 21 March 2019 | Messe Stuttgart, Germany
Visit the international marketplace for the fastener and fixing industry!
Industrial Fasteners and Fixings
Fastener Manufacturing Technology
Construction Fixings
Storage, Distribution, Factory Equipment
Assembly and Installation Systems
Information, Communication and Services
NEW in 2019
BONDING&ADHESIVE TECHNOLOGY AREA
Dedicated area for bonding solutions Presentation of innovative adhesive technologies for lightweight, automotive & electronics industry
Organisers:
www.fastenerfair.com/stuttgart
STANDARD & LEGISLATION - UCIF Informs
Ecodesign: Work on Electric Motors Marcello Zinno UCIF – Italian Surface Treatment Equipment Manufacturers’ Association, Milan, Italy
T
info@ucif.net
he issue of electric motors, governed
ranging from 0.12 to 1,000 kW, classified for
private citizens) the chance to comment
by the Commission Regulation (EC)
continuous cycle operation;
on it. Afterwards, the definitive text is
No. 640/2009, also known as Ecodesign,
• VSDs classified to operate with the motors
presented to the Regulatory Committee,
has undergone intense study for a year now.
mentioned above and with a P value
i.e. the Committee of the Member States
The DG Energy was the Directorate General
ranging from 0.75 to 1,000 kW.
that discusses and approves the text
responsible for the development of the update
to be subjected to final approval by the
proposal; last year, it submitted the text to all
The list of motors excluded from this
Parliament. The Regulatory Committee
other DGs of the European Commission to
Regulation’s scope is much wider than that
will meet in the first months of 2019 and
gather their comments. In conjunction with this
of the current one. It also includes a new
it will express itself on all the innovations
assessment process, the ANIMA Federation
definition of a fully integrated motor, as well
included in the Regulation, including the
received the proposed Regulation text and
as other changes being discussed at the
comments and proposals received during
started to discuss its impact on the concerned
moment.
the public consultation phase. The Ministry
sectors. The scope of the Regulation is as
of Economic Development will participate During the second half of 2018, a public
for Italy. The process will end with the
• Induction electric motors with a 50 or 50/60
consultation was carried out. In this phase,
approval of the final Regulation document,
Hz frequency, 2/4/6/8 poles, a UN value
the Regulation text is publicly issued in
which will be presumably issued at the end
ranging from 50 to 1,000 V, and a P value
order to give anyone (institutions and
of the first half of 2019.
aquatarkus©fotolia
follows:
124
N. 55 - JANUARY/FEBRUARY 2019 - international PAINT&COATING magazine
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ZOOM ON EVENTS
The Extraordinary VETECO 2018 Trade Fair Exceeded All Expectations
T
he extraordinary VETECO trade
for Materials, Techniques and Construction
for both segments. With the incorporation of
fair exceeded all expectations,
Solutions, CONSTRUTEC; the International
these new areas, VETECO shows its market
demonstrating its great potential
Fair for Stone Architecture, ARCHISTONE
awareness by expanding its offer in a manner
for progression in future years. The event
(formerly STONE Fair); the second-largest
that is customised to the corresponding
organised by IFEMA took place from 13th
European Fair for BIM services, networking,
segments (Fig. 4).
to 16 November at the Feria de Madrid
knowledge and solutions, BIMEXPO; the
Exhibition Centre within the framework of
19th International Fair for Solutions for the
ePower&Building, an event that registered
Electrical and Electronic Industry, MATELEC,
Wide ranging forums and seminars
almost 90,000 professional participants, 24%
and MATELEC LIGHTING The meeting
A variety of technical conferences were held
th
during VETECO 2018.
fair in 2016, far exceeding
The 2nd Seminar on
prior expectations (Fig. 1).
