The first international magazine for surface treatments
®
ISSN 2280-6083
ipcm digital on In this issue :
www.myipcm.com
SPECIAL ALUMINIUM 2018
INTERNATIONAL PAINT&COATING MAGAZINE
9th Year - Bimonthly N° 53 - SEPTEMBER/OCTOBER
MACCHINE, IMPIANTI, ATTREZZATURE PER LA LAVORAZIONE DI LAMIERE, TUBI, PROFILATI, FILI E CARPENTERIA METALLICA. STAMPI. SALDATURA. TRATTAMENTI E FINITURA. SUBFORNITURA. ROBOT, AUTOMAZIONE E TECNOLOGIE ABILITANTI. MACHINES AND EQUIPMENT FOR THE MACHINING OF SHEET METAL, PIPES, SECTIONS, WIRE AND METAL STRUCTURAL WORK.
1 5 - 1 8 /0 5 / 2 0 1 9
DIES. WELDING. TREATMENTS AND FINISHING. SUBCONTRACTING. ROBOTS, AUTOMATION AND ENABLING TECHNOLOGIES.
LA FORMA DELLE IDEE THE SHAPE OF IDEAS
Promossa da Promoted by
UCIMU-SISTEMI PER PRODURRE
Media Partner
065/2017 LMRX17R
soil
metals
snow
water
space
precious
flora
born iconic
A look ahead into the future of the Architectural Coatings Industry. Top Quality Collection J 20.20 includes 35 iconic colours carefully selected for their timeless appeal. The collection is divided into 7 Elements, representing the same number of facets of taste. Each Element consists of 5 easily matching colours. Available in pastel colours, textured ďŹ nishes and metallic effects for the broadest range of applications.
© ipcm ®
© Muskita
CONTENTS SEPTEMBER/OCTOBER 2018
SP EC IA L A L U M INIU M
SP ECIAL ALUMIN IUM
FOCUS ON TECHNOLOGY
52
From a Compact Vertical System to the Most Advanced Technology in the Aluminium Profile Coating Field: The History of AluK GB
© Luxe Coat
© ALMECO
40
FOCUS ON TECHNOLOGY
Muskita Aluminium Industries: Quality from the Starting Point
SP EC IA L A L U MINIU M
S P ECIAL ALUMIN IUM
FOCUS ON TECHNOLOGY
78 05 06 14 16
FOCUS ON TECHNOLOGY
ALMECO: The First Zero Liquid Discharge Water Treatment Plant in the World Installed on an Anodic Oxidation Line for Aluminium Coils
EDITOR’S LETTER
28
BRAND-NEW
32
BRAND-NEW INNOVATIONS: PRESENT&FUTURE The New Industrial Districts
FOCUS ON TECHNOLOGY
26
39 62
®
ON THE ROAD TO ipcm N. 53
SPE C IAL AL U MIN IUM
HIGHLIGHT OF THE MONTH Chemetall: Your Leading Global Supplier of Applied Surface Treatment Solutions
FOCUS ON TECHNOLOGY The Rotamat at Interseals: The Spring Board For Opening New Markets
ADAPTA: Improving your “Modus VIVENDI®”
18 24
Advanced Technology, Process Renewal, and Industrial Research on Pre-Treatment: Luxe Coat’s Strategy for Its Business Relaunch
Eliminating Process Steps, Increasing Quality. Manufacturer of SMC Housings Relies on FreiLacke’s PIMC Process
SUSTAINABILITY
HIGHLIGHT OF THE MONTH
98
66
FOCUS ON TECHNOLOGY Deep Collaboration with the Paint Supplier to Diversify Production and Ensure High Quality: The Winning Strategy of Lacoviana
Expand your architectural options with the colour shades of the new
Magnifica collection
international@ripol.com
© Metra
© OMSG
CONTENTS SEPTEMBER/OCTOBER 2018
SP EC IA L A L U MINIU M
FOCUS ON TECHNOLOGY
INNOVATIONS: PRESENT&FUTURE
Metra Color: an Italian History of Quality and Innovation in Powder Coating to Conquer the US Market
© Karl Bubenhofer AG
114
Shot Blasting of Extruded Aluminium Profiles: Aesthetic Quality with Time and Cost Savings
© All.co
110
S P ECIAL ALUMIN IUM
SP EC IA L A L U MINIU M
FOCUS ON TECHNOLOGY
124 74 76
BRAND-NEW
106
SUCCESS STORIES
122 136 142
FOCUS ON TECHNOLOGY
144
151 154
BRAND-NEW SUCCESS STORIES
SUSTAINABILITY
BRAND-NEW STANDARD & LEGISLATION - UCIF INFORMS Cybersecurity Act and Industrial Applications: Taking Stock of the Situation
BRAND-NEW
Electric Vehicles from Sokon Will Be Painted Using Highly Flexible Seven-Axis Robots
INNOVATIONS: PRESENT&FUTURE Qualicoat & Qualanod: latest eco-friendly developments for aluminium pre-treatment
New Technical Centre For Powder Coating Strengthens Karl Bubenhofer’s Market Position
Chromium-Free Pretreatment at ELVIAL. A Review of 18 Successful Years
SUCCESS STORIES
Framery in the Pursuit of Happiness with Teknos’ INFRALIT PE 8317-10 Powder Coating
90
134
All.co Group: A Wide Choice of High-Quality Finishes and Colours from a Well-Established Company
Tonon Forty Launches Its New Line of Radiators “Colors Vintage”, with Finishes Dedicated to Vintage Products and Created with Arsonsisi Powder Coatings
88
HIGHLIGHT OF THE MONTH
156 158
TRADE FAIRS & CONFERENCES ZOOM ON EVENTS
ARCHITECTURAL COATING SOLUTIONS
VISION 2020 PALETTE INSPIRED BY GLOBAL COLOR TRENDS LASTING PERFORMANCE TO ENDURE THE ELEMENTS EXCEPTIONAL COLORS Vision 2020 includes superior-performance architectural coating colors carefully selected by Sherwin-Williams’s color experts.
• Color palette creates a lasting impression • Excellent color consistency • Suitable to residential and monumental building design • Color trends orientated to future global development OUTSTANDING PERFORMANCE All Vision 2020 powder coatings fully comply with the criteria and standards set by the Quality Associations: GSB Master and Qualicoat Class 2
• Exceptional exterior durability • Remarkable abrasion resistance • Reduced cleaning frequency
zonamista.it
If you are interested in the Vision 2020 brochure of 48 colors, please send an e-mail to: inver@sherwin.com
Syntha Pulvin is a brand of The Sherwin-Williams Company www.synthapulvin.co.uk
EDITOR’S LETTER
Richiedi la versione in italiano a info@ipcm.it
Q
uality is the ability of a product or service to meet customer needs, requirements, and expectations. It is not an inherent property, but rather it should be defined, applied, and controlled. What does it mean
to produce quality? It means applying well defined methods and sharing a vision. It means using quality operational tools, procedures, people, and skills. It means working with a system that balances all these elements. Quality is therefore the set of factors through which a company creates a product or service that meets effectiveness and efficiency requirements, i.e. customer requests, by optimising the resources used. Quality is a system and it should be pursued as such, through quality raw materials, staff training, and product certifications. This issue of ipcm® includes a large section devoted to the aluminium treatment and finishing fields and it will be distributed at the Aluminium 2018 fair in Düsseldorf (Germany). The interviews included present a few common threads that we would like to share here. First of all, what is the point in certifying a treatment phase and boasting that certification, if inadequate processes or materials are used at the previous or subsequent process stages? Speaking of aluminium, how much does the quality of metal or of the applied paint affects products’ compliance with certifications? In order to offer truthful outdoor resistance guarantees, would it not be more useful to certify a whole treatment cycle rather than just one phase? Secondly, simplifications should be avoided to produce quality. Speaking again of aluminium, the ban of chromium (VI) paved the way to numerous chrome-free alternative solutions that can be combined with a greater or lesser number of previous treatments. Some companies choose a pre-treatment process with acidic phases only, others opt for a combination of acidic and alkaline phases, and others prefer the oxidation flash technology. All these solutions are valid if considered individually, but the choice should be made based on the quality level of end products and not on criteria such as ease of management or investment size. Thirdly, water treatment greatly affects process quality. Purifying and recycling water is not only an eco-friendly choice. If well conceived, it enables to keep the process parameters constant and well balanced. In other words, it creates quality. You will find that all the topics outlined above are further developed in the next pages. This issue however also includes interesting and exclusive contents on the use of powder coatings, new colour collections available, low environmental impact innovations to pre-treat aluminium prior to coating and oxidation, recovery solutions for solvent-based paints, anti-friction coatings, and new resins to formulate better powders for the finishing of heat sensitive substrates. Quality should be perfected with practice and be specifically aimed at a purpose: offering a higher quality than that required is a waste of resources; offering a lower quality certainly leads to disputes.
Alessia Venturi Editor-in-chief Direttore Responsabile
As a publishing company ourselves, we share the mission of a great international publishing house called Condé Nast: Quality is our business plan.
international PAINT&COATING magazine - SEPTEMBER/OCTOBER 2018 - N. 53
05
© adam121 © Fotolia
Opening photo: Regent Paints offers a program of reusability of the batch failures, obsolete materials, gelled batches, washed solvents, mistints, customer returns, non-usable and nonsalable raw materials or paints of all type.
ANALYSIS
Hazmat Waste Put to Use. A Re-use Solution for Solvent-Based Paints and Raw Materials Huzaifa Matawala
T
he paint industry has entered into an
challenging for research and development
industry have changed more rapidly in the
era of continuous enhancement of
teams to create ecofriendly paints with
past decade than ever before. The process of
chemistry from various perspectives,
acceptable cost and product performance.
change results in several batches, raw materials
including customer requirements, costs,
Every year, several formulations are edited,
and stock items that need to be replaced with
environment, durability and reach. It is always
and product is enhanced. Formulations in our
newer ingredients. The more we evolve into
06
N. 53 - SEPTEMBER/OCTOBER 2018 - international PAINT&COATING magazine
ANALYSIS
newer formulations, the more raw material and
based formulations have not reached several
• sorting, batch making and production.
stock inventory that is no longer usable to the
countries across the globe, and traditional
Solvents play an important role in recycling
industry. We leave behind failure batches and
solvent-based coating systems still provides an
paints and resins, as they determine the
obsolete raw materials.
essential coating solution worldwide.
compatibility and the recycling family “house”
The company has successfully reached
the paint or resin will go to. If we initiate a
Purpose
solutions for the reuse of latex-based paints.
manufacturing process without a proper
With industry experience with different type of
With every passing year Regent Paints is able
understanding, we risk having non-favourable
resins, pigments, additives, solvents and paints,
to convert more and more cans of latex paint
batches. Material may turn into cake-like
Regent Paints offers a program of reusability
into a new recycled product. The company has
formations, lumps, chips, harden like rock or
of the batch failures, obsolete materials, gelled
several projects for procuring the latex paint
lose viscosity. Successful recycling is based on
batches, washed solvents, mistints, customer
cans from the market, homes, industries and
the study of the molecular structure, boiling
returns, non-usable and nonsalable raw
counties. These paints are used for producing
point, dispersing ability and density of the
materials or paints of all types (ref. Opening
stucco, plasters, driveway sealers and recycled
solvent used in paint or resin.
photo). The attempt is to reduce the waste
latex-based paints. This article will also
generation from the factory process itself by
discuss the paint process, how it effects the
Solvent and Resin Compatibility
finding use for the items into Regent Paints’ line
environmental system and how the reuse of
Hansen Solubility Parameter Values
of products. Once the chemistry, ingredients,
oil paints offers both economic and ecological
Hansen solubility parameter values are based
compatibility, resin and solvent nature are
benefits.
on dispersion bonds (δD), polar bonds (δP)
ascertained, the reuse of the items can be
and hydrogen bonds (δH). These contain
ascertained.
Process
This article shares data and possibilities on
Important things to consider with solvent-based
interactions with other solvents and also with
working with oil paints and solvents. There
paints and resins include:
polymers, pigments, nanoparticles, etc. This
is an extensive use of oil paints and solvents
• solvent and resin structure, compatibility,
allows for rational formulations knowing, for
internationally. Advanced, ecofriendly, water-
information about the inter-molecular
example, that there is a good HSP match
density and boiling point;
Table 1: Comparing nonpolar, polar aprotic and polar protic molecules to determine compatibility.
Solvent
Chemical Formula δD Dispersion NONPOLAR SOLVENTS
δP Polar
δH Hydrogen Bonding
Hexane Benzene Toluene Diethyl ether Chloroform 1,4-Dioxane
CH3CH2CH2CH2CH2CH3 C6H6 C6H5-CH3 CH3CH2-O-CH2CH3 CHCI3 /-CH2-CH2-O-CH2-CH2-O-\
0.0 0.0 1.4 2.9 3.1 1.8
0.0 2.0 2.0 4.6 5.7 9.0
Ethyl acetate Tetrahydrofuran(THF) Dichloromethane Acetone Acetonitrile (MeCN) Dimethylformamide(DMF) Dimethyl sulfoxide(DMSO)
CH3-C(=O)-0-CH2-CH3 /-CH2-CH2-O-CH2-CH2-\ CH2CI1 CH3-C(=O)-CH3 CH3-C=N H-C(=O)N(CH3)2 CH3-S(=O)-CH3
5.3 5.7 7.3 10.4 18.0 13.7 16.4
7.2 8.0 7.1 7.0 6.1 11.3 10.2
Acetic acid n-Butanol Isopropanol n-Propanol Ethanol Methanol Formic acid Water
CH3-C(=O)OH CH3CH2CH2CH2OH CH3-CH(-OH)-CH3 CH3CH2CH2OH CH3CH2OH CH3OH H-C(=O)OH H-O-H
8.0 5.7 6.1 6.8 8.8 12.3 10.0 16.0
13.5 15.8 16.4 17.4 19.4 22.3 14.0 42.3
14.9 18.4 18.0 14.5 17.8 17.5
POLAR APROTIC SOLVENTS 15.8 16.8 17.0 15.5 15.3 17.4 18.4
POLAR PROTIC SOLVENTS 14.5 16.0 15.8 16.0 15.8 14.7 14.6 15.5
international PAINT&COATING magazine - SEPTEMBER/OCTOBER 2018 - N. 53
07
between a solvent and a polymer. Rational substitutions can also be made for “good”
Table 2: The boiling points of various solvents.
solvents (effective at dissolving the solute)
Solvent
Boiling point (°C)
or “bad” solvents (expensive or hazardous
ethylene dichloride
83.48
to health or the environment). Table 1
pyridine
115.25
shows that the intuitions from nonpolar,
methyl isobutyl ketone
116.5
polar aprotic and polar protic molecules
methylene chloride
39.75
are put numerically – the polar molecules
isooctane
99.24
have higher levels of δP and the protic
carbon disulfide
46.3
solvents have higher levels of δH. Because
carbon tetrachloride
76.75
numerical values are used, comparisons can
o-xylene
144.42
be made rationally by comparing numbers. For example, acetonitrile is much more polar than acetone, but exhibits slightly less hydrogen bonding. When studying the detailed characteristic properties of the solvent bond with resin, pigment metals and fillers, we can ascertain the use and breaking of such bonds into newer or similar products for use. For example, toluene and benzene are more compatible with xylene than mineral spirits. However, xylene is compatible with mineral spirits as well. Certain solvents are soluble with each other, some are soluble only to an extent and some are non-soluble. When reacted with resins and pigments, solvents change the loyalty towards their “house,”
Sorting, Batch Makings and Productions
The intention is to have a final brand of such products in the market from local facilities. The use of these coatings is minimal in developed countries, but can serve as a major help in the economies that need infrastructural development. The infrastructural zones of developing countries can be served with these durable, eco-friendly products that are created from solvents and oil paints.”
becoming more compatible most of the time.
compatibles together, we sort the materials on the basis of sheen, color, density and gloss. Depending on the inventory, the products with common sheens, colors and densities are mixed together into batch sizes as an intermediate pulp. This is an important ingredient mix check stage, where pulp is created from the oil paint, resin, solvent, pigment or waste/scrap/lots. These pulps are usually made keeping in mind the usability for the final product. We again check the pulp batches on the final gloss and resin/solvent/ pigment/filler ratio on the basis of density, hardness, gloss, weight and viscosity.
The use of additives, extenders and fillers plays an important role.
Once we have classified the groups of
We finally craft final product batches of Density
floor paints, primer paints, stucco items,
Most organic solvents have a
texture coatings, topcoats, bitumen paints,
Boiling Point
lower density than water, which means
etc. All the formulations, blends, processes
The boiling point is an important
they are lighter than and will form a layer
and other ingredients remain an important
property because it determines the
on top of water. Important exceptions
part of chemistry. These various products
speed of evaporation. Small amounts
are most of the halogenated solvents
are served in several brands and markets.
of low-boiling-point solvents like diethyl
like dichloromethane or chloroform, which will
Regent Paints is able to serve the markets
ether, dichloromethane or acetone will
sink to the bottom of a container, leaving water
with a final recycled product that saved
evaporate in seconds at room temperature,
as the top layer. This is crucial to remember
many important ingredients from land
while high-boiling-point solvents like
when partitioning compounds between
burial or fuel blending. These products
water or dimethyl sulfoxide need higher
solvents and water in a separator funnel during
are also created without the extraction of
temperatures, an air flow or the application
chemical syntheses.
resources, resulting in energy savings, which
of vacuum for fast evaporation (Table 21).
Often, specific gravity is cited in place of density.
is environmentally beneficial.
• Low boilers: boiling point below 100 °C
Specific gravity is defined as the density of the solvent divided by the density of water at the
Scope
• Medium boilers: between 100 °C and 150 °C
same temperature. As such, specific gravity is a
The scope of recycling is based on the
• High boilers: above 150 °C.
unitless value. It readily communicates whether
requirements of paint reuse projects,
a water-insoluble solvent will float (SG < 1.0) or
cost/financial benefits, and research
sink (SG > 1.0) when mixed with water.
and development.
(boiling point of water)
1
Solvent Properties – Boiling Point Archived 14 June 2011 at the Wayback Machine. Xydatasource.com. Retrieved on 2013-01-26.
08
N. 53 - SEPTEMBER/OCTOBER 2018 - international PAINT&COATING magazine
Š Regent Paints
ANALYSIS
1
Figure 1: Programs that receive latex paint.
Recycling and Utilization of Latex-Based Paints Compared to Oil-Based Paints Figures 1-4 show the opportunity to fill the gap between collection and reutilization. A project can be created for savings in the cost of disposal and the cost of manufacturing oil paints. This data was obtained from results of a DNR/DATCP survey, conducted summer 2015 (Wisconsin State). Costs and Benefits of Reusing Oil Paints Table 32 gives an example of the approximate cost of disposal of paintrelated items. In all calculations the cost of disposal of the products is included. As an environmental lifecycle calculation, the cost of solventbased paint on extraction is about twice the cost of disposal. https://admin.ks.gov/docs/default-source/ofpm/procurement-contracts---adds/tradebe-treatment-recycling.pdf?sfvrsn=2
Š Regent Paints
2
2 1
Figure 2: Disposal methods for latex paint.
© Regent Paints
© Regent Paints
3 1
4 1
Figure 3: Bulk waste streams.
Figure 4: Disposal methods for oil-based paint.