© IFEMA
more than at the previous
Solar Protection and
A total of 15% of the
Management took place
visitors were international,
on November 14 it was
coming mainly from the
organised by VETECO
European Union, the
SOLAR, ASEFAVE and
Maghreb region and
the magazine Protección
Ibero-America, especially
Solar, published by
Colombia and Morocco,
Interempresas Media.
the two countries invited
The seminar addressed
on this occasion. The
the issue of “How
number of exhibiting
to Improve Comfort
companies exceeded
Through Solar Control
1,600, which represents an
and Management” and
increase of 25% compared
was aimed at specifiers,
to the previous fair (Fig. 2). The fair occupied eight halls at the Feria de Madrid Exhibition Centre and revolved around the
industrialists and 1
installers. The objective
Figure 1: VETECO trade fair organised by IFEMA took place from 13th to 16th November at the Feria de Madrid Exhibition Centre within the framework of ePower&Building, an event that registered almost 90,000 professional participants.
themes of sustainability,
was to present and discuss the latest trends in this sector and report on the new regulatory
innovation and technology for the
once again coincided with the second
measures to be implemented soon. This last
construction industry (Fig. 3). For the second
International Industry and Smart Factory
aspect was addressed by Inés Gómez, from
consecutive edition of the fair, the event
Solutions Fair, MATELEC INDUSTRY.
the Technical Department at ASEFAVE.
integrated all the sectors and areas related to
This VETECO saw the definitive
the entire building process, which was a great
consolidation of VETECO SOLAR, which
In addition, the seminar “Insulating Glass
success as it multiplied synergies and business
was created in 2016 to respond to this
Beyond the Concept” took place on
opportunities.
sector’s needs. It also demonstrated a high
November 15, and was organised by VETECO
ePower&Building 2018 hosted the 16
level of acceptance for the new VETECO
GLASS, ASEFAVE and Interempresas Media,
International Window, Façade and Solar
GLASS fair, which serves the entire glass
which publishes Vitrea magazine.
Protection Fair, VETECO; the International Fair
industry, as well as the specific seminars
The first part of the seminar included three
th
128
N. 55 - JANUARY/FEBRUARY 2019 - international PAINT&COATING magazine
ZOOM ON EVENTS
presentations from companies related
by Cortizo, but also by the other exhibitors.
the opportunity to generate a perfect setting
to the insulating glass manufacturing
We have noticed an upbeat mood in visitors
and environment to show all the latest products
process. The second part of the seminar
and exhibitors that was not perceived in
for this year, especially our new ThermoFibre
consisted of a round table with senior
the last few fairs. In our case, we are very
material, which we managed to demonstrate
representatives from the sector in the
satisfied, both with the reception for the
both graphically and physically to the many
Iberian Peninsula. The main objective of
innovations we presented and also with the
visitors we received. The people attending had
the round table was to deal with all the
thousands of visits received during the four
a high degree of knowledge of the sector, they
general topics related to insulating glass
days of the fair, customers and potential
were deeply interested in the latest developments
that professionals in the sector should be
customers from all over the world, a reflection
and ongoing projects and they were also open
aware of. Agustí Balbuena, expert architect
of the internationalisation process we have
to launching them and using them in their
and consultant, and moderator of the
experienced in the last few years”.
businesses”.
history of insulating glass and its evolution,
EMMEGI IBÉRICA: Antonio Domínguez, sales
© IFEMA
round table, discussed issues such as the
manager with Emmegi Ibérica: “If we analyse
analysis of its performance, the demands
the evolution that VETECO has gone through
in its production and future innovations.
from 2012 to 2018, we can be certain that, at
All the members of the round table agreed
last, professionals in the sector have decided to
that glass is gaining in importance.
invest in technology, quality and future solutions to improve the enclosure industry. The window
For its part, ASEFAVE, the Spanish Light
and façade industry is increasingly demanding
Façades and Windows Manufacturers
excellent aesthetic quality. In response to
Association, organised a further
this, Emmegi has presented solutions such
two seminars. On November 13,
as the Fusion 4H Seamless welder, which
The Ibero-American Enclosure Forum’s
demonstrates excellent performance in zero
Open Seminar hosted representatives from
welding. On the other hand, we also observed
the enclosure associations from Brazil,
how the aluminium sector is resurfacing and
Chile, Colombia, Mexico, Paraguay and the
finally, professionals are investing in high-tech
Dominican Republic, who analysed the
precision machinery with a high production
situation in their markets and the challenges
capacity. Finally, the great innovation is how
and opportunities in each of them.
the final consumer can see the final design of their windows thanks to digital platforms such
The association also organised the seminar “Taxation as an Engine for Rehabilitation” on the morning of Friday, November 16. During the event, successful cases in which tax treatment was involved and tax proposals to boost the renovation sector were presented.
2 1
Figure 2: A total of 15% of the visitors were international, coming mainly from the European Union, the Maghreb region and Ibero-America, especially Colombia and Morocco, the two countries invited on this occasion.
as Voilàp, which unites the B2B world with B2C. This solution shows that Industry 4.0 is not only possible in our sector, it is already here. We are very grateful to the ePower&Building organisation for the opportunity it has given to all the actors in the window, glass and sun protection sector to present our proposals to suppliers and final consumers”.
Exhibitors’ assessments
DECEUNINCK IBÉRICA: Giorgio Grillo,
NICE: Enrique Fernández, commercial
The assessments of VETECO 2018 were
general director of Deceuninck Ibérica:
director at Nice Spain: “At this Veteco we have
positive, as the impressions collected from
“At Deceuninck, we assess very positively
seen that there is more movement in the sector,
different participating companies show.
the manner in which this year’s Veteco was
perhaps due to a more favourable economic
Here are some testimonies:
organised, both in terms of the programming
situation than previously. Our assessment is
CORTIZO ALUMINIOS: Daniel Lainz,
of activities parallel to the fair and in the
quite positive. The influx of people attending,
director of architecture systems at
concentration of potential customers and the
both in quantity and quality, has been highly
Cortizo: “Our evaluation of VETECO 2018
loyalty of existing ones. As a reference in the
satisfactory; approximately, 80% of the visits
is very positive, something noted not only
world of construction, VETECO has given us
have been from professionals. The private
international PAINT&COATING magazine - JANUARY/FEBRUARY 2019 - N. 55
129
© IFEMA
ZOOM ON EVENTS
3 1
Figure 3: The fair occupied eight halls at the Feria de Madrid Exhibition Centre and revolved around the themes of sustainability, innovation and technology for the construction industry.
from all over Spain.
MINIMAL WINDOWS: Marcelino López,
We appreciated
general director of Minimal Windows: “We
the good level of
assess VETECO 2018 very positively. Our
exhibitors present
participation in the exhibition has been a
in Veteco and the
success in term of visitors interested in our
high number of new
minimalist windows solutions both nationally
features presented,
and internationally, many of these resulting in
a true reflection
promising contacts”.
of the high level
“Likewise, receiving the award for the best
of activity in the
Stand at VETECO was highly satisfying for the
sector. We were
entire team as this work was done entirely
also pleasantly
by Minimal Windows, in which we wanted to
surprised by the
reflect the innovation, design and high quality
increase in visitors
of our products”.
from abroad, with
EXLABESA: Pachu Doblas, marketing
clients from South
director at Exlabesa: “Our stand at VETECO,
America, Portugal
designed by Ansede Quintáns Arquitectos, was
and France,
awarded the Architecture with an Ñ Award
among others. In summary, the atmosphere
in the ephemeral architecture category. The
the latest in the sector to be able to apply it
at the fair was very good, customers exuded a
stand was very well received by our customers,
in their homes. It should be noted that the
certain optimism and desire to undertake new
associates, architects and visitors in general,
end user is increasingly demanding and not
projects”.b
integrating some of our main products into its
only demands quality and innovation, but
TVITEC: Roberto Arias, communication
construction, especially our curtain wall, which
also that the product design be attractive,
director at Tvitec: “We think it has been
had a great impact. A fair, Veteco, which can
as is the case for Nice products. What has
the best of the three fairs, there was more
only be described as a total success and this
generated the most interest has been the
content and real business opportunities
award was the perfect finishing touch”.
products linked to integrating automation
were generated, amidst a relatively
into the home, particularly the entire Fibaro
buoyant and expansive atmosphere
For more information:
line that follows the latest market trends with
in the sector. We are very satisfied with
www.epowerandbuilding.com
the most innovative technology”.
the presentation of
ROTO FRANK: Francesc Gimeno,
innovative products,
general director of Roto Frank for Spain
such as solutions in
and Portugal: “We are very happy with
screen-printed glass
our participation at this year’s VETECO.
that emulate finishes
Our new products have had an incredible
in any type of natural
reception, both the Roto NX tilt-and-turn
stone for ventilated and
hardware, as well as the Solid C hinge and
interior façades. We
the hardware for Inowa slider systems, and
are also very satisfied
we have established many commercial
with the debate and
contacts. In addition, at this year’s fair we
the reflection generated
were accompanied by our distributors in
in the round tables
the Peninsula -Accesorios Alu y PVC, Centro
with the participation
del Accesorio, Comalfer Complementos
by the main players in
de Aluminio, Comercial Ignacio, Ferretería
architectural glass in
Alcantarilla, Rotofer and Sumpai Exclusivas
Spain. In summary, this
de Aluminio-, who were buttressed by a very
edition has been very
high number of local visits by customers
positive”.