The process and cost of making paint
Patent Products, Research and Processes
The intention is to have a final brand of such
from scratch is saved when paint is
Regent Paints has performed detailed
products in the market from local facilities. The
reused.
scientific studies over several years. It
use of these coatings is minimal in developed
For example, when making paint,
has been working in the industry for
countries, but can serve as a major help
resins are cooked in a reactor with
five decades, and now has presence in
in the economies that need infrastructural
amines, natural agricultural oils,
recycling, paint manufacturing and raw
development. The infrastructural zones of
phallic anahydrides, penta, maelic
materials on multiple continents. The
developing countries can be served with
and monomers. The process utilizes
company was able to patent with the United
these durable, eco-friendly products that are
energy, resources, power and rare
States Patent and Trademark Office with oil
created from solvents and oil paints. There are
blends of nature. If we are able to reuse the paint, we save the ingredients and the energy that
BULK WASTE STREAMS
would have been spent creating
Type 1 Bulk Halogenated 2 Bulk Non-Halogenated* 3 Paint Waste 4 Ink Waste 5 Lab Wastes 6 Bulk Corrosive Liquids 7 Filter Waste 8 Mud Pit Wastes 9 Bulk Solids or Liquids (HAZ)
those raw materials. Additionally, when we fuel blend these items in fire, we are unable to save them. The cycle of generation of newer resins, solvents, metallic driers, pigments, additives, etc. has to take place. We have to extract more gums from more trees, erode more mountains
markets who use these items as
Table 3: Bulk waste streams.
economical coatings to protect items. Quantity 55 gal 55 gal 55 gal 55 gal 55 gal 55 gal 55 gal 55 gal 55 gal
9.1 Bulk Solids or Liquids (nonhaz) 55 gal
Cost $129.38 $74.52 $108.68 $98.33 $175.95 $175.95 $155.25 $112.82 $263.93 $87.98
for minerals, and extract the oils from the sea to create specialty
* Bulk Non- Halogenated: >5000 BTU’s and <5% Chloride
Disposal Fuel Blend Fuel Blend Fuel Blend Fuel Blend Treatment Treatment Recycle Treatment Stabilization/ Landfill Stabilization/ Landfill
Regent Paints produces bitumen paints and several coatings that use lower-end resins and solvents in the formulations. Such primers serve as an undercoat. The company has also formulated several primers for wood and metals. It has listed technical data sheets with the ministry of Kuwait with the element of alkyds and its CAS details as a part of the new formulation. These products have been tested in the market.
monomers and hydrocarbons to attain solvent-based paints. Such
paint recycling and Regent Recycling dollar
Fuel blending may be appropriate with other
savings offers much more in value and
concept of free paint against recycling, with
petrochemicals, oils or flammable items.
utility than the fuel blending properties
a vision to initiate a process of oil paint
Solvent-based paints like alkyd enamels,
a paint can provide. Also, in most cases
reuse and recycling. The patents cover a
stains, ink products, primers, paint thinners,
certain grades of paint do not help the
total program of recreating a product form
tank washing solvents, alkyd resins, epoxies,
burning process, and in fact hamper
solvent-based items at the same cost of
hardeners, etc., can be reutilized, saving costs,
the fuel blending costs.
latex recycling.
ingredients and the environment.
10
N. 53 - SEPTEMBER/OCTOBER 2018 - international PAINT&COATING magazine
SUSTAINABILITY
Sustainability of Interpon Powder Coatings Confirmed by EPD Renewal
A
environmental performance of a product
The EPD system looks at all ingredients
supplier of powder coatings to have
throughout its lifecycle, enabling customers
and process steps in the manufacturing
the quality of its products verified by
to better understand a productâ&#x20AC;&#x2122;s sustainable
of a product, and measures the impact on
an Environmental Product Declaration (EPD).
qualities and ultimately make more informed
the environment. For example, if a wax is
The international EPD reveals the
product selections.
made in Thailand and exported to Sweden
Š AkzoNobel
kzoNobel is the only major global
1
Figure 1: EPD certifications are increasingly requested in the construction industry, as architects and building owners want their projects to be recognized as environmentally-friendly.
12
N. 53 - SEPTEMBER/OCTOBER 2018 - international PAINT&COATING magazine
SUSTAINABILITY
it scores less than a wax made locally in Sweden, as a result of the CO2 generated by its transport. Similarly, if a material contains a
high amount of solvent, its impact on the ozone layer will be higher than a solvent-free product. Having first undertaken the complex process in 2015, AkzoNobel was the first global powder coatings supplier to obtain the declaration. The renewed EPD for its Interpon D range of architectural powder coatings (D1000, D2000 and D3000) lasts until 2023. The results show an improvement on the previous score and highlight various factors that are contributing to lower environmental impact, including a reduction in both waste and energy usage. “In retail markets nowadays, it’s almost unthinkable that a product would not have its origin and ingredients printed on the packaging” said powders’ Architectural Segment Manager, Jean-Paul Moonen, “yet in industrial goods it is still a new concept to ask about the origin of the ingredients. Environmental Product Declarations (EPD) are a first step on the way to change this.” Among a plethora of green and eco-labels which are not independently controlled, EPDs stand out as a trusted benchmark. The factors to be included, and how to measure them, are controlled by an international ISO standard, and so are comparable from country to country, region to region and between different suppliers. Third-party verified EPDs are the gold standard, as they prevent manufacturers from making false claims. There are several recognition schemes, with LEED being among the leading ones. Using products with an EPD gives LEED credits, and more credits lead to higher LEED ratings (from Bronze to Platinum). “EPDs are increasingly requested in the construction industry, as architects and building owners want their projects to be recognized as environmentally-friendly” continued Moonen. “Powder is an inherently sustainable product, as it does not contain VOCs, but this is another step in offering our customers sustainable coatings solutions, so I’m very proud of this EPD certification for our Interpon D series.” AkzoNobel supplies powder coatings to more than 30,000 customers worldwide, covering several market segments. The company’s products are used on buildings and landmarks around the world, including La Sagrada Família (Barcelona, Spain); the Shard (London, UK); and the Water Cube (Beijing, China). For further information: www.interpon.com
BRAND-NEW
T
© Arsonsisi
Arsonsisi’s New e-commerce Website is Online. Innovation at Hand! otally revamped in its graphics
Customers ordering Arsonsisi coatings benefit from the
and navigation
paths, Arsonsisi’s new
same advantages as
e-commerce website
when they use the
has been designed and
main e-commerce
developed to improve
sites for private
the user’s experience
purchases: cheaper
and make online
prices and reserved
order acquisition and
promotions, access
management easier.
to their customer
4 years after its launch,
accounts to check
Arsonsisi presents a
their order and
more modern and
invoice history,
functional version for
simple and fast
the e-commerce of its
order processing,
powder coatings, capable
easy access when
of enhancing the user’s
using mobile devices
shopping experience.
and safe payments.
“Arsonsisi first introduced
Arsonsisi’s
the powder online
e-commerce website
purchasing service in
is also a support tool
Italy in 2014. It was a
for customers’ daily
courageous choice,
activities, since, on
motivated by the
each product page,
subcontractors’ request for more flexibility and autonomy in order management”, states
they can immediately
1
find the information on the preparation
Figure 1: Home page of the new e-commerce of Arsonsisi.
and application of the coating and can
Cristoforo Brendas, Powder Coatings Business Manager Italy.
explains Luca Troiani, Powder Coatings
download the technical sheets of all the
The new e-commerce website has
Area Manager Italy and Project Leader
codes on the online catalogue at any
been realised by Overweb, an IT and
for Arsonsisi’s new e-commerce
time.
web services company from Milan, with
website. “Apart from the graphics
The service is currently available to
Magento, one of the best and most widely
and design, the improvements
purchase only powder coatings in Italy,
used open source CMS that offers many
affect mainly the navigation path,
but Arsonsisi is planning to extend it also
functions for the development of online
order management process and
abroad and to the sale of other industrial
purchasing platforms.
optimisation of internal search with
painting lines.
“The digital world is constantly evolving
clearer and more intuitive filters for
and it is important to keep up to date with
colour, price, finishing effect and
For further information:
the times if you want to be competitive”,
chemical nature.”
www.arsonsisisi.com
14
N. 53 - SEPTEMBER/OCTOBER 2018 - international PAINT&COATING magazine
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HIGHLIGHT OF THE MONTH
ADAPTA: Improving your “Modus VIVENDI®” David Pellicer Adapta Color SL, Peñíscola, Spain
T
adaptacolor@adaptacolor.com
he VIVENDI® collections of
the capacity of self-ignition under the
In relation to rail transport, the VIVENDI®
Adapta® comprise a wide range
effects of high temperatures, as well
collections have obtained the classifications
of colours and finishes which
as its subsequent behaviour regarding
R1HL3 and R7HL3 according to the European
combustion or flame.
standard UNI-EN 45545-2:2013+A1:2016
are at the forefront of powder coatings
• Smoke emission and opacity:
for architectural purposes. Developed
“Railway applications. Fire protection on
with new innovative materials and
assessment of the amount and size of
railway vehicles.” Its purpose is to reduce the
manufactured with state-of-the-
solid particles in suspension generated
risk of generating a fire, control its spread and
by the combustion of materials.
its extinguishing, as well as minimising the
art technologies, they imbue a high
• Falling droplets or particles: estimate of
performance to products that makes
damage that products generated during the
them ideal for use in the most demanding
the amount of inflamed droplets that can
fire (heat, smoke and toxic gases) cause on
applications and situations.
contribute to the spread of the fire.
passengers and crewmembers.
Its high light reflective capabilities and
The classification of VIVENDI products is
In its pursuit to increase maritime safety
the impressive chromatic effects make
as follows: A2, very limited contribution to
and prevent pollution, the European
these powder coatings an excellent tool
fire; s1, low smoke production and d0, no
Union requires that equipment installed
in the design of emblematic projects that
inflamed drops/particles are produced.
on board comply with certain safety
®
standards in terms of design, construction
require differing finishes together with
© Adapta
high quality standards. Its functional characteristics along with the different approvals from
and performance. Hence, the International Maritime Organization (IMO) and
accredited laboratories allow the
international and European
VIVENDI® collections to transcend
standards organisations have
just the architectural scope; enabling
developed detailed performance
use in other sectors such as maritime
and testing standards for some
and rail transport. In addition, it
types of marine equipment
contributes substantially to greater
included in European Directive
safety in transport, comfort and
2014/60/EU of July 23, 2014. For
sustainability, in short, improving our
compliance with this directive,
“modus VIVENDI®”.
VIVENDI® products have been
European Directive 89/106/CEE of
tested in accordance with IMO
December 21, 1988 for construction
Resolution MSC.307 (88)-(PEF
products establishes the regulatory
Code 2010) and comply with
framework for European standard
the requirements set out in
UNI-EN 13501-1: 07 + A1:2010 rating
section MED/3.18b of Annex 1
construction products and building
Part 5 of executive regulation
elements in accordance with their behaviour against fire (EUROCLASS). The products are rated in relation to three indicators: • Contribution to fire: defined as
16
EU 2018/773 dated May 15, 1
Figure 1: Its functional characteristics allow the VIVENDI® collections to transcend just the architectural scope, enabling use in other sectors such as maritime and rail transport.
N. 53 - SEPTEMBER/OCTOBER 2018 - international PAINT&COATING magazine
2018 where design, construction and performance requirements and test standards for marine equipment are developed.
HIGHLIGHT OF THE MONTH
exposed to an extremely high number of substances in very low concentrations, mainly due to the high proliferation of
Figure 3: When it comes to maritime safety and pollution prevention, VIVENDI® products are compliant with European Directive 2014/60/ EU of July 23, 2014.
© komi$ar © Adobe Stock
In interior spaces, we can find ourselves
new materials in recent times. This wide group of substances, together with specific temperature and moisture conditions, usually make it difficult to predict whether they will be perceived as hazardous or rarefied, that is, of low quality. Adapta has proceeded to test the products of its VIVENDI® collections for architectural use according to
3 1
ISO 16000-9:2006 for the related to the environmental
Adapta Bonding System® technology
of volatile organic compounds
behaviour of the product based
that enables and ensures a
from construction products and
on its Life Cycle Analysis (LCA).
homogeneous optical effect, essential
furniture. According to the results,
The information is structured in
for use in emblematic projects or those
the company has received the A+
different impact categories (global
that require high quality standards.
distinction (very low emissions) for
warming, depletion of the ozone layer,
ADAPTA® can develop customized
the wall, ceiling, window and door
acidification, etc.) along with other
colours upon request.
decoration.
additional information such
The VIVENDI® collections have the
as produced emissions,
Environmental Product Declaration
generated waste, etc.
(EPD). The EPD collects in a
All the colours of the
transparent way, and verified by an
VIVENDI® collections
independent third party, information
incorporate the new
© Brian Kinney © Fotolia
determination of the emission
2 1
Figure 2: In relation to rail transport, the VIVENDI® collections have obtained the classifications R1HL3 and R7HL3 according to the European standard UNE-EN 45545-2:2013+A1:2016.
BRAND-NEW
Touch the Colour With spectro2guide – Next Generation Colour Measurement by BYK-Gardner © BYK-Gardner
B
YK-Gardner - worldwide partner of the automotive, paint and plastic industries for quality
control of colour, appearance and physical properties - is introducing the new spectro2guide, the revolution in colour measurement. Like its predecessor, the new spectro2guide combines colour and gloss measurement in one instrument. Completely new, is the measurement of fluorescence to predict colour stability. Like a fluorimeter the fluorescent light can be detected using monochromatic illumination and for the first time ever an ΔEzero can be calculated to predict how the colour will change when fluorescence has degraded. This combination of a spectrophotometer with a fluorimeter opens up completely new perspectives to not only control colour harmony, but also to analyse the colour stability with measurement of fluorescence.
1
Figure 1: The new spectro2guide by BYK-Gardner combines colour and gloss measurement in one instrument.
Beside the combination of innovative measurement methods, the
operation and handling. Because of
calibration function. Thereby, the white
spectro2guide uses innovative,
its balanced and upfront design, the
calibration standard is always protected
high performance LED technology as
3.5” colour touchscreen is always in
and a reliable calibration is guaranteed.
light sources. Due to the outstanding
the right position and easy-to-read.
In addition, data transfer has never
performance of these LEDs, the
A perfect premise for the icon-based
been easier or more flexible. The
short-term, long-term and temperature
menu, which allows an intuitive smart
spectro2guide offers three possibilities:
stability as well as a homogeneous
phone like operation and the integrated
Via docking station or directly connected
illumination spot are unsurpassed in
camera, that shows a live preview
with USB cable or wireless with a Wi-Fi
the industry. As a result, a superior
of the measurement area to ensure
function.
accuracy and excellent inter-instrument
precise positioning and to prevent false
Raise your expectations and get ready
agreement allow the use of digital
readings on imperfections or scratches.
for the future!
standards.
As the first spectrophotometer on
This new high technology is
the market, the spectro2guide offers
For further information:
complimented by its easy-to-use
auto diagnosis and an automatic
www.byk.com/instruments
18
N. 53 - SEPTEMBER/OCTOBER 2018 - international PAINT&COATING magazine
BRAND-NEW
© Solintellysys
A New Futuristic Headquarters for the Portuguese Plant Designer Solintellysys
1
Figure 1: The project of the new headquarters of Solintellysys, in the Parque Empresarial Do Casarão of Borralha.
P
ortugal 2020 is the partnership agreement
an indoor garden, a swimming pool, and a gym for
undertaken between Portugal and the European
employees.
Commission, which brings together the five
“We work constantly under pressure, because the
Structural and Investment European Funds (ERDF,
surface treatment market is demanding and it requires
Cohesion Fund, ESF, EAFRD, and EMFF) setting the
very tight delivery times. Our target market is also
programming principles that enshrine the economic,
vast, since we supply plants and machines throughout
social, and territorial development policy to be
Europe, Central and South America, and Africa: that
advanced in Portugal between 2014 and 2020. These
is why the physical and psychological well-being of
programming principles are aligned with the Smart,
Solintellysys’ team is crucial to our success,” says João
Sustainable and Inclusive Growth goals of the Europe
Figueiredo, the founder, owner, and general manager of
2020 Strategy. Under this program, Portugal is set to
the company. “Precisely the know-how and harmony of
receive 25 billion Euro until 2020 to stimulate growth
our team have enabled our company to develop to such
and job creation.1
an extent in just ten years, and my goal is to protect it
The impressive investment recently made by
and offer it the best.”
Solintellysys, a plant engineering company (Águeda
By 2020, Solintellysys intends to increase not only its
de Cima, Portugal) established in 2008 for the design
turnover but also the number of its employees, as well
and manufacture of highly efficient and advanced
as becoming among the ten leading European plant
technological surface treatment solutions, falls within the
designers. “The new headquarters will also include a
scope of Portugal 2020. Thanks to an investment of 11
large area dedicated to the industrial training of recent
million Euros, financed for about a third by the European
graduates in scientific and technical subjects,” states
Community, Solintellysys’ brand new headquarters
Figueiredo. “We have created a cluster with Bosch,
(Fig. 1) located in the Parque Empresarial Do Casarão
Siemens, and the Universities of Lisbon, Coimbra, and
in Borralha, a few kilometres from Águeda, will cover
Porto to create training events helping young people
an area of around 15,000 m2. It will feature a large
understand the industrial world and face the world of
production area equipped with the latest production
work with greater preparation.”
technologies (laser cutting, bending, welding, etc.),
Solintellysys’ new premises will be inaugurated by the
a large technical and design office, meeting rooms,
end of 2018 to celebrate the company’s ten-year history.
training areas for employees and customers, and even For further information: 1
https://www.portugal2020.pt/Portal2020/o-que-e-o-portugal2020
www.solintellysys.com
BRAND-NEW
Š AGTOS
Shot Blasting Power Also For Large Steel Beams
1
Figure 1: The AGTOS roller conveyor shot blast plant RT 15 for processing steel profiles and metal sheets.
T
he quality of surfaces is
the exhibition booth at the Euroblech
becoming more and more
2018.
Functioning of the roller conveyor shot blast plant
important. Users are paying
The passage width is 1.500 mm. Thus, the
The work pieces will be supplied to the
more attention to economical
shot blast plant can treat steel beams up
machine via a roller conveyor. They pass
concepts and the aspect of time
to a width of 1.100 mm and a height of 420
a switching threshold installed in front of
when it comes to shot blasting.
mm. Rust and scale will be removed reliably.
the inlet sluice. This threshold releases
Large steel beams are used more
Furthermore, this machine type is also
the automatic supply of abrasive to the
and more often. Depending on the
suitable for the treatment of metal sheets.
running high performance turbines. By
condition of the beams, the shot
The max. sheet width is 1.500 mm.
means of this measure, it is made sure
blasting process is very complex. In
In case smaller parts shall be processed,
that the blasting only takes place when
order to solve this task, AGTOS is
appropriate wire baskets are available.
there are work pieces in the blasting
offering a powerful roller conveyor
The machine shown at the exhibition is
area. This limits the wear and tear of the
shot blast plant (Fig. 1). This
part of a product series which is offered in
machine and saves energy and abrasive
machine type will be exhibited at
different sizes.
media.
20
N. 53 - SEPTEMBER/OCTOBER 2018 - international PAINT&COATING magazine
Una nuova generazione di prodotti bucciati! La nuova formulazione offre prodotti in grado di coprire con facilità i difetti del substrato metallico, grazie a una buccia più uniforme, un utilizzo industriale più versatile e un maggior risparmio energetico. La temperatura di reticolazione di 150° C ha permesso di diminuire il tempo di cottura dei pezzi e migliorato la produttività dei nostri clienti. • Bucciatura uniforme in tutte le tinte • Migliore copertura dei difetti, spigoli e punti di taglio • Versatilità d’impiego (diverse geometrie e dimensioni) • Temperatura di reticolazione rapida (150° C) • 50 nuovi colori • Ridotto impatto ambientale
marketing.italia@akzonobel.com www.interpon.it
I prodotti Interpon di AkzoNobel sono amici dell’ambiente
Le finiture a polvere sono prodotti chimici vernicianti privi di solventi, di VOC (Composti Organici Volatili) e di metalli pesanti tossici, come cromo o piombo. Questi sono da considerarsi come requisiti standard per tutti i prodotti Interpon di AkzoNobel che sono formulati per rispettare l’ambiente e la salute dei loro utilizzatori. Inoltre sono riciclabili, poiché l’over-spray può essere recuperato fino al 99%, e la maggior parte dei prodotti Interpon di AkzoNobel richiede un minor impiego energetico in fase di applicazione rispetto ad altri sistemi vernicianti.
marketing.italia@akzonobel.com www.interpon.it
BRAND-NEW
The inlet sluice is sealed with easily replaceable and wearresistant rubber curtains in the upper part. They avoid the escape of abrasive and dust. The lower part is sealed by means of adjustable rubber lamellas which adapt to the contour of the respective work pieces. While passing the blasting chamber itself, the work pieces are blasted evenly and accurately. Four AGTOS high performance turbines with up to 22 kW have been provided for this task. They are distinguished by their high performance and long life times of the wear parts. In case of maintenance, they can be changed relatively quickly and easily. After having passed the blasting area, the work pieces reach the combined brush and blower unit. Here, the abrasive cleaned from the surfaces of the work pieces is returned to the abrasive circuit. In order to do this, the abrasive is collected in the hopper below the machine, forwarded by means of a screw conveyor and transported to the upper part of the machine by means of a bucket elevator. There, bigger particles are filtered out and small grain and dust are removed from the abrasive. The purified abrasive is led from the abrasive silo back to the high performance turbines by means of the abrasive control unit. The dust separation of the shot blast plant is realised by means of a cartridge filter. The filter has a fan which creates a negative pressure. A deflecting separator and filter cartridges with an appropriate medium clean the aspirated air. It is clean when it returns back into the factory hall. An additional filter provides double security.