130
N. 55 - JANUARY/FEBRUARY 2019 - international PAINT&COATING magazine
© IFEMA
visitors were very interested in discovering
4 1
Figure 4: With the incorporation of new areas, VETECO shows its market awareness by expanding its offer in a manner that is customised to the corresponding segments.
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Excellence and Industrial perspectives
ZOOM ON EVENTS
DeburringEXPO 2019: Perfect Surfaces – Burr-Free, Clean and Precise
W
hether they’re required for
the supplementary program including
appearance and risk of injury. “Available
downstream manufacturing
theme parks covering the issues of
manufacturing processes don’t make it possible
steps or for error-free
the “Sheet Metal Deburring Process
to produce the required workpiece surfaces
functioning, surface characteristics are
Sequence”, “AM Parts Finishing” and
entirely without burrs. This makes intermediate
decisive with regard to part and product
“Cleaning After Deburring”, as well as
and downstream processing operations such
quality. Processes such as deburring
the bilingual expert forum, will offer
as deburring, rounding and precision surface
and precision surface finishing are
specialised knowledge and know-how
finishing more and more important as a
becoming more and more significant
that’s unavailable anywhere else in such a
requirement for parts manufacturers which
as a result – regardless of whether
compact form.
decisively influences value creation and product
the parts are produced by means of
quality,” explains Hartmut Herdin, managing
erosion, forming, primary forming or
Surface and edge zone characteristics are
director of fairXperts GmbH & Co. KG,
additive manufacturing. DeburringEXPO,
decisive with regard to further processing
promoters of DeburringEXPO. At the same
the world’s only trade fair which deals
and the functionality of the respective
time, manufacturing companies are faced with
exclusively with the removal of burrs
components. Amongst others, these
new challenges resulting from ever stricter
and the production of precision surface
characteristics include coatability and
specifications and heightened requirements for
finishes, will be held at the Karlsruhe
bondability, friction, resistance to wear,
process reliability and economic efficiency.
Exhibition Centre from the 8th through
sealing performance, noise, smoothness,
As a unique information, communication
the 10 of October, 2019. Beyond this,
roughness, improved performance,
and procurement platform for deburring,
th
© fairXperts GmbH & Co. KG
rounding and precision surface finishing, DeburringEXPO will provide a complete overview of current and new solutions and development trends from the 8th through the 10th of October, 2019.
Cross-Industry, Cross-Technology Portfolio “As of mid-January 2019, more than 100 exhibitors from ten countries had already made firm bookings for their booth locations. The solutions offered by the exhibiting companies are designed to efficiently and reproducibly fulfil current and future requirements for deburring, rounding and precision surface finishing in a great variety of industry sectors,” reports Hartmut Herdin. The exhibitor presentations will be supplemented by DeburringEXPO’s
1
multifaceted supplementary program
Figure 1: DeburringEXPO will be held at the Karlsruhe Exhibition Centre from the 8th through the 10th of October, 2019.
132
N. 55 - JANUARY/FEBRUARY 2019 - international PAINT&COATING magazine
which is continuously updated to the ever-changing market.
© fairXperts GmbH & Co. KG
ZOOM ON EVENTS Theme Park: Sheet Metal Deburring Process Sequence The “Sheet Metal Deburring Process Sequence” theme park, initiated together with market leaders and experts from the industry sector, will present the deburring step of the manufacturing process live in action, as well as up and downstream processes such as straightening, measuring and coating of sheet metal parts. Visitors will be able to feed a reference part (made available to them for this purpose) to the individual processing steps such as deburring, rounding and edging. Beyond this, information will also be provided on issues such as the relationship between edge rounding
2 1
and corrosion protection, methods for measuring radii on rounded sheet metal components, development trends where tools for sheet metal
Figure 2: DeburringEXPO will provide a complete overview of current and new solutions and development trends for deburring, rounding and precision surface finishing.
deburring are concerned, automated surface finishing and much more.
Theme Park: AM Parts Finishing Industry is focusing more and more attention on additive manufacturing.
in accordance with the specified
processes economically and in
requirements at, amongst other
accordance with actual requirements.
platforms, the “AM Parts Finishing” theme park.
Bilingual Expert Forum As an integral part of DeburringEXPO,
opportunities in parts production
Theme Park: Cleaning After Deburring
with regard to shaping, flexibility and
Oil, grease, emulsions, chips, grinding
source of knowledge thanks to its
individuality. In particular additively
dust or lapping paste from the
character as an advanced training
manufactured metal components
production processes still adhere
event. The simultaneously interpreted
have in many cases already achieved
to the component, even if it’s been
presentations (German <> English)
levels equivalent to those of industrial
ideally deburred, rounded or
provide visitors with comprehensive
manufacturing, and are now able to
polished. Cleaning is thus absolutely
knowledge from the fields of
compete with conventional processes.
indispensable because component
deburring and rounding, as well
Requirements for the surface quality
cleanliness has a decisive influence on
as precision surface finishing, and
of 3D printed parts are increasing as a
the intended function, as well as on
concerning the special content of the
result. Required post-processing steps
the quality of downstream processes
theme parks. Practical examples and
such as cleaning, deburring and coating
such as bonding, welding, coating and
benchmark solutions make it possible
are thus a significant cost factor and are
assembly.
to gather ideas and inspiration for
crucially decisive for industrial use of
Experts will present solutions and the
optimising one’s own processes.
additively manufactured parts.
necessary knowledge at the “Cleaning
DeburringEXPO’s exhibitors will
After Deburring” theme park in order
For further information:
present solutions for perfect surfaces
to layout and optimise cleaning
www.deburring-expo.com
Additive manufacturing offers creative
the 3-day expert forum has established itself as a highly popular
international PAINT&COATING magazine - JANUARY/FEBRUARY 2019 - N. 55
133
ZOOM ON EVENTS
F
rom February 5-7 Surface Design Show 2019 will take place
at London’s Business Design
© Montgomery Exhibitions
Surface Design Show 2019: Celebrating the Best in New and Innovative Surfaces
Centre to provide a platform for architects, designers and specifiers to explore the best in interior and exterior surface materials, lighting design, development and innovation. Surface Design Show is the only event in the UK that focuses solely on interior and exterior surfaces. For more than ten years Surface Design Show has been the place where industry professionals immerse themselves in the latest materials for the
1
built environment, gain new insights and network with like-minded designers,
Figure 1: Surface Design Show will take place at London’s Business Design Centre from February 5-7 2019.
architects and suppliers. Surface Design Show 2019 also features some 40 talks from over 50
Rounding of shedkm debating the topic
modern architecture’ in an exciting and
industry professionals, all designed to
‘Factory-made Housing: is this the solution to
inspiring format using 20 images, each
engage and inspire.
building better homes long term?’.
discussed for 20 seconds.
The Opening Night Debate returns
Returning for 2019 is the ever popular
Stone Gallery, which is officially
from 6.30pm on the first day of the
PechaKucha Evening, hosted by Chris Dyson
supported by Stone Federation
Show, Tuesday February 5. Organised
of Chris Dyson Architects on 6 February
GB whose Stone Knowledge Hub
in association with the Royal Institute
from 6.30pm. Speakers include Nigel Ostime
forms a focal point for the event, will
of British Architects (RIBA) and
of Hawkins Brown; Soraya Khan of Theis
also be returning to Surface Design
New London Architecture (NLA) it
and Khan Architects; Alex Scott-Whitby of
Show 2019. Stone Gallery, which is
will discuss whether factory-made
ScottWhitbyStudio; Stuart Piercy of Piercy
also supported by media partner
housing can provide Londoners with
and Co; Simon Fraser of Hopkins Architects;
Tomorrow’s Tile & Stone, is an
better places to live. The panel will
Alison Brooks of Alison Brooks Architects;
industry-leading event for architects
be chaired by Peter Murray of NLA,
Lucia Berasaluce of Haptic Architects
and designers to meet and specify
with Ben Derbyshire of HTA Design
and Ben Cousins of Cousins & Cousins
natural stone. The Stone Hub stage will
and RIBA President, Carl Vann of
Architects. Presenters will discuss ‘Identities
host a series of presentations curated
Pollard Thomas Edwards and Hazel
and Boundaries: site specific responses to
by Arup.