Further topics at AGTOS exhibition booth AGTOS exhibition team will be happy to inform you about the different versions of the high performance turbines - the most important component of a shot blast machine - as well as their maintenance options. They reach a long service life also when using aggressive abrasive media. Examples of already produced machines will be shown and the best solutions for processing work pieces by means of shot blasting will be demonstrated.
The AGTOS booth at the EUROBLECH 2018 AGTOS will be at EUROBLECH exhibition, 23 - 26 October 2018, Hannover, hall 13, booth B141 For further information: www.agtos.de
BRAND-NEW
Encore nLighten LED Kit from Nordson – for continuous Quality Control during the Coating Process
T
he new Encore nLighten LED Kit
every operator the power to both spray and
projects a powerful LED beam from
inspect, reducing the need for post-coating
the manual spray gun onto the surface
quality checks. • Improve safety
being coated. Even in darkened working
Using un-rated potential ignition sources
environments, it facilitates uniform coating © Nordson
and enables the operator to reliably monitor surface quality already during application (Fig. 1). With 42% of customers surveyed claiming light paint coverage as their biggest cause for rejects and rework (Fig. 2). Especially under poor visibility conditions, even experienced coating
in airborne dust cloud environments is a Figure 1: Bringing light into the darkness – the Encore nLighten LED kit was developed for high quality assurance.
1
dangerous combination. Rated for use in all powder coating environments, you can trust the Encore nLighten LED kit to provide safe, reliable illumination in hazardous areas.
Easy to retrofit on all Encore manual spray guns
operators often fail to coat their workpieces uniformly. This usually results in rework and
simple LED unit effectively highlights deep
The nLighten LED kit mounts on the Nordson
raises reject rates.
recesses and cavities. Any imperfections
Encore manual spray gun in just five simple
The new Encore nLighten LED mounts easily
or missed areas are quickly identified and
steps.
to any Encore manual spray gun. It turns on
addressed by the operator on the fly.
Nordson’s Encore spray gun range is already
automatically with the start of the spraying
• Reduced material waste
the best performing and most respected in
operation and remains on for an additional
In dark or dusty working environments,
the powder coating world, with many operator
15 seconds after spraying stops, becoming
many operators ‘spray and pray’ due to poor
benefits. With the addition of the Encore
brighter for even more precise quality control
visibility. Optimum light levels enable precisely
nLighten LED Kit, users can add powerful, safe,
(Fig. 3).
targeted powder application to reduce waste
lightweight, and controllable illumination to its
and save on material costs.
impressive list of capabilities.
Using the Encoe nLighten LED Kit, powder
• Increased efficiency
coaters benefit from: • Reduced or eliminated rejects or rework
For further information:
application and inspection tool, that gives
www.nordsoncoating.com/nlighten
Figure 2: Encore nLighten LED kit – light off. A typical working environment without lighting.
22
© Nordson
Encore nLighten LED is an all-in-one
© Nordson
The powerful light beam projected from the
2 1
N. 53 - SEPTEMBER/OCTOBER 2018 - international PAINT&COATING magazine
3 1
Figure 3: Focused light beam for easy inspection during and after spraying.
BRAND-NEW
BASF Invests in a State-Of-The-Art Surface Treatment Site for its Chemetall Brand in Pinghu, China
T
he Surface Treatment global
solutions customers have come to expect
our customer support and supply chain to
business unit of the Coatings
from Chemetall. The site is ideally located
China. It will contribute to the expansion
division of BASF, operating under
at the Dushan Port Economic Development
of a broad global portfolio across multiple
the Chemetall brand, invests in a state-
Zone of Pinghu, which provides excellent
segments, with quality and environmentally-
of-the-art surface treatment site in the
infrastructure to this project.
friendly products and system solutions
Dushan Port Economic Development Zone
Asia Pacific is the largest surface treatment
for diverse market segments. These
of Pinghu, Zhejiang province, China.
market. “For Chemetall, a strong local
include automotive, auto components, coil,
The site – which is planned to be
presence in China is key to servicing our
general industry, cold forming, aerospace,
completed by 2021 – will house
customers and delivering on the ‘expect
aluminium finishing and glass,” adds Mike
production, warehousing, a state-of-the-art
more’ brand commitment to deliver the best
Watson, Vice President, Surface Treatment
laboratory and administrative offices in
customized solutions in the surface treatment
Asia Pacific.
an ideal environment for manufacturing
industry,” states Martin Jung, Senior Vice
BASF’s Coatings division has frequently
development. This investment will
President, Surface Treatment.
invested in China, especially in Shanghai, to
strengthen Chemetall’s position in China to
“This investment will create Chemetall’s most
further enhance its proximity to customers
deliver the high level of service and quality
comprehensive site globally and enhance
in the fastest growing region for automotive coatings solutions. Examples
© BASF
are the first regional Automotive Application Centre in Asia Pacific at the BASF Innovation Campus Shanghai as well as a world-scale production facility which supports the growing Chinese automotive industry. The latest investment positions BASF as an even more complete solution provider for coatings by adding the surface treatment business operating under the Chemetall brand. “We are looking forward to serving our customers in China with outstanding products and services from a state-of-the-art surface treatment site in the Dushan Port Economic Development Zone of Pinghu,” says Jin Hui, General
1
Manager Chemetall China.
Figure 1: Martin Jung (left), Senior Vice President Surface Treatment, BASF and Fu Guoquan, Party Secretary and Director of Dushan Port Economic Development Zone, sign the agreement to invest in a state-of-the-art surface treatment site in Pinghu, Zhejiang province, China.
For further information: www.basf.com
international PAINT&COATING magazine - SEPTEMBER/OCTOBER 2018 - N. 53
23
INNOVATIONS: PRESENT&FUTURE
The New Industrial Districts Adriano Antonelli IBIX S.r.l - DIVISIONE TECNO SUPPLY, Santa Maria in Fabriago (RA), Italy
L
adriano.antonelli@tecnosupply.com
ately, there has been much debate
District of Belluno, and the Pharmaceutical
Just think that, in order to maintain its sales
about international competition:
District of the Lazio region. But how has
levels, the goods produced by an Italian
how can the market affect the
the District concept changed in the last few
company have to travel an average of
domestic production process? How
years of economic challenges? Production
400 km more than just ten years ago. The
can we face the new challenges that
Districts have certainly transformed. The
answer, therefore, are no longer districts,
await us? Economic recovery seemed
skills needed to sell goods globally are
but rather expansion. The supply chain that
sustained, but it is currently weakening
increasingly complex and challenging. It
brings products beyond the borders can
also due to political choices that hinder
may even happen that the ones required
now be distributed throughout the national
the free movement of goods. So, how
are not available in oneâ&#x20AC;&#x2122;s own jealously
territory, in various specialised industrial
can we face the new international
guarded stronghold of knowledge, which
areas. This system creates a network of
economic policies and unilateral choices,
until a few decades ago was one of the
companies that are able to maintain high
such as those concerning the heavy
most precious assets for a small business.
quality standards and low prices. Š HangOn
duties imposed by the USA on Europe? Whereas Germany has a fabric of
The coating of mechanical parts and components is certainly an important
stable companies in terms of
part of the Italian
both finance and production,
productive fabric, as well
Italy has always been the
as an important process
country of small businesses.
in terms of both product
Of course, we are not
protection and packaging.
referring to micro or nano
Coating is now a key
companies, which nowadays
factor also for highly
tend to have more and
technological products.
more problems because
For any firm needing to
of their difficulty to adapt
coat in a short time and
to the now unavoidable
on workpieces subject
insourcing trend. Here, we
to unilateral changes in
are talking about the small
terms of shape and size,
but reliable companies that
being always prepared
have managed to cope with
can be complicated and
the challenges of the global
expensive. Increasing
market despite not having
production density should
the structure and size of
be the primary goal.
many of their European
The pictures presented
competitors.
can help understand
Traditionally, in Italy, the
how a few changes in
creation of Production
the hanging method
Districts was the answer. We all know, for example, the Ceramic District of Modena, the Eyewear
24
1
Figure 1: Optimising the hanging phase can bring huge benefits in terms of time and cost savings.
N. 53 - SEPTEMBER/OCTOBER 2018 - international PAINT&COATING magazine
used can ensure great benefits in terms of time and cost savings (Fig. 1). Switching from individual
© HangOn
INNOVATIONS: PRESENT&FUTURE
hooks to structured and flexible frames (in order to avoid an exponential increase in the number of frames required) can immediately bring significant improvements. The devices described below, such as HQL, HQC, and HQS, have costs comparable to those of individual hooks, but ensure an advantage in terms of hanging speed, production density, and unloading operations. The following innovations by HangOn can help make the right decision about the best coating method. A recently presented innovative solution are the ready-made hanging bars HQC, an evolution of HQL bars. The harmonic steel hooks are already inserted on the bar
Catalytic panel for fixing oven Components for pre treatment tunnel Transport systems, Water treatment Electric Motors, Electrical components Filtering elements for Industrial Filters Gearboxes for various applications Normal and special Fans for high temperature Oven Burners, Pumps Spare parts for conveyor
© HangOn
and ready to use. The bar is then located on
Spare Parts for Industrial Plants
2 1
Figure 2: The HQC hanging system, featuring a bar holder with a silicone protection.
The coating of mechanical parts and components is certainly an important part of the Italian productive fabric, as well as an important process in terms of both product protection and packaging. Coating is now a key factor also for highly technological products. For any firm needing to coat in a short time and on workpieces subject to unilateral changes in terms of shape and size, being always prepared can be complicated and expensive. Increasing production density should be the primary goal.”
ANTARES S.r.l. 3 1
Figure 3: The HQS hanging system (left) compared with an individual hanging solution.
Via F.lli Cervi 12/B - 37036 San Martino Buon Albergo (Vr) ITALY T. +39 045 8780567 F. +39 045 994606 email: info@anteresitaly.net WWW.ANTERESITALY.NET
© HangOn
HQL, HQC and HQS have costs comparable to those of individual hooks, but ensure an advantage in terms of hanging speed, production density, and unloading operations.” a BH R58 bar holder, welded on a 10 mm hook (Fig. 2). The silicone protection ensures free conductivity. The bar has been designed to be produced entirely automatically and it can be used for a large quantity of parts, thus proving extremely
HQS features metal sheets enabling to hang individual parts, up to profiles. The 4 or 5 mm central hook ensures a total frame capacity up to 100 kg. HQS has been recently launched on the market with various types of hooks, enabling each customer to create the most suitable configuration for its specific needs.”
economic. Its cost is around 2 Euros per bar. Moreover, it is possible to insert a series of hooks in the
The HQL bar, finally, has been in the
bar holder to hang medium-sized
catalogue for some years now (Fig. 4).
workpieces, since the central hook
It can be integrated on the universal
has a 10 mm diameter.
frames. The 1 mm hook leaves only a
Another tree frame manufactured
slight mark on the coated part. Also
automatically and therefore costing
for this bar range, Ibix has launched
less than 2 Euros/bar is called HQS
a triple V-shaped bar preventing the
(Fig. 3). It features metal sheets
workpieces to unhook during pre-
enabling to hang individual parts, up
cleaning.
to profiles. The 4 or 5 mm central hook ensures a total frame capacity up to 100 kg. HQS has been recently launched on the market with various
4 1
Figure 4: The HQL hanging system.
types of hooks, enabling each the most suitable configuration for
simple workpieces need to be hung. Sometimes, it is necessary to hang and mask the parts at the same time. And the only hanging point available can be, for example, a pivot.
© HangOn
customer to create
As we all know, however, not only
For these cases, HangOn has created
its specific needs.
the GHA accessory,
The tree can be
compatible with
up to 2400 mm in
the HCL BHL bar
length, while the
that can house it
sheets are 1.0 mm
internally (Fig. 5).
thick and 18 mm
This enables to mask
high. It is possible
and hang parts
to create different
with one simple
configurations:
operation. The cap
sheets on one side
features grooves
only (i.e. sheared), zigzag-shaped, or bent from 0 to 180°.
26
5 1
Figure 5: The special GHA Style, masking and hanging system.
N. 53 - SEPTEMBER/OCTOBER 2018 - international PAINT&COATING magazine
that do not hinder the conductivity of metal.
IGP-DURA®face 5807 Surface-robust powder coating system for facade and metal construction
Surface-robust powder coating system for facade and metal construction. We lend all shades of powder coatings more scratch and abrasion-resistance, making transportation and handling more secure and protecting the value of your output. – More abrasion resistant – More scratch resistant – Easier to clean – Optimized flow
C
RO
BU
ES
Learn more about IGP-DURA®face 5807 at: www.igp-powder.com
ST SU RF
A
IGP Pulvertechnik AG 9500 Wil, Switzerland Phone +41 71 9298111 www.igp-powder.com info@igp-powder.com A member of the DOLD GROUP
© Emil Frei
Opening photo: Mitras Composites GmbH manufactures housings using a sheet moulding compound (SMC), i.e. plate-shaped, dough-like moulding materials made from thermosetting reaction resins and glass fibres, to produce the individual components.
FOCUS ON TECHNOLOGY
Eliminating Process Steps, Increasing Quality. Manufacturer of SMC Housings Relies on FreiLacke’s PIMC Process John-David Mäbert, Mitras Composites GmbH Peter Lobendank, Emil Frei GmbH & Co. KG
T
he grey junction and distribution boxes
Those who take a closer look can detect the
Mitras Composites GmbH from Radeburg,
that can be found on pavements,
weathering of the top coats of older models,
near Dresden, manufactures these types of
in front yards or the edges of
as well as the corrosion of the resin layer on
housings. The company uses a sheet moulding
properties largely go unnoticed. Only
the surface, which allows the fibres of the
compound (SMC), i.e. plate-shaped, dough-like
children sometimes use them when they
housing to become visible. The result is that
moulding materials made from thermosetting
play hide-and-seek or as pommel horses.
not only their optics suffer but, to a small
reaction resins and glass fibres, to produce the
Their housings are exposed to the elements
extent, also their mechanical properties and
individual components (ref. Opening photo).
every single day – sometimes for decades.
fire-resistance.
The flat fibres guarantee very good mechanical
28
N. 53 - SEPTEMBER/OCTOBER 2018 - international PAINT&COATING magazine
FOCUS ON TECHNOLOGY
properties. â&#x20AC;&#x153;The SMC is moulded in
Titze explained. â&#x20AC;&#x153;Frankly, the effort was
important for outdoor uses (Fig. 1). The
150°C steel pressing tools and, thanks
enormous and very expensiveâ&#x20AC;?.
team built a manual sampling plant in-
to the pressure and high temperature,
With regard to the increased surface quality,
house. The initial manual coating attempts
is distributed evenly within them. The
â&#x20AC;&#x153;the customer particularly wanted maximum
were very promising, Titze said. However,
polymerisation being used ensures a
weather and scratch resistance, but also a
the process engineers realised right away
crosslinking of the material and cures it
high anti-graffiti protection as well as a very
that only an automated solution could be
when it has reached its final formâ&#x20AC;?, explains
high resistance against aggressive cleaning
used for series production. Later in the
Sebastian Titze, a Research & Development
agents and corrosive solutions that are used
same year, Mitras built one â&#x20AC;&#x201C; once again
project manager at Mitras.
for removing any smearingâ&#x20AC;?, the project
in-house. It included a robot, an extraction
manager explained.
system and a powder plant.
A customer for whom Mitras also produces
PIMC testing
cable distribution cabinets demanded an
That is why the Powder In-Mould Coating
Fine tuning the powder coating
increased surface quality. Until recently,
(PIMC) process was tested at Mitras in early
In FreiLacke, Mitras found a reliable
the production of the components had
2015. In a single-step process, electrostatically
coating supplier for the process: â&#x20AC;&#x153;we
been a very logistically complex process
charged powder coatings that are based on
received a lot of support during the
for the Radeburg-based company. The
UP resins are applied onto the hot mould.
application process. When the process
components were wet-coated at an
During the hot-pressing process the coating
was introduced, FreiLacke employees
external job coater but then brought back
creates a chemical compound with the
were literally available to us around
to Radeburg for shipping. â&#x20AC;&#x153;Overall, nine
material. This compound is scratch-resistant,
the clock. Time and time again, short-
separate process steps were required until
and also very resistant against chemicals,
term adjustments to the powder were
the component was ready to be shippedâ&#x20AC;?,
graffiti and UV radiation, which is particularly
possibleâ&#x20AC;?, the engineer said.
Complex logistics
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© Emil Frei
solvents, hazardous substances or carcinogenic raw materials. “PIMC is fire-retardant in accordance with EN45545, HL3, R1 and, thanks to its good properties, can be used for many applications. Its high weather resistance makes it perfect for use outdoors. In the facade standard area, our PIMC coatings achieved a residual gloss of more than 50% in tests of 300 hours according to QUV-B”, explained Peter Lobendank. Thanks to its barrier properties, PIMC is also suitable as a primer for the automotive industry.
One process, many factors Sebastian Titze called the transition to PIMC
1
a “core learning process”. It was very complex Figure 1: The Powder In-Mould Coating (PIMC) is a single-step process, where electrostatically charged powder coatings that are based on UP resins are applied onto the hot mould. During the hot-pressing process the coating creates a very resistant chemical compound with the material.
and demanding, because some new tools had to be built and brought up to standard for series production. In addition, the process involved many factors – the powder coating
In its laboratory in Döggingen, in the Black
Extreme weather resistance
Forest, FreiLacke has a state-of-the-art
PIMC offers a wide range of colours since
and the moulds. “All of these parameters are
laboratory press with cooling unit that
nearly all RAL colours can be used. However,
subject to variations – each of which affect the
meets all of the requirements to create
the cable distribution cabinets receive a plain
process”, Titze said. Thanks to continuously
samples for viewing or inspections. “We
grey coat at Mitras. In rare cases, orders call
pursued experimental designs, an optimisation
used it to perform experiments on the
for green or orange – the latter particularly
as well as an improvement of the development
original substrate with different time,
for municipalities. In addition, PIMC can
process could be achieved on all levels.
temperature and pressure settings”, Peter
also be used for special applications, such
Lobendank, System Coordinator Industries
as high-gloss, multiple colours and metallic
Elimination of process steps
at FreiLacke, explained. In addition, many
granite effects. The material is free from
Mitras has now been using the process for
were conducted in the laboratory until the correct
six months. However, not
© Emil Frei
surface and cause analyses
as well as the SMC material, the temperature
only the surface quality has benefited from the
parameters were found.
transition to PIMC in
The FreiLacke team also
Radeburg. The handling
assisted the company
of the components
from Saxony with the
has also become more
implementation of the
efficient. The transition
process, the improvement
permitted the elimination
of the application efficiency,
of several process steps
the plant design and much
– the integration of the
more. “We were also very
external service provider
satisfied with regard to the
and the complex logistics
development work”, said
are no longer needed
Sebastian Titze. Therefore,
(Fig. 2). The components
it is no surprise that the two companies have launched the next joint project in the meantime.
30
2 1
Figure 2: The transition to PIMC permitted the elimination of several process steps, simplifying logistics.
N. 53 - SEPTEMBER/OCTOBER 2018 - international PAINT&COATING magazine
remain in-house until they are completed and can then be shipped immediately.