134
N. 55 - JANUARY/FEBRUARY 2019 - international PAINT&COATING magazine
ZOOM ON EVENTS
awards that recognise exterior and
of creative and innovative use of
home of architectural lighting, allows
interior surfaces for different sectors
materials and lighting in both interior
architects and designers to touch,
of design, including commercial,
and exterior schemes. Some projects
compare and learn about innovative
housing, light and surface, public
received nominations across several
lighting and technology products.
building, retail, sustainable, and
categories, resulting in 48 finalists.
The Light School arena, Light Talks, will
temporary structure.
The Awards Presentation will take
return once again supported by the
The shortlist for this yearâ&#x20AC;&#x2122;s Surface
place on the morning of Thursday
Institution of Lighting Professionals
Design Awards consists of an
February 7, at Surface Design Show.
and LED Linear.
impressive 43 categories across
Tickets to the Presentation are
Since 2013 the Show has hosted the
seven categories, including entries
available via the Surface Design Show
Surface Design Awards, now recognised
from Zaha Hadid Architects,
website. Award partners include:
as one of the most respected events
Studio Egret West and Chris Dyson
James Latham, Finsa, Business Design
in the design calendar. The 2019
Architects from the UK, Rockwell
Centre, Soluis and Roof Maker.
Awards received 197 entries from
Group from the USA, and Kengo
22 countries, including America,
Kuma & Associates from Japan.
For more information:
Italy, China and India. There are 13
Each entry is an exemplary example
www.surfacedesignshow.com
Š Montgomery Exhibitions
Now in its fifth year Light School, the
2 1
Figure 2: Surface Design Show is the only event in the UK that focuses solely on interior and exterior surfaces.
international PAINT&COATING magazine - JANUARY/FEBRUARY 2019 - N. 55
135
ZOOM ON EVENTS
MADE expo 2019: An Accelerator of Ideas for Revitalizing the Construction Industry
O
Key components of this quality are urban
necessary impetus for the construction
the result of the encounter
and infrastructural regeneration and
industry to grow and expand once
between virtuous supply
the must-haves of contemporary living,
more.
chains, new knowledge and technologies
guided by new lifestyles: comfort, safety,
The quality of living and its various
that allow the creation of harmony
sustainability and design. Innovation,
forms will be at the heart of the ninth
between inhabited spaces and the built
which encompasses all these components,
edition of MADE expo, the largest
environment.
is the driving force that can provide the
international event in Italy for the world
Š MADE expo
ur quality of living today is
1
Figure 1: MADE expo will take place at Milano-Rho Fiera from 13th to 16th March 2019.
136
N. 55 - JANUARY/FEBRUARY 2019 - international PAINT&COATING magazine
© MADE expo
ZOOM ON EVENTS
of construction and architecture with more than 100,000 visitors and which will be held at Milano-Rho Fiera from 13th to 16th March 2019. MADE expo is intended to be a platform for dialogue where all those involved in every part of the process can come together in one place and contribute to the relaunching of the construction sector in a complex market context. Such an action will mean having an important impact on the national economy by a sector that already contributes 8% of Italian GDP, increases Italian wealth by half a percentage point a year and which employs 1.4 million people. MADE expo is notable for its specialized format offering four display halls (MADE Construction and Materials, MADE Claddings, Doors and Windows, MADE Interior and Finishes and MADE Software, Technologies and Services) and a busy schedule of
2 1
Figure 2: Our quality of living today is the result of the encounter between virtuous supply chains, new knowledge and technologies that allow the creation of harmony between inhabited spaces and the built environment.
technical and cultural training programmes. the earthquake-struck areas of Marche and
Milan and nationally renowned institutions such
Visitors will have the opportunity to discover
Abruzzo are still going on. The solutions
as the Triennale.
all the latest in specialist equipment and see
aimed at prevention and structural
it in action against a backdrop of ideas and
reinforcement will be one of the major areas
“We are getting very positive feedback from
new features while at the same time having
of attention.