P O W E R F U L
I N
V E R T I C A L
I
M
I
T L E S S
I N
H O R I Z O N T A L
Powder coating lines since 1976. V E R O N A
I T A LY
B A R C E L O N A S A N T A
S P A I N
C A T A R I N A
F L O R I D A
U S A
B R A Z I L
© Interseals
32
N. 53 - SEPTEMBER/OCTOBER 2018 - international PAINT&COATING magazine
FOCUS ON TECHNOLOGY
The Rotamat at Interseals: The Spring Board For Opening New Markets Dieter Adamkiewicz, Interseals Srl Frank Siegel, Walther Trowal GmbH
W
hen it comes to placing an
demanding anti-friction coatings to facilitate
technical aspects but was also influenced
anti-friction coating on small
the separation of the parts. Of course,
by the “German business outlook” of the
parts, Interseals early on was
reducing the coefficient of friction of the
Italian-German management team: In all its
betting on the Rotamat coater from Walther
coatings along with demands for higher
capital investments Interseals has always
Trowal. The first machine, installed in 2009,
cleanliness in automatic assembly lines were
been guided by its desire to buy from the
became the foundation for a brand-new
also key factors for changing the coating
renowned market leaders to take advantage
business division. In the meantime, the
material.
of their decades old know-how and, in the © Interseals
Italian company is operating seven Rotamat coaters at two locations and has become
end, achieve optimum process stability with, at the same time, low “costs of
the Trowal customer with the
ownership”.
largest number of Rotamat
Walther Trowal established
coaters used within a single
its leading role as a reliable
group of companies.
supplier in the field of
At its Capriolo plant in
mass finishing – deburring/
Lombardy (in the province of
radiusing grinding and
Brescia) Interseals produces
polishing of all kinds of work
O-rings, and special moulded
pieces. This reputation and
parts (ref. Opening photo).
the brand name associated
In addition to coating its own
with it, along with the
work pieces the company
excellent performance of
also provides coating services to other manufacturers of similar products. About 65% of the Interseals production volume is sold to automobile
the Rotamat, were decisive
1
factors in the investment
Figure 1: In its Capriolo plant, Interseals operates four Rotamat coaters; at Pol-Technology another three.
decision. No doubt, it also helped that the excellent name of Walther Trowal in the industry and with
manufacturers and their suppliers.
Since 2009 the trend towards the use of anti-
auditors can be very helpful in marketing
Interseals has established an excellent
friction coatings has dramatically accelerated.
and with audits.
reputation for coating with multi-component
Interseals recognized this significant shift in
lacquers and continues to be market leader
customer requirements early on and reacted
in this field.
by planning to expand its “coating” operations
Seven Rotamat coaters within the same group of companies
Before switching to these multi-component
and investing in new equipment. In its search
Positive processing trials with parts from
coating materials, the company, founded
for qualified suppliers the company also
the Capriolo plant in the test lab at Walther
in 1995, was mainly using lubricants like
contacted Walther Trowal.
Trowal in Haan (Germany) convinced
Molykote , silicone oil, talcum and graphite.
The decision for the Walther Trowal
Interseals to purchase its first R 90 Rotamat
However, the customers were increasingly
equipment was not only based on purely
coater in 2009.
®
Opening photo: Among other products, Interseals produces and coats O-rings made from different elastomers.
international PAINT&COATING magazine - SEPTEMBER/OCTOBER 2018 - N. 53
33
© Interseals
Conclusion The decision to expand the company’s product and service portfolio with the Rotamat coater has proven to be a full success. While initially only intended for the in-house production, Interseals very quickly received enquiries from other companies. That is how the Rotamat coaters were forming the foundation for a new, continuously growing business field. The machines produce excellent surface finishes, are very sturdy and require a surprisingly low degree of maintenance. The first machine, delivered nearly 10 years ago, still runs at full capacity. A big help was
2 1
that the process parameters are
Figure 2: The automatic spray gun evenly applies the coating material onto the gently tumbling mass-produced small parts.
stored in the PC in Italian and Polish language.
New parts require extensive testing
The fact that Interseals had no prior
three R 90 Rotamat systems (usable volume
to determine the optimum process
knowledge whatsoever about coating
up to 50 L) and one R 90 C (usable volume
parameters like air volume &
of mass-produced small parts was no
up to 75 L). The drum diameter in these
temperature as well as the rotary speed
doubt a challenge. The process was
machines amounts to 800 mm providing an
and inclination angle of the drum. After
completely new to the employees,
average capacity of about 50 kg and 50 L.
approval by the customer the process
and no specialists were to be found
At the subsidiary plant Pol-Technology, near
parameters are stored and locked in the
in the Lombardy region.
Katowice (Poland), established in 2016,
integrated recipe administration.
initially two Rotamat coaters were installed
With any new purchase orders for
with a third one going into operation in
the same articles the parameters
2017 (Fig. 1). All machines are in line with
are called up from the internal
the standard Walther Trowal technical
recipe administration. The
specifications. No technical modifications
process itself is automatically
were required which greatly facilitates spare
controlled and monitored by
parts supply and maintenance.
an industrial PC with touch
Basis for the successful coating with multi-
panel, which is integrated into
component lacquers is the perfectly timed
the control panel (Fig. 3). Even
coordination of the pre-treatment and
the spraying rate and spraying
coating operations: to achieve optimum
pattern are controlled by the
coating results the parts must be coated
program, ensuring a high
within a few hours after the pre-treatment
process stability with absolutely
step (Fig. 2). For this reason, Interseals is
repeatable coating results.
operating two in-house plasma systems.
With the integrated report
On average each Rotamat coater processes
administration module all coating
nearly 40 million parts per year with water-
processes run in the past can be
based lacquers, of which 30% are destined
easily recalled allowing review of
for the company’s own production in Italy
the process parameters of every
and 70% as service for external customers.
single batch ever run.
34
N. 53 - SEPTEMBER/OCTOBER 2018 - international PAINT&COATING magazine
© Interseals
Today Interseals in Capriolo works with
3 1
Figure 3: The entire coating process is controlled and monitored by an industrial PC with touch panel integrated into the control panel.
FOCUS ON TECHNOLOGY
That is why in the beginning the experts from Haan intensively supported Interseals. But for several years now the colleagues in Italy and Poland have been adapting the coating process to new customer work pieces. But, of course, the experts from Haan still help Interseals with special questions and customer demands. It no doubt helps that the Walther Trowal technicians and engineers have been working with Interseals
GANCI | HOOKS
know the company’s requirements inside out.
© Walther Trowal
for many years and
The future Recently a new trend has developed: The products of many Interseals customers
TELAI | RACKS
are becoming more compact, but must provide the same high performance. This means that the seals are
4 1
Figure 4: The new Rotamat R 60 coater is ideal for processing work piece batches with volumes of up to 15 L.
also becoming smaller. For example, the volume of 50,000 O-rings with an
plans to purchase a new R 60 Rotamat coater with
internal diameter of 3 mm and a cord width of
a nominal usable volume of only 15 L (Fig. 4), but
1 mm only amounts to 0.5 L!
with the performance characteristics of its “bigger
However, since a certain, minimum batch size is
siblings”. This machine is intended for smaller
always required, Rotamat coaters with smaller
batches as well as the sample processing of larger
drums are needed. For this reason, Interseals
work pieces.
The coating of mass-produced small parts in a Rotamat coater is a high temperature process, whereby the small parts are coated in a rotating, enclosed spray chamber. The process can be applied on parts made from different plastic materials like elastomers, ABS, PC, PS, etc., as well as parts made from metal and wood. The Rotamat systems allow processing of water based as well as solvent based coating materials. The parts do no longer have to be placed individually on special racks but are simply loaded in bulk into the rotary drum of the Rotamat system. One or – even better - two automatic spray guns are evenly applying the coating material, while the small parts are gently tumbling over each other.
To induce the required process temperature into the parts, warm air is injected into the coating drum with an absolute minimum of turbulence. The work piece temperature is directly measured with an IR sensor. Depending on the work piece temperature a PID controller regulates the temperature of the inlet air always taking into account the actual air volume. Due to its outstanding efficiency the Rotamat coaters require only a few kW’s of installed electrical power. Once the coating process is completed, the work pieces are discharged by simply tilting the drum downwards with a gear motor. A post process drying step, for example, in an oven, is no longer required. The parts coming from the drum can be immediately used for the next production step.
MASCHERATURE | MASKING
PER INFORMAZIONI E ORDINI VI INVITIAMO A CONTATTARE: PLEASE CONTACT:
Cecilia Ghizzi Gola ghizzi-gola@emptmeyer.it Fon: +39 02 947 58 58 2
www.emptmeyer.it
ON THE ROAD TO ipcm
®
n. 53
ipcm® editors in Cyprus enjoying the last days of summers with our dear guest Andreas Marcou (Muskita Alumnium Industries) and with Loris Rossi (ALIT Technologies) and his wonderful family
international PAINT&COATING magazine - SEPTEMBER/OCTOBER 2018 - N. 53
37
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FOCUS ON TECHNOLOGY Chromium-Free Pretreatment at ELVIAL. A Review of 18 Successful Years
110
INNOVATIONS: PRESENT&FUTURE Shot Blasting of Extruded Aluminium Profiles: Aesthetic Quality with Time and Cost Savings
114
FOCUS ON TECHNOLOGY Metra Color: an Italian History of Quality and Innovation in Powder Coating to Conquer the US Market
BRAND NEW FOCUS ON TECHNOLOGY All.co Group: A Wide Choice of High-Quality Finishes and Colours from a Well-Established Company
© ipcm ®
122 124
Š Muskita
Opening photo: Muskita Aluminum Industries, a Cyprus-based company that has recently celebrated 60 years of activity, has been at the forefront of the global aluminium extrusion and finishing market for years, with systems for architecture designed by itself or developed based on customer projects.
FOCUS ON TECHNOLOGY
S P E C I A L ALU MINIU M
Muskita Aluminium Industries: Quality from the Starting Point Alessia Venturi ipcmÂŽ
M
uskita, a Cyprus-based
and processes, which made it one of the
high solar radiation, high humidity and
manufacturer of aluminium profiles
few, if not the only company that has never
salinity, large amounts of dust settling on
and accessories, has a history of
had any complaint about the durability of its
structures at night, and continuous dilations
success. The history of a firm that has turned
finishes or the filiform corrosion of its profiles
and contractions of substrates due to
its technology investments into a weapon
in the last fifteen years, i.e. since it adopted a
temperature changes. This is a lethal mix for
to conquer the global market starting from
chrome-free pre-treatment process.
the durability, colour retention, and corrosion
a little corner of Europe. The history of an
The weather conditions of Cyprus are
resistance of finishes.
obsession with the quality of raw materials
among the most challenging for aluminium:
Thanks to its technological and process
40
N. 53 - SEPTEMBER/OCTOBER 2018 - international PAINT&COATING magazine
FOCUS ON TECHNOLOGY
heat and uses it to warm the diathermic
choices, Muskita has been at the forefront of the global aluminium market for years, with systems for architecture designed by itself or developed based on customer projects (ref. Opening photo). Its quality-oriented approach did not change even following the serious financial crisis that hit Cyprus in 2013, causing numerous companies to collapse. This firm’s entrepreneurial ability, passion for aluminium, and great technical expertise have enabled it to go back to producing, although below its capacity, exporting all over the world, and investing in technology. In the last two years, Muskita has invested in energy efficiency, installing an
oil that feeds a steam generator, which, in turn, heats the two fixing tanks of the anodic oxidation line. The company has also invested in production and it will soon add a fourth 20,000-ampere oxide tank to the three 16,000-ampere ones already present on the anodic oxidation line, bringing the total capacity of the plant to 68,000 amperes (Fig. 1). Finally, Muskita has invested in an accessory phase of the coating process, greatly affecting productivity, energy efficiency, and operational safety: it has installed a paint stripping system to treat its profile hanging hooks, choosing the technological evolution of the Fastrip ISP machine produced by Alit Technologies © ipcm ®
economiser that recovers the extrusion
Muskita, a Cyprus-based manufacturer of aluminium profiles and accessories, has a history of success. The history of a firm that has turned its technology investments into a weapon to conquer the global market starting from a little corner of Europe. The history of an obsession with the quality of raw materials and processes, which made it one of the few, if not the only company that has never had any complaint about the durability of its finishes or the filiform corrosion of its profiles in the last fifteen years, i.e. since it adopted a chrome-free pre-treatment process.”
1
Figure 1: Overview of the anodic oxidation line.
international PAINT&COATING magazine - SEPTEMBER/OCTOBER 2018 - N. 53
41
© ipcm ®
SP ECIAL ALUMIN IUM
(San Bonifacio,
completed the
Verona, Italy – Fig.
process with
2). The system
the addition of
will help increase
thermal cutting
the speed of its
and assembly
coating line and
machines, long
it will enable
before the issue
the company
of European
to significantly
regulations on
reduce energy
energy efficiency,”
consumption and
states Demos
process costs.
Mouskis. “The
This is crucial for
in-house extrusion
a company like
also started the
Muskita, bearing
era of aluminium
much higher costs
exports: our
for energy supply
production
than in the rest of
Sixty years of success
capacity exceeded
2 1
Europe.
domestic demand.
Figure 2: The paint stripping system to treat its profile hanging hooks, technological evolution of the Fastrip ISP machine produced by Alit Technologies, is Muskita’s latest investment.
Besides Cyprus, our target market is now northern Europe
Muskita Aluminium Industries, which recently celebrated
existing ones to local climate and needs
– especially island countries, such as Great
sixty years in the aluminium industry, is
but above all to the new material.
Britain, Ireland and so on, which have the
currently led by Demos G. Mouskis, one
Muskita implemented its first anodic
same logistic and supply difficulties as Cyprus
of founder George Mouskis’ sons. “At
oxidation plant in 1965. “In 1985, the
and where we can even out our competitors’
the beginning of the 1960s, Muskita was
company installed its first extrusion
advantages on the mainland.”
among the first industrial companies
plant and, one year later, powder coating
The firm was listed on the stock exchange in
in Europe to introduce aluminium. My
with a horizontal plant. In 1990, the firm
the past, but for some years now it has gone
aluminium for the first
back to being an entirely
© ipcm ®
late father George saw
private capital company.
time at a fair in Switzerland
“In 2004, we took a
in 1963 and he had the
big step: after twenty
brilliant idea of bringing
years of continuous
back some samples of
expansion, we needed
metal to promote that
to rationalise our spaces
light but highly ductile and
and production flows.
resistant material with
We have reorganised
architects. It was difficult
our production, created
to move them away from
an automatic profile
the conventional wood
warehouse (Fig. 4),
and steel materials, but he
replaced our anodic
succeeded,” says Demos
oxidation line, and
Mouskis (Fig. 3).
installed a vertical
George Mouskis threw himself headlong into the design of new systems for architecture, adapting
42
3 1
Figure 3: Demos G. Mouskis, Executive Chairman, with his daughter Anna, Marketing Manager.
N. 53 - SEPTEMBER/OCTOBER 2018 - international PAINT&COATING magazine
powder coating system (Fig. 5),” says Demos Mouskis. “Muskita offers products that have never
FOCUS ON TECHNOLOGY
Quality as a mission
had any filiform corrosion problem even in the harshest environments. There are two reasons for this success: the exclusive use of primary aluminium for extrusion and the collaboration with highly skilled partners, with which there is a continuous exchange of knowledge and experience.” In 2013, Muskita suffered the Cypriot financial crisis: due to the failure of national banks, the economy was at a standstill and a turnover reduced by 60%. “That period tested all of us and shook Muskita from the ground up. However, today we are back to working well, although far below our potential and with slower exports. On the other hand, these moments of slow production are often the most creative ones: we have diversified our range and we have developed new products and services. And here we are, once again at the forefront of the global aluminium market”.
Muskita has invested in an accessory phase of the coating process, greatly affecting productivity, energy efficiency, and operational safety: it has installed a paint stripping system to treat its profile hanging hooks, choosing the technological evolution of the Fastrip ISP machine produced by Alit Technologies (San Bonifacio, Verona, Italy). The system will help increase the speed of its coating line and it will enable the company to significantly reduce energy consumption and process costs. This is crucial for a company like Muskita, bearing much higher costs for energy supply than in the rest of Europe.”
“The choice of primary aluminium for extrusion largely affects our products’ performance. However, quality can only be achieved through a production process that is quality-oriented in all its phases,” says plant manager Andreas Marcou. “It makes no sense to certify the pre-treatment phase, if the substrate is of poor quality or if non-compliant raw materials are used in other process steps. Quality is a system, and it should be treated as such. We only use primary aluminium for extrusion because we do not want to contaminate our warehouse with extruded parts that are not of high quality, but also because its advantages in terms of higher
SP ECIAL ALUMIN IUM
© Muskita
Figure 4: The large automatic profile warehouse.
© ipcm ®
4 1
Figure 5: Overview of the vertical powder coating system by SAT.
44
5 1
N. 53 - SEPTEMBER/OCTOBER 2018 - international PAINT&COATING magazine
®
© Muskita
SP ECIAL ALUMIN IUM
anodic oxidation products and we chose Alufinish.” “Our collaboration with Muskita started about ten years ago, when they decided to implement a chrome-free pre-treatment process,” says Loris Rossi, representing Alufinish. “We currently supply 75% of their anodising products. Over the years, there has been a continuous exchange of experience and technical knowledge between Muskita and us. This has enabled us to develop highly stable anodising products, which allow them to work in complete autonomy. Muskita’s oxidation process is perfectly fine-tuned, so much so that their grey range is one of the most beautiful on the market. For their
6 1
pre-treatment phase prior to coating,
Figure 6: Athens Olympic Stadium, one of the prestigious projects in which Muskita was the protagonist.
we provide them with our chrome-free conversion product Alficoat 748/3, an easy-to-use product that ensures excellent corrosion resistance and is GSB and
but stable and easy-to-use products.
Qualicoat approved. We also supply them
oxidation and painting quality, less use of
We cannot afford to request daily
with all chemicals used upstream of the
chemicals, and above all lack of complaints
technical assistance, because we are
conversion process: also in this case,
from customers compensate for its greater
on an island and the response time
Muskita chose a high quality solution by
purchase cost,” explains Marcou.
of our suppliers is clearly longer. That
implementing a both acid and alkaline
“Quality also entails the selection of reliable
is why we have decided to rely on
pre-treatment process to obtain maximum
partners, with technologically advanced
one provider of pre-treatment and
resistance performance.”
© ipcm ®
extrusion speed, less waste, better
Muskita implemented its first anodic oxidation plant in 1965. In 1985, the company installed its first extrusion plant and, one year later, powder coating with a horizontal plant. In 1990, the firm completed the process with the addition of thermal cutting and assembly machines, long before the issue of European regulations on energy efficiency. The inhouse extrusion also started the era of aluminium exports: its production capacity exceeded domestic demand.”
46
7 1
Figure 7: The anodic oxidation tanks.
N. 53 - SEPTEMBER/OCTOBER 2018 - international PAINT&COATING magazine
FOCUS ON TECHNOLOGY
Alufinish collaboration with Muskita started about ten years ago, when they decided to implement a chrome-free pre-treatment process. Alufinish currently supplies 75% of their anodising products. Over the years, there has been a continuous exchange of experience and technical knowledge between Muskita and Alufinish. This has enabled Alufinish to develop highly stable anodising products, which allow them to work in complete autonomy.”
FATI
srl
CATENE PER TRASPORTATORI CUSCINETTI A SFERA
CATENE AD ALTE PRESTAZIONI HIGH PERFORMANCE CHAINS LEISTUNGSFÄHIGE KETTEN
NOVITÀ NEW NEUHEIT
HPCOAT
The production process: a global quality system Muskita is a plant engineering company: it designs and produces in-house architectural profiles based on its own systems or tailored to customer needs, offering design support and technical advice. An example of this was the
Particolare dei cuscinetti con HPCOAT Detail of bearing with HPCOAT Ausschnitt der Lager mit HPCOAT
coverage of the Athens Olympic Stadium (Fig. 6), designed by Santiago Calatrava, for which Muskita supplied 250 tonnes of powder-coated extrusions. says Andreas Marcou. “Since we are located on an island, we must maintain a very large stock in order to always offer a quick and punctual delivery service. Our automatic raw material warehouse has 1,300 slots and it can store up to 2,000 tonnes of profiles. When orders arrive from
con | with | mit HPCOAT
customers, the planning department determines the profiles to be picked up and sent to the oxidation (Fig. 7) or coating station. Once assembled through thermal cutting, the end products are sent to our four warehouses located in the main cities of the Country: Pafos, Larnaca, Limassol, but we can oxidise or paint parts up to 7.2 metres in length upon request. We can also supply raw profiles up to 9 metres.” Muskita’s coating station is a vertical plant provided by SAT and equipped with a cascade pre-treatment station and two SAT booths featuring 20 GEMA guns each with a traditional Venturi system (Fig. 8). The pre-treatment process includes four active stages: acid attack, alkaline attack, acid neutralisation, and chromefree conversion. Each stage includes three rinses with mains water, except the last one, which is performed with demineralised water. “Our pre-treatment process is Qualicoat Seaside certified. We preferred a cascade system
MORE
and Nicosia. The standard size of our profiles is 6.5 metres,
A tt dopo Aspetto d 2 200 ore in nebbia salina Surface after 200 hours of salt spray test senza | without | ohne Aussehen nach 200 Stunden in Salzsprühtest HPCOAT
Coefficiente Resistenza alla d’attrito corrosione Friction factor Corrosion protection Reibwert Korrosionsfestigkeit Costi di Durata alle alte manutenzione temperature Maintenance costs Life-time at high Wartungskosten temperatures Corrosione Beständigkeit gegen Corrosion hohen Temperaturen Korrosion Autolubrifcazione Abrasione alle Self lubrification alte temperature Selbstschmierung Wear at high Produttività temperatures Productivity Abrieb bei hohen Produktivität Temperaturen
LESS
“We have two extrusion lines, 2,200- and 2,800-ton presses,”
FATI srl Via C. Porta, 14 | 23861 Cesana B.za (LC) | Italy t. +39 031 655688 | f. +39 031 656772 info@fatisrl.com | www.fatisrl.com
© ipcm ®
SP ECIAL ALUMIN IUM
8 1
Muskita’s coating station is a vertical plant provided by SAT and equipped with a cascade pre-treatment station and two SAT booths featuring 20 GEMA guns each with a traditional Venturi system. The pre-treatment process includes four active stages: acid attack, alkaline attack, acid neutralisation, and chrome-free conversion. Each stage includes three rinses with mains water, except the last one, which is performed with demineralised water.”
48
© Alit Technologies
Figure 8: Detail of Gema guns with traditional Venturi system.
9 1
Figure 9: Using hooks that are perfectly suited to each coating process is fundamental in a quality system: it is the only way to ensure perfect electrostatic conductivity. That is why properly paint stripping all hooks between one cycle and another is crucial.
N. 53 - SEPTEMBER/OCTOBER 2018 - international PAINT&COATING magazine
FOCUS ON TECHNOLOGY
The Fastrip ISP system installed at Muskita’s premises is a 6-metre long chemical stripping tank, with a capacity of 2 tonnes of product and with a hook immersion depth of 30 cm. It is the first tank of this type to have a wall heating system with diathermic oil. The stainless steel tank is jacketed and it contains a circuit fed with electrically heated diathermic oil, which guarantees very low operating costs and optimal temperature maintenance.” because, although spraying ensures more uniformity on the outside of the workpieces, the cascade process allows to pre-treat also the inside of profiles,” explains Marcou. “For us, guaranteeing a Seaside quality level means to use first-choice metal, correct pre-treatment processes, and Qualicoat Class 2 coatings. That is the secret for not receiving any complaints for corroded or chalking profiles. Also the choice to use only Class 2 paints stems from our quality policy: we do so also for our wood-effect finishes obtained by sublimation, where we use films of the same quality.” For Muskita, colour is crucial, too. “Our main supplier, accounting for about 70%, is Sherwin Williams with the brand Syntha Pulvin. We also use colours from Akzo Nobel’s Futura and Structura ranges. Together with GI Color, finally, we have developed a 12-tint collection called “Colours of Earth” as well as all wood-effect finishes obtained by sublimation. In total, we manage about 100 colours, plus the ones that we have formulated by our partners on request,” says Andreas Marcou.
Fastrip ISP: paint stripping contributes to quality Using hooks that are perfectly suited to each coating process is fundamental in a quality system: it is the only way to ensure perfect electrostatic conductivity. That is why properly paint stripping all hooks between one cycle and another is crucial, too (Fig. 9). “Before installing Alit’s machine, we used an induction system that did not guarantee perfect cleaning results and above all modified our hooks’ metal structure, thus
+49 89 13928723
© Alit Technologies
SP ECIAL ALUMIN IUM
causing their embrittlement and therefore hanging safety issues,” states Marcou. “Alit’s system was
a slightly higher cost,” says Andreas Marcou. “This tank can withstand a speed of 2 m/min:
convincing in terms of productivity,
we now operate up to 1.75-
but also of efficiency and
1.80 m/min, but we are ready
environmental impact.”
for any possible increase in
The Fastrip ISP system installed at
productivity in future. After the
Muskita’s premises is a 6-metre
first few weeks, we are pleased
long chemical stripping tank, with
with both the machines’ ease
a capacity of 2 tonnes of product
of management and its deep
and with a hook immersion depth
cleaning results. The unloading
of 30 cm. It is the first tank of this
operators no longer have to
type to have a wall heating system
tear off the hooks from their
with diathermic oil (Fig. 10). “The
housings due to an increase in
stainless steel tank is jacketed
size caused by badly removed
and it contains a circuit fed with
paint.”
electrically heated diathermic operating costs and optimal
A never-ending success against all odds
temperature maintenance,”
“Muskita never stops investing.
says Alit Technologies CEO Loris
Always being a step forward
Rossi (Fig. 11). “The tank can be
and offering impeccable quality
completed with a water rinse
and service are our weapons
module to remove the residual
to convince customers that
oil, which guarantees very low
paint stripping oil and with an infrared lamp module for drying. The active paint stripping solution should never be changed, because
10 1
Figure 10: The stripping tank is 6 meters long.
we can provide high precision engineering products even from the South Eastern frontier of Europe. We are a small company, © ipcm ®
the system is designed to be in balance: two
but with huge expertise in terms
products are used, one
of aluminium and
for the tank and one for
its processing” ends
feeding. Management
Demos Mouskis.
is simple: the sludge is
“Despite facing higher
filtered by a filter press
energy costs than our
that produces a dry
competitors, scarcity
residue to be disposed
of water, strict
of.”
discharge regulations
“The length of the
and considerable
machine is determined
non-current assets
by the maximum chain
related to raw
speed. A 5-metre
material, we do not
tank would have been
stop, we do not cease
enough for us, but
to invest, and above
we chose to install a
all we do not give up
6.3-metre tank because it will enable us to increase the speed of the vertical plant with
50
11 1
Figure 11: From the left Andreas Marcou, plant manager of Muskita, Alessia Venturi of ipcm® and Loris Rossi, CEO of Alit Technologies.
N. 53 - SEPTEMBER/OCTOBER 2018 - international PAINT&COATING magazine
offering the superior quality level and competitiveness that distinguishes us.”
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
© ipcm ®
Opening photo: The showroom of AluK GB in Chepstow, South Wales.
FOCUS ON TECHNOLOGY
S P E C I A L ALU MINIU M
From a Compact Vertical System to the Most Advanced Technology in the Aluminium Profile Coating Field: The History of AluK GB Alessia Venturi ipcm®
A
coating (ref. Opening photo).
the Cube system of SAT (Verona, Italy), a firm
built over the years with frame manufacturers,
The Welsh company made its debut in the
specialising in aluminium processing plants
installers, architects, and contractors across the
world of powder coating only three years ago,
and technologies. After three years, now with
UK and beyond. It has adopted this approach
when it decided to insource this phase, crucial
the expertise needed to master the painting
luK GB’s mantra is “Collaboration is King”.
also for the selection of its suppliers, especially
to the quality of its products, by installing a
This company based in Chepstow, South
those involved in a key production process:
compact coating system. The choice fell on
Wales, is very proud of the partnership
52
N. 53 - SEPTEMBER/OCTOBER 2018 - international PAINT&COATING magazine
FOCUS ON TECHNOLOGY
first time that we use flash oxidation as a
process, AluK GB has chosen another SAT technology to make a quality leap in
AluK GB has chosen a SAT technology to make a quality leap in terms of finishes and offer an even higher-level product. The choice has fallen on a technology called FOX, which integrates a pre-treatment stage with a flash oxidation process into a vertical coating line, in order to ensure maximum resistance to filiform corrosion.”
terms of finishes and offer an even higherlevel product. This time, the choice has fallen on a technology called FOX, which integrates a pre-treatment stage with a flash oxidation process into a vertical coating line, in order to ensure maximum resistance to filiform corrosion (Fig. 1).
About AluK GB AluK GB was established in Newport (Wales) as a family-run company specialising in the distribution of coated
requires full mastery of the process,” explains AluK GB plant manager Michael Burke (Fig. 4). “Three years ago, we bought our first powder coating plant and we chose Cube because it was perfect to learn the ropes of powder coating and acquire the right skills to offer a quality product. When the company’s owners resolved to move to Chepstow, we also decided to turn the powder coating stage into one of the key points of our growth
© ipcm ®
on the European market and it was first
ensures a very high quality level, but it
on the market. Therefore, it deserved an
aluminium for residential and commercial buildings. The company grew very fast
pre-treatment method. This technology
acquired by Blyweert Aluminium (Belgium) and then by the AluK Group. AluK GB now designs and builds aluminium systems for buildings and it offers a complete range of windows, doors, and curtain walls in the United Kingdom as well as all over the world. AluK’s systems are suitable for both commercial and residential buildings and they combine high performance and functionality with modern design and lasting finishes (Fig. 2). In 2017, AluK GB has moved to a new and larger facility in Chepstow, in the Monmouthshire, to implement an ambitious expansion plan following three years of intense growth in the British market. The new plant has increased the production capacity of the company, allowing for the integration of technological innovations
1
Figure 1: The loading area of the new vertical line supplied by SAT.
investment proportional to its role. We
manufacturing phases, while providing
The new coating plant featuring the FOX technology
the necessary space for warehouses,
The new line was started in June, less than
install another, much more technologically
offices, and showrooms. “The decision
a year after the order, and it is already
advanced SAT line. It includes a pre-
to transfer the company to a larger
fully operational (Fig. 3). The company
treatment stage with the flash oxidation
site, here in Chepstow, was essential
is performing a series of tests to ensure
technology, which creates an oxide layer
to continue growth,” said AluK general
that the products’ quality is in line with
with a 3 to 8 micron thickness to protect
manager Russell Yates. “In the last
its standards. “We want to make sure
aluminium against filiform corrosion
three years, we had completely
that we have thoroughly understood the
(Fig. 5)”.
saturated the Newport plant. Now,
process and we fully control it: although
“The UK aluminium market is divided into
we can finally invest in cutting edge
we have powder coated with the Cube
two sectors: commercial and residential.
technology and create new jobs.”
system for three years now, this is the
The residential market accounts for 92%
in both the product design and
decided to divest the Cube system and
international PAINT&COATING magazine - SEPTEMBER/OCTOBER 2018 - N. 53
53
© ipcm ®
© ipcm ®
SP ECIAL ALUMIN IUM
2 1
3 1
Figure 2: Section of a profile coated by AluK GB.
Figure 3: Overview of the new coating line.
of our production. We own a few specific
we have 400 tonnes of raw aluminium in
and training support. SAT turned out to
systems for the residential construction
stock. After coating, this is transferred to
be a partner with which we could grow,
field and our flagship products, accounting
the finished product warehouse, waiting for
a company that shared and adopted our
for about 40% of the total, are sliding and
assembly and shipping,” explains Michael
vision, and above all a plant engineering
folding doors. Our investment in the new
Burke. “AluK GB has always considered the
firm able to provide us with the ideal
premises, and above all in the new powder
finishing of its products a commercial lever:
product to achieve our market objectives © ipcm ®
coating plant, was motivated by the will to
from time to time.” “This strategy meant
conquer the commercial
choosing Cube as our
market. We are now
first plant because it
developing our systems
guaranteed maximum
to adapt them to the
flexibility with our
needs of this market and
numerous colour change
we have already won two
operations, as well as
significant projects. Our
being a “training ground”
goal is to expand our
for our operators. In this
portfolio of solutions.
way, we have acquired
Thanks to the new plant
the necessary skills
with the FOX technology,
to meet the market
we are now able to compete at a higher level of the market.”
The reasons for the choice
demands in terms of
4 1
coating. At that point,
Figure 4: From left to right: Michael Burke, Plant Manager of AluK GB, Alberto Formenti, Sales Engineer of SAT and Leon Hoog, UK Business Unit Manager of GEMA.
we started planning to further grow and we decided to make a big investment in a new
AluK GB receives extrusions from various
since 1992, when the company opened up,
line that was not only perfect for the
European suppliers. The incoming
we have focused on the finishing process by
requirements of that moment, but also
aluminium is then stored in the raw
entrusting it to expert contractors. However,
ready to meet future ones. We also knew
material warehouse waiting to be coated,
a leap in quality would have been possible
that pre-treatment is a critical part of the
assembled with a thermal cutting process,
only by insourcing this operation (Fig. 6).
painting process in order to ensure high
and packaged for shipping. “Currently,
That is why we needed adequate technical
quality. That is why we opted for the FOX
54
N. 53 - SEPTEMBER/OCTOBER 2018 - international PAINT&COATING magazine
© ipcm ®
FOCUS ON TECHNOLOGY
5 1
Figure 5: The FOX system.
system. Our process was already Qualicoat Seaside certified, but the new line even exceeds the requirements.” “The transition from Cube to the new line was perfect and smooth, since the technology is practically the same, except for the FOX system,” states Burke. “The plant is very easy to use: the control PLC works like a Windows system: it is possible to “browse” through the various process phases. SAT’s engineers are highly skilled and they deeply know their technologies. Their support was essential to adapt to the use of such a large treatment line. Even the installation phase was smooth: it took three days to start and test the electrical and mechanical parts, and the system had been already started while we were still in Newport.”
Two pre-treatment technologies in one line The peculiarity of AluK GB’s new coating line is the integration of two different pre-treatment systems: a conventional chemical cycle, with a double active stage (acid and alkaline) and a chrome-free conversion
AluK GB designs and builds aluminium systems for buildings and it offers a complete range of windows, doors, and curtain walls in the United Kingdom as well as all over the world. AluK’s systems are suitable for both commercial and residential buildings and they combine high performance and functionality with modern design and lasting finishes.”
© ipcm ®
SP ECIAL ALUMIN IUM
stage, and a
to the inner
flash oxidation
ring of the FOX
process. “The
system, without
chemical spray
reducing the
pre-treatment
overall speed
cycle includes as
of the line.”
follows: alkaline
“AluK GB works
etching, rinsing
constantly at
with mains water,
1.5 m/min.
acid degreasing,
When the
double rinsing
system control
with mains water,
software
rinsing with
matches a
demineralised
load bar with
water, and
a treatment
chrome-
program that
free surface
includes the
conversion
flash oxidation
with Chemetall
phase, the
products,”
profiles are
explains Michael Burke (Fig. 7). “SAT’s technology comes into play
removed
6 1
from the main ring of the
Figure 6: Finished profiles.
line through a 4-switch
after the rinses
system and they are transferred to the FOX’s
following the acid degreasing stage: here,
internal conveyor,” says Formenti (Fig. 10).
based on the quality requirements of the aluminium profiles to be treated, we can decide whether to divert the parts toward the oxidation tank for a flash treatment aimed at improving their corrosion resistance or to complete the conventional cycle (Fig. 8).” The latest version of the FOX system was implemented. “Originally, the FOX system was based on two separate tanks, one for the flash oxidation process and one for rinsing the profiles. The speed of the main conveyor was limited by the number of profiles that could be processed by the tanks, thus limiting productivity accordingly,” says SAT sales engineer Alberto Formenti. “In the latest version of this system, however, the oxidation tank is wider in order to immerse several profiles at the same time (Fig. 9), whereas the rinse with demineralised water occurs vertically in a spray tunnel module. In this way, the main conveyor of the coating line can transfer a greater number of profiles
56
AluK GB has always considered the finishing of its products a commercial lever: since 1992, when the company opened up, they have focused on the finishing process by entrusting it to expert contractors. However, a leap in quality would have been possible only by insourcing this operation. That is why they needed adequate technical and training support and SAT turned out to be a partner with which they could grow and above all a plant engineering firm able to provide the ideal product to achieve market objectives from time to time.”
N. 53 - SEPTEMBER/OCTOBER 2018 - international PAINT&COATING magazine
“Otherwise, the profiles proceed on their path toward the chrome-free passivation station. The winning aspect of this plant is its flexibility in terms of final quality. The company can offer a standard and more affordable product using the chrome-free pre-treatment as well as a premium quality, more expensive product using the flash oxidation technology, thus meeting the requirements of the most diverse aluminium markets.” “The anodising process lasts 3.51 minutes. We recover part of the sulphuric acid in the solution from the dripping of the profiles and we recirculate it into the system,” states Michael Burke. “Moreover, we converted the rinse with mains water included in the original project into a rinse with demineralised water, thus obtaining great benefits: the anodising process is always critical and strict parameter control is required.”
© ipcm ®
SP ECIAL ALUMIN IUM
capacity and flexibility,” states Burke. “On average, we perform twenty-five
AluK GB knew that pre-treatment is a critical part of the painting process in order to ensure high quality. That is why they opted for the FOX system.”
colour change operations a day. In the most intense months, we can handle 22 tonnes of aluminium per day, but we even performed forty-two colour changes with only 16 tonnes of aluminium treated. For AluK GB, flexibility is of the essence, as well as quality. We use © ipcm ®
almost exclusively Qualicoat 2 polyester powders provided by AkzoNobel, our main supplier with which we collaborate in terms of both colour and paint performance development. Also with AkzoNobel, we have established a partnership of mutual growth, in which the support of their engineers is crucial. For us, finishing is a “quality system” and not a series of production phases
7 1
disconnected from each other.”
Figure 7: On the right the pre-treatment tunnel.
Technology as a primary selling argument “We are confident that we have installed
Finishing: a quality system
the most advanced technology available on the market today,” Michael Burke
After pre-treatment, the profiles are dried in 110° C, depending on the room temperature. Then, they reach the application area equipped with two V-shaped booths and Gema’s feeding and AP01 dense phase powder spraying in-line technology (Fig. 11).
8 1
© ipcm ®
the oven at a temperature between 95 and
Figure 8: The conveyor can divert the parts towards the pre-treatment tunnel or toward the FOX system.
“In terms of application, dense phase is the first choice for coating aluminium profiles, although it requires a greater investment than the Venturi injector technology,” states Leon Hoog, the UK Business Unit Manager of GEMA. “However, it is the best technology available today as for transfer efficiency, extrusion penetration, paint yield, and standard thickness deviation (Fig. 12).” The two coating booths work simultaneously: during loading, the software matches each bar with a treatment program and with its assigned booth’s number (Fig. 13). “One of the greatest benefits of the plant technology supplied by SAT is that no empty spaces are needed on the chain: this has considerably increased our production
58
SAT’s technology comes into play after the rinses following the acid degreasing stage: here, based on the quality requirements of the aluminium profiles to be treated, they can decide whether to divert the parts toward the oxidation tank for a flash treatment aimed at improving their corrosion resistance or to complete the conventional cycle.”
N. 53 - SEPTEMBER/OCTOBER 2018 - international PAINT&COATING magazine
9 1
Figure 9: Top view of the FOX tank.
© ipcm ®
FOCUS ON TECHNOLOGY
The winning aspect of this plant is its flexibility in terms of final quality. The company can offer a standard and more affordable product using the chromefree pre-treatment as well as a premium quality, more expensive product using the flash oxidation technology, thus meeting the requirements of the most diverse aluminium markets.” Figure 10: The descender of the FOX system.
10 1
Application Pump with SIT technology Improve your coating line's automation and achieve a more uniform finishing quality
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www.gemapowdercoating.com
© ipcm ®
© ipcm ®
SP ECIAL ALUMIN IUM
11 1
12 1
proudly says. “We can now start thinking
Figure 12: The GEMA nozzles that work with dense phase powder technology.