the leading companies in the various sectors,
access to a vast amount of experience and
On another topic, MADE expo also stands
consolidating our role as a provider of common
specific dedicated areas in which they will be
out for being a showcase of the best of
ground for our sector” says Massimo Buccilli,
able to get to know and even put their hands
Made in Italy in architecture and interior
President of MADE expo. “We also want to
on the latest top quality products in building,
design. In order to offer inspiration and
be seen as an “accelerator of ideas “ and
architecture and finishes.
suggestions related to this sector, the 2019
to do this we are also working to organize
This opportunity is certainly appreciated as
edition will host an exclusive exhibition/
an important conference on the theme of
the satisfaction surveys carried out by Kantar
event in collaboration with ELLE DECOR
infrastructure regeneration involving leading
Tns found that 95% of professional visitors
and the architects Calvi Brambilla. The
institutional figures and representatives
were satisfied with their experience in the
international Archmarathon Selections
from some of the foremost construction and
2017 edition.
Architecture Competition will also contribute
materials associations. In addition the period
The MADE expo conferences and workshops
to highlighting the best projects by putting
during which the event is being held will also
organized by Build Smart will be dedicated to
30 national and international studies in
be conducive to assessing the effects of the
Safety, Comfort, Sustainability and Innovation,
competition with each other in 13 different
planned extension of the Fiscal Bonus until
in which all the latest solutions and materials
categories.
the end of next year so as to encourage
will be looked at as components of an
The 2019 edition of MADE expo, which has
restructuring/renovation and the energy
integration logic.
developed a close working collaboration
efficiency of technical cladding materials”
Particular attention will then be dedicated
with ANCE and its main associations as well
concluded Buccilli.
to the topic of seismic activity, closely
as different partnerships with the most
related to the concept of territorial safety
prestigious Italian universities, will also see
For more information:
and where ongoing efforts to reconstruct
increasingly close connections with the city of
www.madeexpo.it
ZOOM ON EVENTS
“A
rtificial intelligence has the
and their diverse
potential to revolutionize
qualifications.
the production and energy
Industrial Intelligence
© Deutsche Messe
HANNOVER MESSE 2019: Industry 4.0 Meets AI therefore stands
Chairman of the Board of Deutsche
for the expansion
Messe. “People teach machines to
of knowledge
act logically and purposefully to meet
management and the
customer needs. AI systems generate
training of knowledge
knowledge and today, based on data and
carriers.
algorithms, can continuously optimize
The theme of
operating states or reliably predict faults
HANNOVER MESSE
and failures – in production processes,
2019 underlines the
in the power grid or in logistics. That’s
growing importance
what Integrated Industry – Industrial
of artificial intelligence
Intelligence stands for.”
and machine learning
The networking of people, machines
in the production and
and data is created through common
energy industries,
platforms where they exchange and
including such areas as energy efficiency and
multiply their knowledge. The role
use and autonomous production processes
HANNOVER MESSE – Get new technology first!
of humans is that of an enabler. The
as well as challenges in terms of interfaces,
HANNOVER MESSE is the world’s
production of tomorrow is not possible
protocols and security. At HANNOVER MESSE,
leading tradeshow for industrial
without their process knowledge
international thought leaders from the fields
technology. With the lead theme
© Deutsche Messe
industries,” says Dr. Jochen Köckler,
1
Figure 2: The lead theme of the next edition will be focused on “Integrated Industry – Industrial Intelligence”.
of AI and industry
“Integrated Industry – Industrial
come together
Intelligence”, it serves as the global
to jointly discuss
platform for the digital transformation
and develop
of production and energy systems.
solutions for
In addition to six exhibit sectors
tomorrow. Köckler:
– IAMD–Integrated Automation,
“Managers who
Motion & Drives, Digital Factory,
are responsible
Energy, Industrial Supply, ComVac
for strategic
and Research & Technology – there
decisions in their
are special areas for startups and
companies should
career development. More than
deal in detail with
90 conferences and forums round
potential uses
out the program. The next edition
and impending
runs 1–5 April 2019 in Hannover,
upheavals.
Germany. Sweden is Partner Country
HANNOVER
of HANNOVER MESSE 2019.
MESSE 2019 is the
Figure 1: The Hannover Messe next edition will take place from 1st to 5th April 2019.
138
2 1
N. 55 - JANUARY/FEBRUARY 2019 - international PAINT&COATING magazine
platform to stay
For more information:
informed.”
www.hannovermesse.de
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