© ipcm ®
Figure 11: One of the coating booths supplied by SAT/equipped with GEMA system.
is actually not very wide. SAT’s
about a possible development of the pre-
vertical technology can favour
treatment process with the introduction of a
the opposite approach, that is,
polymer technology for surface conversion,
high volume/high variation. I
or assess the possibility to integrate a
believe this possible change is
brushing machine in the SAT line, since our
exciting for the English market.
goal is to manipulate our profiles as less as
Pre-treatment will become an
possible. However, we are more than pleased
increasingly critical aspect, when
with our current equipment. In the United
chrome VI will be permanently
Kingdom, the powder coating technology
banned in Europe and the United
level is quite low and few investments are
Kingdom. Companies must now
made in new plants, especially the vertical
equip themselves to understand
ones. The horizontal lines based on a low
the alternative chrome-free
volume/high variation approach account for
processes, otherwise quality
90% of the aluminium coating market, which
problems will be certainly an issue.” “The FOX system is undoubtedly our USP on the
AluK GB uses almost exclusively Qualicoat 2 polyester powders provided by AkzoNobel, the main supplier with which they collaborate in terms of both colour and paint performance development.”
60
market,” says Burke. “There is only one other UK contractor offering profiles pre-treated with the flash oxidation technology. However, we are 13 1
Figure 13: Entry and exit of the polimerization oven.
N. 53 - SEPTEMBER/OCTOBER 2018 - international PAINT&COATING magazine
the only ones to have installed this system in-house and in-line on a vertical system.”
HIGHLIGHT OF THE MONTH
S P E C I A L ALU MINIU M
Chemetall: Your Leading Global Supplier of Applied Surface Treatment Solutions From an interview with Martin Jung, Senior Vice President Surface Treatment of Chemetall
I
n December 2016 BASF’s Coatings
and in Clermont-Ferrand, France. Jung
Ipcm: Which kind of synergies will you
division acquired Chemetall, a leading
received his PhD in Polymer Chemistry from
have with BASF after the acquisition?
global surface treatment supplier.
the Eindhoven University of Technology,
MJ: Being part of BASF’s Coatings division
Being well-known within the industry for
Netherlands. He joined BASF in 2000 and
creates opportunities to offer the combined
its high-quality products and solutions,
held different management positions within
expertise of BASF within the coatings industry
Chemetall now operate as a brand of the
the group in Germany and overseas.
and Chemetall to increase customer benefits © Chemetall
Surface Treatment global business unit of BASF’s Coatings division.
with improved products and services. Obviously, we are looking in the first
Chemetall develops and
place at top performing,
manufactures customized
aligned pretreatment
technology and systems
and e-coat systems to
solutions for applied surface
reduce consumption and
treatment. The products
at the same time enhance
protect metals from
performance. We are
corrosion, facilitate forming
tapping into the huge R&D
and machining, allow parts
pool of BASF, especially in
to be optimally prepared
the surfactant and polymer
for the painting process
area, to develop new
and ensure proper coating
cleaner systems or
adhesion. These products
high-performing sealants.
are used in a wide range of
We are really excited about
industries and end-markets,
the new opportunities and
such as automotive, aerospace, aluminium
Figure 1: Chemetall is the Surface Treatment global business unit of the Coatings division of BASF.
our customers will benefit from systems and solutions across the value chain.
finishing, and metal forming. In occasion of this special issue on
Ipcm: Can you trace the evolution of the
aluminium finishing distributed at the
company in the last 10 years?
Ipcm: Which is Chemetall’s current
upcoming international exhibition
MJ: Chemetall enjoys a great history of global
strategy on the market?
Aluminium 2018 in Düsseldorf, ipcm®
recognition for providing its customers with
MJ: Chemetall’s strength is to enable our
interviewed Martin Jung, Senior Vice
high-performance products and individual
customers to run their metal treatment
President Surface Treatment of
solutions for the metal industry. Over the
processes successfully. Our offering
Chemetall.
past ten years, our sales have grown by
comprises tailor-made products as well as
Before assuming his current role, Martin
more than 70 percent. The growth is built on
tailor-made service models. That is the basis
Jung headed the Automotive OEM
impressive team performance and organic
for further growth with our customers in
Coatings Solutions Europe business
growth with our customers as well as on
the automotive, components, aerospace,
unit of BASF’s Coatings division. He
the continuous expansion of our business
cold-forming, general industry, aluminum
studied chemistry and mathematics at
by acquisitions, e.g. in the glass industry or
finishing or glass industry – to name the most
the University of Heidelberg, Germany,
aluminum finishing businesses.
important ones.
62
N. 53 - SEPTEMBER/OCTOBER 2018 - international PAINT&COATING magazine
© Chemetall
HIGHLIGHT OF THE MONTH
We build on our strong local presence globally to deliver fast service and a smooth supply chain. On the other hand, we trust in globalized R&D networks to deliver top notch products. Going forward, we will also expand in adjacent segments where we can build on our strengths. Furthermore, we will leverage the synergies 2 1
Figure 2: Martin Jung, Senior Vice President Surface Treatment.
with neighboring BASF businesses.b Ipcm: Which are the most important
industrial markets (segments and countries) for Chemetall’s business? MJ: Chemetall focuses on markets where metalworking processes are used – in a variety of industries and end markets, such as Automotive, Aerospace, Aluminum Finishing, and Metal Forming. Our growth plan is built on Chemetall’s good market positions in all regions of the world. In Pinghu, China, BASF has invested in a new state-of-the-art surface treatment site for the Chemetall brand with state-of-the-art laboratories, production and warehousing. We are also expanding our production site in Langelsheim/Germany for our NADCAP-certified aircraft sealant technologies. We expect continued profitable growth in Europe & South America as well as in North America. We will further increase our efforts in emerging markets in Asia Pacific, including Vietnam, Indonesia, Bangladesh, or Pakistan.
Chemetall develops and manufactures customized technology and systems solutions for applied surface treatment. The products protect metals from corrosion, facilitate forming and machining, allow parts to be optimally prepared for the painting process and ensure proper coating adhesion. These products are used in a wide range of industries and end-markets, such as automotive, aerospace, aluminum finishing, and metal forming.”
© Chemetall
SP ECIAL ALUMIN IUM
3 1
Figure 3: Aluminium pretreatment and anodizing with Chemetall products generate desired surfaces.
Ipcm: What is the focus of
Ipcm: How is the situation of the
countries, as is CR III. At the same time, this
Chemetall’s R&D activities?
market regarding chrome free
project gets of higher importance for global
MJ: Chemetall is focused on multiple
processes?
quality label organizations such as Qualicoat,
R&D activities: We are working on
MJ: The market demands for chrome-free
Qualisteelcoat or GSB, who are discussing
improving the environmentally friendly
technologies for galvanized material and for
this trend. This is another confirmation that
thin film technology Oxsilan for the
aluminium are constantly rising over the past
chrome-free technologies are on the rise
automotive industry and developing
years – that is what we notice worldwide.
and will be more and more in the spotlight in
a new generation of our Naftoseal®
The fact is that CR VI is under attack in many
the next time.
®
aircraft sealants for the aerospace
Chemetall at the ALUMINIUM 2018
industry, allowing wider application windows and faster curing. We also focus on the introduction of functional cleaners to optimize Chemetall’s surface treatment solutions for key industries, such as Automotive OEM. And we develop more environmentally-friendly chromium-free surface treatment solutions for Automotive, Coil and General Industry.
64
Chemetall will be exhibiting and presenting
Being part of BASF’s Coatings division creates opportunities to offer the combined expertise of BASF within the coatings industry and Chemetall to increase customer benefits with improved products and services.”
N. 53 - SEPTEMBER/OCTOBER 2018 - international PAINT&COATING magazine
at the ALUMINIUM 2018 in Düsseldorf, Germany from October 9th to 11th. The Surface Treatment global business unit of the Coatings division of BASF will be present at booth 12G12 and highlight its complete portfolio for all types of aluminium finishing applications as well as anodizing processes.
powder coatings Paint Engineering
Premium quality Formulation, design and manufacture adapted to technical requirements, and highly complex facilities.
Anticorrosive systems
Coil Coating Superdurable Superdurable coatings for sublimation effect Metallic bonding
www.titanpowdercoatings.com
© ipcm ®
Opening photo: The range of wood-effect finishes included in the wide colour collection created in collaboration with Titan.
FOCUS ON TECHNOLOGY
S P E C I A L ALU MINIU M
Deep Collaboration with the Paint Supplier to Diversify Production and Ensure High Quality: The Winning Strategy of Lacoviana Barbara Pennati ipcm®
I
s “quality” the result of a teamwork or of
every product, plant, or service used
Experience, quality and satisfaction:
one company’s efforts to monitor every
must be of high quality, too.
these are the three pillars of the
production and service parameter?
That is why any company should
corporate philosophy of Lacoviana
The first option is obviously right. Having
create a network of suppliers suited to
(Viana do Castelo, Portugal), a company
a quality system in place is not enough:
its quality needs.
specialising in the finishing of aluminium.
66
N. 53 - SEPTEMBER/OCTOBER 2018 - international PAINT&COATING magazine
In the last thirty years,
© ipcm ®
FOCUS ON TECHNOLOGY
by collaborating
this approach has
closely with Lacoviana
enabled it to become
to develop new
the partner of choice
tailor-made finishes
for the production
and technologies
of aluminium in
for its customers.
architectural projects
The wood-effect
all over the world.
one obtained with a
Established in 1988,
powder-on-powder
the company started
technology is the
with a modest plant for
best example of this.
treating and coating
It is now one of the
aluminium profiles. It
flagships and what
now coversbanbareabof
distinguishes the
approximately 12,000
Portuguese company
m2, of which 7,000
from others (Fig. 2).
m2 are devoted to a horizontal coating plant with 2 booths and an anodising line, 1,000 m2 with 2 lines devoted
Lacoviana’s
1
production structure
Figure 1: From right to left, Lacoviana CEO Luís Cambão and production manager Diogo Barreto.
© ipcm ®
to the standing seam of thermal cutting profiles, and 4,000 m2
includes as follows: a totally automated anodising line among the most modern
in Europe, featuring an installed power of
are reserved for one vertical coating plant
36,000 amperes (Fig. 3) and using chemicals
installed at the end of 2017.
by Alsan (Valencia, Spain); a horizontal coating
“Our production is mainly intended for the
line with 2 booths; and a vertical coating line,
architecture sector, followed by the industrial
the most recent one, for which the Cube
one,” says CEO Luís Cambão (Fig. 1). “In
system provided by SAT (Verona, Italy) was
the last few years, we have worked hard
chosen (Fig. 4). Chemicals by Chemetall are
to diversify our production and conquer
used for the coating lines. The production
the international markets. We currently
capacity installed exceeds 6 million square
operate not only in Portugal but also in most
metres per year (±4 million coated products
European countries, with particular reference
and ±2 million anodised products).
to Spain, France, Holland, Belgium, United
The flexibility guaranteed by its aluminium
Kingdom - and in non-European countries
coating and treatment systems, its
such as the United States, Angola, and
collaboration with Titan, and the great
Mozambique. This exponential growth was
attention paid to the quality certifications
made possible by the investments made in
of its production (Qualicoat, Qualideco and
new technologies and the close partnerships
Qualanod) have enabled Lacoviana to widen
with our customers, while we are always
its range of products and finishes over time,
supported by our suppliers, honest and
thus becoming one of the services providers
reliable collaborators.”
in Europe in the treatment of aluminium for
The partnership with Industrias Titan for
architecture and industry.
the supply of powder coatings is just one
Optimising products and services
example. This partnership has lasted for more than twenty years and it has actively contributed to creating the current company image on the market, not only by providing high quality and reliable products, but also
Lacoviana pursues quality also through
2 1
careful selection of paints: the polyesters
Figure 2: A stand with different wood-effect finishes.
for architecture provided by Industrias Titan represent absignificant percentage of these.
international PAINT&COATING magazine - SEPTEMBER/OCTOBER 2018 - N. 53
67
© ipcm ®
SP ECIAL ALUMIN IUM
worked with Titan to expand our colour and finish range,” states Cambão. “By enhancing our brand and modernising our company, we have created a pretty wide colour catalogue. It includes not only matt and gloss standard RAL colours but also a selection of textured and metallised shades and the wood-effect finishes (ref. Opening photo). These polyesters are always available from stock to guarantee fast deliveries within the established deadlines. The anodised shades’ catalogue follows the same philosophy with a wide range of coloursbfrom natural satin effect to stainless steel, champagne, bronze and black effects, through the gold, blue and ash grey colours. The range is completed with the mechanical treatments of brushing, polishing and repolishing.
3 1
“Such diversification in coated products
Figure 3: The fully automated anodising line, with an installed power of 36,000 amperes.
was possible thanks to the joint efforts of Lacoviana and Titan, with which we have also developed a powder-on-powder
68
technology for our wood-effect finishes,
of trust with Titan,” says Luís Cambão. “Only
with excellent realism and resistance
in the last year, we have been required to
properties (Fig. 5). By using coatings
use 500 different colours. Taking account
provided by one supplier and perfectly
of these coatings differences, as well as
suited to our needs, we maintain optimal
replacing our old coating booths with two
compatibility between different layers of
new last generation machines by Gema with
paint, which ensures quality consistency,
a very quick colour change system, we have
reliability, and durability,” says Cambão.
© SAT
Experience, quality and satisfaction: these are the three pillars of the corporate philosophy of Lacoviana (Viana do Castelo, Portugal), a company specialising in the finishing of aluminium. In the last thirty years, this approach has enabled it to become the partner of choice for the production of aluminium in architectural projects all over the world. Established in 1988, the company started with a modest plant for treating and coating aluminium profiles. It now covers an area of approximately 12,000 m2, of which 7,000 m2 are devoted to a horizontal coating plant with 2 booths and an anodising line, 1,000 m2 with 2 lines devoted to the standing seam of thermal cutting profiles, and 4,000 m2 are reserved for one vertical coating plant installed at the end of 2017.”
“We have established an excellent relationship
4 1
Figure 4: The Cube system provided by SAT (Verona) was chosen for the vertical coating line.
N. 53 - SEPTEMBER/OCTOBER 2018 - international PAINT&COATING magazine
© ipcm ®
FOCUS ON TECHNOLOGY
5 1
Figure 5: An aluminium frame treated by Lacoviana with a wood-effect finish.
The partnership with Industrias Titan for the supply of powder coatings is just one example. This partnership has lasted for more than twenty years and it has actively contributed to creating the current company image on the market, not only by providing high quality and reliable products, but also by collaborating closely with Lacoviana to develop new tailor-made finishes and technologies for its customers. The wood-effect one obtained with a powder-on-powder technology is the best example of this. It is now one of the flagships and what distinguishes the Portuguese company from others.”
© ipcm ®
SP ECIAL ALUMIN IUM
The vertical coating plant: compactness and versatility
“SAT’s Cube system is the best solution for our needs. It ensures the end quality to which our clients
The new Cube vertical coating plant
havebbecome accustomed, while
is fully operational from January
having a compact structure: this was
2018. The pre-treatment process
crucial for us due to the expansion
includes an alkaline phase followed
of the existing line” says Lacoviana
by an acid phase to improve
production manager Diogo Barreto.
corrosion resistance and it uses
“Moreover, we already knew SAT’s
Chemetall products.
products and their corporate
The coating stage in the vertical
philosophy similar to ours, focussing
plant is performed in a quick colour
on customer trust and on the ability to
change booth (Fig. 6), equipped
react quickly and efficiently in case of
with GEMA application technology
any problems.”
with Venturi injectors (Fig. 7). “The
“Gema’s last generation system,
growth of Lacoviana has required
changing colour in about 5-6 minutes,
the need to increase production
have enabled us to perform up to
that led us to add a compact and
twenty colour change operations a
versatile vertical coating plant to our already-existing horizontal system (Fig. 8). This gives us greater flexibility and production speed,”
Figure 6: One of the two vertical booths, with a GEMA quick colour change system.
© SAT
explains Luís Cambão.
6 1
7 1
Figure 7: Each booth features 18 Gema dispensers with a Venturi system.
70
N. 53 - SEPTEMBER/OCTOBER 2018 - international PAINT&COATING magazine
day (Fig. 9). This has also allowed us to effectively distribute the workload between the two lines, depending on the needs and features of each production,” states Barreto.
© ipcm ®
FOCUS ON TECHNOLOGY
8 1
Lacoviana’s production structure includes as follows: a totally automated anodising line among the most modern in Europe, featuring an installed power of 36,000 amperes and using chemicals by Alsan (Valencia, Spain); a horizontal coating line with 2 booths; and a vertical coating line, the most recent one, for which the Cube system provided by SAT (Verona, Italy) was chosen. Chemicals by Chemetall are used for the coating lines. The production capacity installed exceeds 6 million square metres per year (±4 million coated products and ±2 million anodised products).”
by the certification processes, such as the
“Lacoviana made all its
immersing a part in a solution for 48 hours,
investment choices with the
but we also carry out salt spray tests. Every
aim of ensuring quality of
workpiece treated is checked, regardless
the end product, flexibility of
of its intended use. We are among the first
the response, and customer
companies in Portugal to perform this service
satisfaction. This led us to
in-house, without outsourcing it (Fig. 11).”
certify our products according
“Thanks to the type of pre-treatment and
to the Qualicoat with A1 and
the quality of the coatings used, we can
A2 Seaside-class (coated
get a salt spray resistance value up to
products), Qualideco
3000 hours. Today it is not possible to
(wood-effect coated products),
offer a product that only has an excellent
and Qualanod (anodised
look: it is also necessary to guarantee
products) standards. We are
the materials durability by increasing the
also ISO 9001 certified; our
product’s life. If the object’s substrate is
next goal is to get the ISO
not treated optimally, the coating does
14001 certification,” explains
not adhere well; at the same time, if the
Diogo Barreto. “In order to
coating is not of excellent quality, the
check the actual quality of its
final quality and corrosion resistance
products, Lacoviana relies on
levels are compromised. That is why
an internal laboratory that
both the pre-treatment with Seaside-
employs the latest technologies
class and salt spray test stages come as
in terms of analysis and testing
a standard in all our processes, without
(Fig. 10). Here, not only do we
additional costs for the customers,” says
conduct the tests required
Barreto.
Machu test, an accelerated corrosion test required by Qualicoat and performed by
© SAT
Figure 8: Coated profiles exiting the horizontal plant.
Certified quality and maximum production versatility
9 1
Figure 9: Gema’s OptiCenter powder management units allow for very quick colour change operations.
international PAINT&COATING magazine - SEPTEMBER/OCTOBER 2018 - N. 53
71
© ipcm ®
SP ECIAL ALUMIN IUM
10 1
© ipcm ®
Figure 10: Lacoviana relies on an internal laboratory for testing and analysis.
the most suitable coatings for our needs. The increase in our production capacity
The new Cube vertical coating plant is fully operational from January 2018. The pre-treatment process includes an alkaline phase followed by an acid phase to improve corrosion resistance and it uses Chemetall products. The coating stage in the vertical plant is performed in the quick colour change booth, equipped with GEMA application technology with Venturi injectors.”
allowed by the new vertical line has enabled us to optimise workloads. The vertical system is now devoted to large-size batches, while the horizontal one is used for special projects, thus allowing us to meet fast delivery requests within just 24 hours,” explains Luís Cambão. “The technologies and products used have made our production flow more flexible and agile in order to meet the needs of different markets, whose specifications often change depending on the target country. We can offer the same optimal qualitative yield for both big and small projects, whether destined for the US, English, or French market. “We are laying the foundations for our
A common path in the pursuit of quality
future in order to become a company able to work for large firms but also to meet
“Some of the great advantages of
even the smallest businesses’ requests.
Lacoviana include its wide 30-year
This is our reason for pride and it would
experience in the coating field and its
11 1
quality offered by our suppliers,” says
long-standing collaboration with Titan, which has allowed us to learn a lot about
72
not be possible without the trust and high
Figure 11: The salt spray chamber.
N. 53 - SEPTEMBER/OCTOBER 2018 - international PAINT&COATING magazine
Cambão.
sataluminium.com SAT (Surface Aluminium Technologies) S.p.A. | Via Antonio Meucci, 4 | 37135 Verona | Italy | ph +39 045 8280601 | info@sataluminium.com
BRAND-NEW
S P E C I A L ALU MINIU M
Adapta Color Launches the New ANODIC Collection for Architectural Design
T
he new ANODIC collection
The products available feature a
All the colours in the collection boast the
launched by ADAPTA® is part
meticulous colorimetric adjustment
cutting-edge Adapta Bonding System®
of the VIVENDI® SDS range
and are intended as an option for all
technology, which provides and
for design and planning in the field of
those who appreciate the benefits this
guarantees a homogeneous visual
architecture. These products have been
kind of coating brings to their goods,
effect, essential for use in emblematic
designed in extra-durable, premium
including:
projects or where the highest standards
polyester to ensure the maximum
• A product life-cycle with less impact on
of quality are required. At the request
standards of quality with regard to shine and colour fastness to light, and always in compliance with the applicable international quality specifications. The collection bears an environmental product declaration (EPD) and has been
the environment. • Greater uniformity of colour between manufacturing batches. metal substrates. • Greater chemical resistance.
awarded an
© Adapta Color
to standard ISO having been A+ rating for extremely low emissions in indoor environments. The colours on offer cover a wide range of the most popular anodized finishes on the market.
Figure 1: The new ANODIC collection is part of the VIVENDI® SDS range and the products have been designed in extra-durable, premium polyester.
74
colour not featured in the ANODIC collection.
• The same appearance on different
certified pursuant 16000-9:2006,
of the client ADAPTA® will develop any
1
N. 53 - SEPTEMBER/OCTOBER 2018 - international PAINT&COATING magazine
Fur further information: www.adaptacolor.com
BRAND-NEW
S P E C I A L ALU MINIU M
Clariant To Debut New Striking Shade for Transforming Applications at Aluminium 2018
C
lariant, a world leader in specialty
capabilities offered by its complete portfolio of
consumer experiences, we are pleased to draw
chemicals, invites aluminium
Swiss-made colorants, process chemicals and
on our long history of supporting the anodizing
anodizers, product designers
special printing inks for sub-eloxal printing.
industry worldwide and introduce
and engineers visiting Aluminium 2018 to
Clariant supports the industry with a wide range
easy-to-use vibrant, eye-catching colours that
heighten their creativity with the latest
of products, such as dyes based on heavy
extend designers’ creativity and increase
high-durability, sustainable colour solutions
metal-free structures (Sanodye ),
end-user value perceptions.”
for aluminium finishing.
borax-free degreasers/cleaners, and
Centre stage at Booth G13 Hall 12 will be a
nickel-free sealing solutions, for improving the
Aluminium 2018 will be held at the
new magenta shade with a unique level of
sustainability profile of finishing processes or
Messe Düsseldorf, Germany,
light and weather fastness that is perfect for
products.
rom October 9-11, 2018.
adding long-lasting vibrancy to indoor and
Thomas Heber, Technical Marketing Aluminium
outdoor applications. Adding to its
Europe, Business Unit Pigments at Clariant
For further information:
appeal, the single dye formulation has a
comments: “Aluminium lends an extra touch of
www.clariant.com/aluminumfinishing
heavy metal-free structure, non-bleeding
quality to a wide range of
and easy to handle. It shows good dye
applications. As segments
bath stability and enables a stable dyeing
such as electronics,
process.
cosmetics packaging,
Clariant will be joined by Omya (Schweiz)
appliances, automotive
AG, the exclusive distribution partner
and transportation,
for its aluminium finishing portfolio in
sports goods and also
Europe, North Africa and the Middle East,
architecture focus on
to demonstrate the product enhancing
creating enhanced
®
© Clariant
Competence in Shot Blast Technology We offer new and second-hand wheel blast machines including conveyor and filter systems. Our range of products and services include: • Wear and Spare Parts • Repair and (remote) maintenance • Services … for wheel blast machines of other makes as well. stand on me to our co se a le P CH, EUROBLE , 2018, Oct. 23-26 r, e v o n Han 1 tand B 14 Hall 13, S
Figure 1: Clariant’s colourful anodized aluminium dyes lend an extra touch of quality to a wide range of applications.
AGTOS Gesellschaft für technische Oberflächensysteme mbH Gutenbergstraße 14 D-48282 Emsdetten Tel. +49(0)2572 96026-0 info@agtos.de
www.agtos.com
253-09/18-4c-GB
1
SUCCESS STORIES
S P E C I A L ALU MINIU M
© Tonon Forty
Tonon Forty Launches Its New Line of Radiators “Colors Vintage”, with Finishes Dedicated to Vintage Products and Created with Arsonsisi Powder Coatings selected finishes dedicated to vintage products, the Colors radiators give a touch of style to any environment, focussing on materials to recreate the sensations for which the Italian design is appreciated in the world. Simple materials such as copper, aluminium, stone, and soil have inspired the finishes chosen for this new line: mixed together, they create unique and surprising shades reminding of the
© Arsonsisi
different elements in all their nuances.
1
Figure 1: The new “Colors Vintage” radiator range, designed by Tonon Forty and coated with Arsonsisi powders.
T
onon Forty is an Italian leader
including different thicknesses and
in the design, production, and
dimensions and it fits perfectly in
sale of heating appliances and
any room, embellishing it with its
systems. In collaboration with Arsonsisi,
unmistakable style.
a well-established Italian leader in
Tonon Forty and Arsonsisi have
the industrial coating market, it has
been collaborating for years to
revamped its well-known foil radiators
ensure maximum results and
from the Colors range. Colors is
the high quality that is typical of
Tonon Forty’s flagship product, which
Italian-made products of excellence.
established itself on the market in 1967
This collaboration also led to the
thanks to its reliability and versatility. It
creation of the new “Colors Vintage”
is available in a wide range of options
range (Fig. 1). With their carefully
76
N. 53 - SEPTEMBER/OCTOBER 2018 - international PAINT&COATING magazine
2 1
SUCCESS STORIES © Arsonsisi
S P E C I A L ALU MINIU M
That is how the Vintage Corten finish
industrial products (Figs. 2 and 3). However,
was conceived. “Our design department
quoting the Colore Sicuro project of
worked closely with the sales department
Assovernici (the Italian association of paint
of Arsonsisi,” states Tonon Forty
producers), “there is value beyond colour”.
Marketing Manager Arianna Giuseppin.
Arsonsisi has joined Colore Sicuro to support
“Arsonsisi’s expertise and technical
the values of respect for its paints’ users,
assistance helped us a lot in this project
society, and the environment.
and they were decisive for the success of
The peculiarity of these two well-established
our Vintage collection.”
Italian companies lies precisely in their values.
The Copper, Aluminium, and Stone
Tonon Forty’s collaboration with Arsonsisi
finishes are based on coloured epoxy-
once again confirms its attention to quality,
polyester coatings, whereas the Vintage
safety, and the environment through the
Land and Vintage Corten ones are
choice of eco-friendly technologies and the
obtained through a particular treatment
protection of its operators, collaborators,
on raw radiators followed by the
and customers’ health – with maximum
application of transparent polyester
transparency.
Figure 2 and 3: Tonon Forty’s radiators during powder coating.
3 1
Touch the color with our new spectro2guide: There it is in black and white: The new spectro2guide has arrived. The revolution in color management. Upfront design. Color touchscreen. Camera preview. Auto calibration. Gloss. Fluorescence. Digital standard… www.touchthecolor.com
For further information: www.arsonsisi.com
© ALMECO
Opening photo: Bandoxaldecor™ is the widest range of anodised aluminium on the market, with 21 different finishes, 60 colours, and 8 thicknesses available.
FOCUS ON TECHNOLOGY
S P E C I A L ALU MINIU M
ALMECO: The First Zero Liquid Discharge Water Treatment Plant in the World Installed on an Anodic Oxidation Line for Aluminium Coils Alessia Venturi ipcm®
T
he zero liquid discharge (ZLD)
sectors such as the aluminium one where
is even more complicated: the amount of
technology is already commonly
the liquids present high concentrations of
surface treated per hour is far lower than
chosen to purify coating waste
this metal in the solution and where both
the surface coated by a plant with the
water, i.e. active baths and rinsing water
acid and alkaline pickling is often used. In
same production potential; on the other
from the pre-treatment phase, even in
the anodic oxidation field, this operation
hand, the concentration of pollutants
78
N. 53 - SEPTEMBER/OCTOBER 2018 - international PAINT&COATING magazine
FOCUS ON TECHNOLOGY
(acids, soda, and aluminium) found in
the first system of this kind in the world to be
active baths is up to 20 times higher. The
implemented on a coil line.
anodising process removes in fact higher
“The fact that the alkaline bath accounts
ALMECO GROUP: an ideal partner at every stage of the industrial process
amounts of aluminium from surfaces,
for 90% of the aluminium removed further
The unique expertise gained in over
although these can vary depending on the
complicates the subsequent water treatment.
fifty years of activity in aluminium
required finish.
Whereas CIE’s PUR-ALL technology already
production. An international
enabled to achieve a 50% abatement with the
organisation with units specialised
“A medium-sized aluminium coating
proper chemical-physical treatment, a much
in the different stages of the entire
plant has a painting potential of 1 ton/h,
more specific and complex technology was
industrial process. A widespread
equivalent to a surface of 300 m2/h; this
needed to treat alkaline water and reach a
presence on the global market through
material is treated with baths with a
zero liquid discharge value of 95% or more.
an extensive commercial network, and
maximum concentration of 1 to 2% (i.e.
Now, CIE owns a technology that, combined
distribution centres and services for
10-20 gr/l). An anodic oxidation line with
with its proven PUR-ALL system, allows to
strategic areas. These are the strengths
a potential of 30,000 amperes can treat
reach the total zero discharge goal even on a
that make the ALMECO GROUP one of
about 150 m /h, but the concentration
continuous flow anodic oxidation line.”
the world leaders in the production of
®
2
®
components and sheet
is 20%. Water pollution in an
materials for the lighting
anodising line is therefore
© ALMECO
of soda and acids in its baths
engineering, solar, and
20 times greater than that
decorative industries
of a coating line, but with a
(Fig. 2). Thanks to its
productivity equal to half, if not
in-depth knowledge
a third of the latter. On average,
of the mechanical and
the anodising baths present
optical characteristics
concentrations of sulphuric
of aluminium and of
acid equal to 200 gr/l and of
surface treatment
aluminium equal to 15 gr/l.
processes, as well as to
Indeed, the surface removal
constant investments in
rate (e.g. the one necessary to
plants and equipment,
produce a completely opaque
ALMECO currently has
anodic oxide) can reach 70 gr/m2,
a production capacity
with the alkaline bath accounting
of over 20 thousand
for 60 gr/m and the acid
tonnes of aluminium
bath accounting for 10 gr/m2.
and more than 3 million
Consequently, coating processes
reflectors per year.
allow for cleaning operations
Lighting has always been
2
with a flow rate of 10 l /m , 2
whereas oxidation processes call for a 200 l/m2 flow rate,” explains
its core business, from
1
the production of high reflectance anodised
Figure 1: CIE Srl general manager Franco Falcone.
CIE general manager Franco
aluminium to the design
Falcone (Fig. 1). CIE Srl designs
and construction of reflecting optics and
and builds ZLD water treatment systems, specialising precisely in the aluminium sector. It has recently installed the first ZLD water treatment plant in Europe on an anodic oxidation line for aluminium coils at the premises of ALMECO (San Giuliano Milanese, Italy), which is also
CIE Srl designs and builds ZLD water treatment systems, specialising precisely in the aluminium sector. It has recently installed the first ZLD water treatment plant in Europe on an anodic oxidation line for aluminium coils at the premises of ALMECO (San Giuliano Milanese, Italy), which is also the first system of this kind in the world to be implemented on a coil line.”
reflectors (Fig. 3). Once achieved a leading position, the Group has progressively developed more specialised skills that have led it to win a leading role in both the renewable energy market,
international PAINT&COATING magazine - SEPTEMBER/OCTOBER 2018 - N. 53
79
© ALMECO
SP ECIAL ALUMIN IUM
Thanks to its in-depth knowledge of the mechanical and optical characteristics of aluminium and of surface treatment processes, as well as to constant investments in plants and equipment, ALMECO currently has a production capacity of over 20 thousand tonnes of aluminium and more than 3 million reflectors per year. Lighting has always been its core business, from the production of high reflectance anodised aluminium to the design and construction of reflecting optics and reflectors.” ALMECO’s production organisation consists of four different units, each structured to manage the specialised process of aluminium manufacturing, depending on the treatment to which it is subjected and the application sector for which it is intended. The Italian plant in San Giuliano Milanese is the Group’s headquarters: in addition to the production of anodised aluminium for the lighting and decorative industry, it focuses on the design and production of reflectors for lighting fixtures.
Figure 2: Solar concentrators made with ALMECO ultra-bright aluminium.
for which it produces reflective and selective metal surfaces for concentrated
© ALMECO
2 1
solar power plants and solar flat plate collectors, and the decorative market. In order to meet the use requirements of aluminium in the decorative field, the Group has developed Bandoxaldecor™ (ref. Opening photo), the widest range of anodised aluminium on the market with 21 different finishes, 60 colours, and 8 different thicknesses. It can be supplied on request with two different types of adhesive, a special treatment that makes it suitable for outdoor use, or a specific primer.
Figure 3: Another application of ultra-bright aluminium are lighting reflectors.
80
3 1
N. 53 - SEPTEMBER/OCTOBER 2018 - international PAINT&COATING magazine
© ALMECO
FOCUS ON TECHNOLOGY
4 1
Figure 4: Giovanni Castelli, the operations director of the ALMECO GROUP.
Light and colour to surfaces with the anodising treatment Aluminium is subjected to a continuous anodising process to improve its reflection and gloss characteristics and protect its surface from corrosion and deterioration. Similar to an extrusion anodising process, the cycle includes brightening, anodising, colouring, and fixing phases. Brightening is the electrochemical process in which aluminium strips are immersed in a tank containing a concentrated mixture of high temperature acids and they are subjected to the action of electric current to smooth their surface in a controlled way and improve their gloss and reflection properties. During anodising, through the
The Group has developed Bandoxaldecor™, the widest range of anodised aluminium on the market with 21 different finishes, 60 colours, and 8 different thicknesses. It can be supplied on request with two different types of adhesive, a special treatment that makes it suitable for outdoor use, or a specific primer.”
SP ECIAL ALUMIN IUM
“ALMECO already had two anodic oxidation lines
ALMECO already had two anodic oxidation lines devoted to thin coils, in its San Giuliano Milanese plant. Recently, it has installed a new line able to process aluminium strips up to 3 mm thick and up to 2 metres wide with a continuous flow. This system has been devoted to the new range BandoxalproTM, designed for outdoor architectural applications. This line is highly advanced and, above all, unique.”
devoted to thin coils, in its San Giuliano Milanese plant,” says Giovanni Castelli, the operations director of the ALMECO GROUP (Fig. 4).
© ALMECO
“Recently, it has installed a new line able to process aluminium strips up to 3 mm thick and up to 2 metres wide with a continuous flow. This system has been devoted to our new range BandoxalproTM, designed for outdoor architectural applications. This line is highly advanced and, above all, unique.” “ALMECO has always focussed on environmental awareness and respect for the local community,” states Giovanni Castelli. “That is why it has decided to further invest in eco-friendliness by installing this unique water treatment plant: a zero liquid discharge system for all its process water (rinsing liquids and concentrates) that eliminates any form of discharge into sewer and external disposal of both acid and alkaline
5 1
concentrates. In addition to
Figure 5: A bird’s eye view of the ZLD water treatment system installed by CIE to guarantee total recycling of process water.
reducing its environmental impact, this system enables ALMECO not to exploit community resources such as
electrochemical process of anodic
of the product unchanged over time.
the city purifier.”
oxide deposition, brightened aluminium
Thanks to its porosity, this layer is also
“The installed system (Fig. 5) guarantees
is covered with a thin film perfectly
particularly receptive: it can be subjected
total recycling of process water as well
adherent to metal. Accurate parameter
to a colouring process by immersion
as maximum flow flexibility of recycled
adjustment ensures perfect control
in special organic baths, thus obtaining
water and conductivity constancy,” says
and consistency of the deposited
metallic shades of great aesthetic effect.
CIE general manager Franco Falcone. “CIE
oxide thickness, improving reflection
The anodising cycle ends with a high
had already supplied the Group with a few
and minimising iridescence. This
temperature fixing phase, during which
services and assistance on old systems,
transparent and very resistant layer
the pores of the anodic oxide layer
and it was chosen again by ALMECO for
protects the surface from deterioration,
close perfectly, thus ensuring maximum
its expertise. We are the most qualified
keeping the optical characteristics
compactness and corrosion resistance.
company in the aluminium sector, as well
82
N. 53 - SEPTEMBER/OCTOBER 2018 - international PAINT&COATING magazine
FOCUS ON TECHNOLOGY
ALMECO’s line operates with
as the one that has built the highest number of ZLD plants in this field, which are entirely made by us without resorting to any external supplier of auxiliary units (demineralised water, UF, RO, or evaporation systems). CIE has also developed the PUR-ALL technology, ®
ensuring the almost total elimination not only of metals but also of acids such as sulphates, fluorides, and phosphates in order to recirculate water without expensive technologies such as ultrafiltration, reverse osmosis, and sometimes even evaporation,”
a continuous flow and with frequent speed changes. Therefore, the water treatment system must be as flexible as the production line, particularly as regards rinses. Indeed, although this is a ZLD system, a variation of even 10 times the flow rate of the rinses is ensured, while guaranteeing the same quality level and without affecting the ZLD process.
© ALMECO
states Falcone.
ALMECO’s line operates with a continuous flow and with frequent speed changes. Therefore, the water treatment system must be as flexible as the production line, particularly as regards rinses. Indeed, although this is a ZLD system, a variation of even 10 times the flow rate of the rinses is ensured, while guaranteeing the same quality level and without affecting the ZLD process.”
6 1
Figure 6: The multi-exchange resin plant that treats all the rinsing water from the new oxidation line.
international PAINT&COATING magazine - SEPTEMBER/OCTOBER 2018 - N. 53
83
S P E C I A L A L UM I NI UM
CIE has developed this water treatment process for a continuous flow anodic oxidation line by implementing a technology that exploits special multi-exchange resins to recycle rinsing water and a chemical-physical purification phase for concentrates that uses the PUR-ALL® ZERO ZERO technology. This guarantees total elimination of pollutants and minimisation of the resulting liquid, which is sent to a special evaporator with half the energy consumption.”
A unique water treatment plant in the world “We have developed this water treatment process for a continuous flow anodic oxidation line by implementing a technology that exploits special multi-exchange resins to recycle rinsing water (Fig. 6) and a chemical-physical purification phase for concentrates that uses the PUR-ALL® ZERO ZERO technology. This guarantees total elimination of pollutants and minimisation of the resulting liquid, which is sent to a special evaporator (Fig. 7) with half the energy consumption,” says Franco Falcone from CIE. “The plant allows to renew the rinsing liquids with a very high flow rate, ensuring maximum water quality and a conductivity value of less than 100 microsiemens. The water leaving the chemical-physical unit is conveyed into an evaporator: the distillate generated by evaporation is recovered and used as rinsing liquid, whereas the residue (less than 2%), exclusively made of neutral sodium salts, is disposed of by an external company.” “This is an innovative system because it is the first example of total zero liquid discharge on an anodic oxidation line. CIE already had plenty of experience in the installation of plants ensuring a 50% water recovery rate (e.g. the one installed by TALEX in Abu Dhabi1) and featuring our PUR-ALL® 1
ipcm® Vol. IX, n. 47, September-October 2017, pages 44-58
FOCUS ON TECHNOLOGY
technology (based on a chemical system exclusively owned by our subsidiary MST Chemicals). In ALMECO’s plant, PUR-ALL® was used, but it is not the only technology implemented: it only deals with the purification of acid water. For alkaline water, we have added a complementary technology whose effectiveness is such as to guarantee total recycling of all process waters, thus eliminating any form of discharge or disposal,” explains Falcone. “The plant we have installed for ALMECO is exceptional: we recycle 100% of rinsing water, an outstanding result considering that the quality of coils and therefore of the treatment water must be very high. It is very difficult to deposit anodic oxide and brighten aluminium coils with such a high aesthetic homogeneity, and ALMECO’s qualitative requirements for rinses were very strict. With our technology, we have allowed the company to achieve excellent treatment results without the need for any environmental authorization in terms of water. We are now finishing the commissioning phase and the company has already expressed satisfaction with its choice.” “Since the tanks of a continuous anodic oxidation line are very large, about 25-30 m3, ALMECO should have discharged at least 20 m3/h of liquid: with our plant, they do not discharge anything,” states Franco Falcone. “The main advantages are a reduction of at least 18-19 m3/h in water
In ALMECO’s plant, PUR-ALL® was used, but it is not the only technology implemented: it only deals with the purification of acid water. For alkaline water, CIE has added a complementary technology whose effectiveness is such as to guarantee total recycling of all process waters, thus eliminating any form of discharge or disposal.”
HIGH
PERFORMANCE POWDER COATINGS
© ALMECO
SP ECIAL ALUMIN IUM
7 1
Figure 7: The evaporator for the resulting liquid of the chemical-physical treatment for final distillation.
consumption, significant management
improvement of production
both inside and outside its various
and operational cost savings, and an
processes enable the Group to
production buildings, where sensitive
ethical and environmental return in line
operate in total harmony with the
parameters and emissions are
with the company’s philosophy.”
environment. Since the 1960s,
constantly monitored. Now, thanks
the ALMECO GROUP has in fact
to the cutting-edge water treatment
initiated the search for “green”
system designed by CIE, the ALMECO
Commitment to the environment is
technologies and it has invested
GROUP is among the first and few
a fundamental value of the ALMECO
in water purification as well as
companies in the world to boast a
GROUP business philosophy. Respect
fume extraction and abatement to
total zero liquid discharge plant on
for current standards and continuous
minimise environmental impact,
an anodic oxidation line.
ALMECO: A green company
86
N. 53 - SEPTEMBER/OCTOBER 2018 - international PAINT&COATING magazine
Every surface has its own individual structure!
Look forward to getting the optimum solution for the chemical reďŹ nement of metal surfaces.
We have been committed to the development, manufacture and GLVWULEXWLRQ RI FKHPLFDO SURGXFWV DQG SURFHVVHV IRU UHĂ&#x20AC;QLQJ metal surfaces for more than 40 years.
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Alufinish GmbH & Co. KG 2WWR :ROII 6WUDÂ&#x2030;H Â&#x2021; ' $QGHUQDFK 7HO
We build on trust!
E-Mail: info@alufinish.de Â&#x2021; www.alufinish.de
SUCCESS STORIES
S P E C I A L ALU MINIU M
© Framery
Framery in the Pursuit of Happiness with Teknos’ INFRALIT PE 8317-10 Powder Coating firm relied on Teknos, another Finnish company specialising in the production of powder coatings. “We have never disappointed our customers’ expectations, and this was no exception,” says Teknos Sales Engineer Tero Lahti (Fig. 2). It was certainly love at first sight for the “Framerians”, who immediately found the right coating during one very brief meeting with Tero Lahti: INFRALIT PE 8317-10.
INFRALIT PE 8317-10 It is a matte powder coating based on a Soft Touch polyester resin, available in 16 different colours and suitable for finishing metal objects that require a certain weathering resistance and the
1
Figure 1: Framery phonebooths and meeting pods are mainly required in open-space offices.
heat or ultraviolet light. The powder is polymerised at high temperatures and it
S
According to a study done by the
forms a protective film with good
are quickly spreading. Framery, a
University of Sydney, more than 50% of
anti-corrosion properties.
Finnish leader in the production and
people sharing their workspace claimed
that doubled its turnover in 2017, is an
that background
excellent example of creativity, innovation,
noises, the lack of
and courage. Its functional products boast
privacy, and the
attractive design as well as metal surfaces
consequent reduction
protected and enhanced by high-tech
in efficiency are the
powder coatings. For years, open space
main problems.
offices have been considered a trend
Framery’s founders
conceived to offer a break during working
have had the same
days spent in small individual offices,
experience: that
improve relations between colleagues,
is how the idea
stimulate the sharing of ideas and
of designing a
teamwork, and optimise spaces; however,
soundproof pods
they now start showing their negative
was born (Fig. 1).
aspects.
For its finishes, the
N. 53 - SEPTEMBER/OCTOBER 2018 - international PAINT&COATING magazine
© Teknos
oundproofing solutions for offices
development of soundproofing solutions
88
ability not to yellow due to exposure to
2 1
Figure 2: Teknos Sales Engineer Tero Lahti.
SUCCESS STORIES © Framery
S P E C I A L ALU MINIU M
ensures higher profits. Being happy at work, therefore, is not just a personal, but also corporate and financial matter. That is why Framery, which has always based its company policy on employee welfare, claims that “the production of soundproof booths and meeting pods is just one of many possible ways we have available to spread happiness in the workplace. By finding the right solution for us, Teknos has become part of one of today’s most exciting success stories.” For further information:
3 1
Figure 3 and 4: Framery’s functional products boast attractive design as well as metal surfaces protected and enhanced by the matte Soft Touch INFRALIT powder coating.
© Framery
www.teknos.com
The metal surfaces of the soundproof booths designed by Framery have therefore been coated and protected by this advanced powder, thus combining functionality with attractive and modern design (Figs. 3 and 4).
Happiness and work: a possible combination Nowadays, more and more companies consider their employees’ happiness a priority. Work can certainly help to make workers happy, but at the same time happiness affects productivity and
4 1
End-to-end solutions – from body shop to coating and final assembly. www.eisenmann.com
INNOVATIONS: PRESENT&FUTURE
S P E C I A L ALU MINIU M
Qualicoat & Qualanod: latest eco-friendly developments for aluminium pre-treatment Dr. Alberto Abad, Alvarez Schaer S.A. Paterna – Valencia (Span)
alsan@alsan.es
A
s with most metals, precise preparation
metal surface. Among these solutions, we
of the aluminium surface is essential
can find ECORINSE LD, a product for the
Qualicoat A-127. Anodic pre-treatment with guarantees
to ensure the adherence of the
improvement of the adhesion of the organic
It is well known that hexavalent
coatings applied subsequently, as well as their
coatings on the anodic layer and MEDSEAL®
chromium compounds are being under
durability and optimum protection against
and FRIOFIX®ECOLINE innovative and green
observation for years. Currently the
corrosion.
sealing products free of toxic metals.
European Commission is still deciding © Alsan
Anodizing, like all industrial surface treatment processes,
on CTAC (Chromium Trioxide Authorization
involves a series of stages to
Consortium) Application
ensure its technical features and
for authorization which
finishes quality and these stages
includes the aluminium
depend on the final purpose
coating sector.
of the anodic layer. Anodic
Chrome use is
layers of 10-25 μm are usually
maintained by means of
employed as a decorative finish
prorogations requested
for aluminium which provides
by various sectors under
excellent wear and corrosion
the fear of whether
resistance.
or not, “alternative
In order for the porous anodic
products to Chromium
film to be perfectly protected against corrosion, it is necessary to seal the anodic layer. In this way, the metal loses its absorbing power, and remains protected
1
Figure 1: Filiform corrosion results obtained in the project BRITE-EURAM at the Italian site (Venice) at different exposition times, with different pre-treatments and using polyester powder as coatings.
(VI)” are able to protect aluminium in the most hostile environments and prevent corrosion, especially filiform
from aggressive exposure
corrosion.
environments.
However, previous
Besides, thin anodic layers of 3-8 μm can also be used as a superior pre-treatment for organic coatings which improves corrosion protection, especially against filiform corrosion. Alsan offers a wide catalogue of products that allows covering each and every one of the pretreatment stages guaranteeing an excellent preparation of the
90
ECORINSE LD is a non-toxic product, which allows preparing the anodic layer for the application of organic coating (liquid and powder coatings). ECORINSE LD works at room temperature in only a few seconds, getting rid of the standard hot rinse and reducing energy costs while guarantees dry and wet adhesion. The use of Ecorinse LD as final rinse for PREOX, provides under the QUALICOAT guidelines, a solution to the problem of the wet adhesion of powder coating with PREOX.”
N. 53 - SEPTEMBER/OCTOBER 2018 - international PAINT&COATING magazine
studies have shown that both, alternative products and Chromium Trioxide, are not effective enough to prevent filiform corrosion when various factors combine, such as an industrial climate or marine environment that is strongly aggressive to aluminium.
© Alsan
INNOVATIONS: PRESENT&FUTURE
The results of the
test correctly. Nevertheless, in
European project
the light of the corrosion results,
BRITE-EURAM II: CRAF 1004-91:
both, the acetic salt spray and
“Development of new systems
the filiform corrosion tests, really
to prevent filiform corrosion”
presented acceptable outcomes.
have already shown that only
Knowing this problem,
profiles coated with anodic base
ALSAN’s R&D department
as pre-treatment, were effective
decided to develop a simple
to give a very good resistance to
solution, following its philosophy
corrosion, even at low anodizing
of providing sustainable and
thickness, when compared with
environmentally friendly
other pre-treated material even
products and processes. This is
with Cr (VI) and with different alternative systems (Fig. 1). Due to these reasons, since 2014 a new boost has been given to the “anodic pre-treatment or PREOX” within the QUALICOAT
how the ECORINSE LD product
2 1
emerged. ECORINSE LD is a
Figure 2: Percentage of tested powder paints that show satisfactory results according to the rinsing temperature used. Anodizing conditions: 22 ºC; 1.5 A / dm2; 10 minutes, 5 μm. Alloy 6063. (Source: AluminiunSan nr. 12).
the application of organic coating (liquid and powder coatings).
© Alsan
© Alsan
“WG Preanodizing”
preparing the anodic layer for
ECORINSE LD works at room
quality label, resulting in the working group
non-toxic product, which allows
temperature in only a few seconds, getting
within the technical
rid of the standard hot
committee. The
rinse and reducing
matter is again, to
energy costs while
determine the most
guarantees dry and
effective way to
wet adhesion. The
perform this “PREOX”
use of Ecorinse LD as
process to guarantee
final rinse for PREOX,
all Qualicoat test
provides under the
requirements when
QUALICOAT guidelines,
anodizing is applied
a solution to the
as pre-treatment
problem of the wet
before powder
adhesion of powder
coating. In particular,
coating with PREOX.
the Guidelines
Since March 2017,
must be updated,
Ecorinse LD, with
clearly defining the application conditions to ensure final quality. In view of these
3 1
Figure 3: Approval certificate of Ecorinse LD.
studies and the
the quality label No
4 1
A-127 (Fig. 3),
Figure 4: Pre-treatment cycle used in the homologation process.
is the first and only product used as final rinse for
compilation of technical information, carried
the acid residues from the pores and prepare
PREOX approved by Qualicoat. Figure 4
out by the WG, it has been noted that more
the samples to pass the crosshatch test
shows the pre-treatment cycle used in the
than 50% of the powder paints did not pass
satisfactorily after 2 h in boiling water (Fig. 2).
homologation process.
the wet adhesion test. This occurs when the
Many proposals have been made on the most
Table 1 and 2 show the results obtained
washing step was carried out after the PREOX,
suitable temperature and the appropriate
with Ecorinse LD in acetic acid salt spray
as stated in the Guidelines, under 60ºC.
rinsing times to pass the wet adhesion test
and filiform corrosion tests during the
Moreover, only temperatures around 90 ºC
with the PREOX, due to the enormous difficulty
approval process. As it can be seen in these
in the subsequent rinse are able to remove
that this system presents to comply with this
tables, besides excellent wet adhesion the
international PAINT&COATING magazine - SEPTEMBER/OCTOBER 2018 - N. 53
91
SP ECIAL ALUMIN IUM
Table 1. Acetic acid salt spray results of the approval process of Ecorinse LD. TEST: Acetic Acid Salt Spray Resistance UNE-EN ISO 9227:2012 PROCEDURE: Acetic Acid Salt Spray Resistance UNE-EN ISO 9227:2012 Codification
AVERAGE WEIGHT (μm)
DEVIATION (μm)
316-16-25
110
316-16-26 316-16-27
EVALUATION DATA CORROSION FACTOR
MAX. LENGTH (mm)
3w
0,00
0,00
0
107
9
0,00
0,00
0
73
8
0,00
0,00
0
316-16-28
110
5
0,00
0,00
0
316-16-29
105
3
0,00
0,00
0
316-16-30
117
5
0,00
0,00
0
Table 2. Filiform results of the approval process of Ecorinse LD. TEST: Filiform Corrosion Resistance. Qualicoat Specifications (Ed. 14)+ Resolution Nº. 10/TC 5.11.14 PROCEDURE: DCT-PE-223 (Ed. 2)
FORMAT: RDCT-PE-323_01 (Ed. 0) HORIZONTAL
DEV. (μm)
316-16-49
78
6
316-16-50
96
9
0,0
0,0
0
0,0
0,0
0
0,0
0,0
0
0,0
0,0
0
316-16-51
113
6
0,0
0,0
0
0,0
0,0
0
0,0
0,0
0
0,0
0,0
0
316-16-52
88
5
0,0
0,0
0
0,0
0,0
0
0,0
0,0
0
0,0
0,0
0
316-16-53
94
2
0,0
0,0
0
0,0
0,0
0
0,0
0,0
0
0,0
0,0
0
316-16-54
112
5
0,0
0,0
0
0,0
0,0
0
0,0
0,0
0
0,0
0,0
0
© Alsan
VERTICAL AVERAGE WEIGHT (μm)
implemented
Codification
RIGHT
LEFT
RIGHT
LEFT
L
M
F/10 cm
L
M
F/10 cm
L
M
F/10 cm
L
M
F/10 cm
0,0
0,0
0
0,0
0,0
0
0,0
0,0
0
0,0
0,0
0
5 1
Figure 5: Lay-out of the FOX pre-treatment line using Ecorinse LD.
ECORINSE LD, in
Sustainable alternatives to classic sealings
one vertical powder
Hot Sealing and Impregnation Sealing with
coating line with Flash
Nickel salts, also known as cold sealing, have
Anodizing in Poland.
been for decades the most frequently used
Ecorinse LD was used
sealing processes in sulfuric acid anodizing
as final rinse, after the
(type II). However, none of the above can be
flash anodizing and
considered Ecofriendly due to the high-energy
rinsing steps (Fig. 5).
consumption in the case of hot sealing, or to
During the first days of
the use of toxic nickel salts in cold sealing.
implementation over 40
For this reason, Alsan has been developing
different coatings were
new and sustainable sealing processes as the
tested in dry and wet
green alternative to classical sealing.
adhesion. All the results
MEDSEAL® 08 (QND-007) has been
were satisfactory.
successfully implemented for over a decade.
In conclusion, with the
It can be considered as catalyzed hot sealing.
combination of PREOX
MEDSEAL® 08 includes light metals and
combination of PREOX and Ecorinse LD
pre-treatment and ECORINSE LD, ALSAN brings
organic additives that allow a reduction
gives perfect results in the corrosion tests
to the market the first approved and definitive
of the temperature or the sealing time
(no corrosion was observed in both tests).
solution to solve the problem of filiform
in comparison to the classic hot sealing
Last August ALSAN has successfully
corrosion.
process.
92
N. 53 - SEPTEMBER/OCTOBER 2018 - international PAINT&COATING magazine
INNOVATIONS: PRESENT&FUTURE
© Alsan
HAI UN IMPIANTO DI MOVIMENTAZIONE A CATENA? TRAS-MEC è la prima azienda che mette in sicurezza il tuo impianto e ti garantisce da contratto una produzione senza fermi improvvisi Non dovrai più lavorare accontentandoti HM YRE WSPY^MSRI GLI RSR XM WSHHMWǻ Progettazione: Mandaci il tuo progetto e studieremo il tuo trasportatore così che risponda alle caratteristiche che rendono il tuo ciclo produttivo unico.
6 1
Non avrai più dubbi sulla produzione del tuo materiale
Figure 6: Evolution of weight loss and times at 85 and 95 ºC, with and without MEDSEAL® 08.
Produzione: Costruiremo il tuo trasportatore secondo metodi standardizzati sviluppati nel tempo per farti avere un impianto performante.
Figure 6 shows that working with MEDSEAL® 08 can decrease the temperature of hot sealing to 85 ºC and get good sealing quality in only 2 minutes/micron. If we do not add MEDSEAL® 08 we would need about 5 minutes per micron to get good sealing quality at 85 ºC. At 95
Non dovrai più preoccuparti del montaggio del convogliatore
degrees, we obtain optimum results in only 1 minute per micron, but three minutes per micron are needed in the absence of MEDSEAL® 08.
Installazione: Con quest’opzione, avrai il tuo convogliatore chiavi in mano montato da un team di tecnici montatori esperti.
Therefore, in both scenarios, sealing is three times faster when we add MEDSEAL® 08. Thus, with MEDSEAL® 08 we can choose between reducing time or temperature. In both cases, we save energy, reduce costs and extend
Non avrai più blocchi di produzione
the sealing bath life, since MEDSEAL 08 sealing is less sensitive to
Servizio di manutenzione: Con il nostro servizio di manutenzione avrai un’assistenza periodica e continuativa che ti eviterà fermi non programmati, perdite di produzione impreviste.
®
pollutants. Besides, by decreasing the temperature, we also reduce the amount of vapor, which can cause problems with the automatic crane. On the other hand, if we shorten the time, we can reduce the size of the sealing bath or the number of sealing positions, saving costs in
© Alsan
maintenance. We can also keep the same number of sealing positions
TRAS-MEC è la prima azienda che ha integrato tutti i processi in un unico sistema industriale, per farti lavorare nel modo più performante senza più fermi di produzione che non sono stati programmati. Se vuoi avere più informazioni sul tuo trasportatore scrivi a customercare@tras-mec.it Riceverai in regalo il report “I 5 errori da evitare per mettere in sicurezza il tuo impianto nto ed eliminare per sempre il rischio dei fermi improvvisi” vvisi”
7 1
Figure 7: Energy consumption in the sealing process working with and without MEDSEAL® 08.
REPORT IIN N RE REGALO! REGALO EGALO! LO
© Alsan
SP ECIAL ALUMIN IUM
Electron Microscopy, with and without MEDSEAL® 08 at 85 ºC (Fig. 8). With MEDSEAL® 08 the pore widening is very fast: after only 5 minutes the pore size has increased from 12 to 14 nm. On the other hand, in the absence of MEDSEAL® 08, pore widening is extremely slow, especially at the beginning. It takes 45 minutes to increase the pore size to 14 nm. If we compare the necessary time to get from 12 to 14 nm, it takes only five minutes with MEDSEAL® 08 and 45 minutes without MEDSEAL® 08. Therefore, by adding the catalyst we speed the process up about ten times in the initial stage. However, if we consider the complete process, the catalyzed sealing is only 3-4 times faster overall. Hence, the catalyst plays a very important role in the initial dissolution of the alumina. More and more frequently, aluminum anodized and sealed with
8 1
nickel salts is not accepted, especially in certain countries and
Figure 8: Morphology of the anodic layer at different times during the sealing process working and without MEDSEAL® 08.
sectors, due to the presence of nickel in the anodic coating or because of the typically greenish appearance that it presents. The use of MEDSEAL® 08 in anodizing lines that are currently using
and increase production.
cold sealing sometimes involves
However, the most evident advantage
changes to adapt the anodizing
of adding a catalyst is to save energy. The energy consumption of hot sealing mainly depends on the surface and the temperature of the bath. Figure 7 shows the overall energy consumption during the process. When the temperature is reduced to 85 ºC, about 25 % of the energy can be also saved. But by working at 95 ºC with MEDSEAL 08, we can ®
also decrease the sealing time to 1
Alsan has been developing new and sustainable sealing processes as the green alternative to classical sealing. MEDSEAL® 08 (QND-007) has been successfully implemented for over a decade. It can be considered as catalyzed hot sealing. MEDSEAL® 08 includes light metals and organic additives that allow a reduction of the temperature or the sealing time in comparison to the classic hot sealing process.”
line to the new sealing process. In response to this problem, Alsan has developed FRIOFIX® ECOLINE, a new nickel-free cold sealing process. Since last June, FRIOFIX® ECOLINE (QND-011) is the first and only free of nickel cold-sealing product approved by the quality label QUALANOD. This process ensures very similar working conditions to those used with the
a reduction in the number of sealing
classic nickel salts, but without
positions. This way, the consumption is 50 % lower compared to the classic hot sealing, and
© Alsan
minute per micron and this leads to
28 % lower than working at 85 ºC and 3 minutes per micron. According to the literature, the mechanism of hot sealing is mainly divided into two different stages: in the first one, the pore walls dissolve and that explains pore widening, while in the second stage the aluminium from alumina dissolution precipitates as hydrated alumina. The volume of hydrated alumina is higher than the volume of anhydrous alumina and pores get blocked. In order to find out how MEDSEAL® 08 accelerates the sealing process, Alsan studied the morphology of the anodic layer at different times during the sealing process by Scanning
94
9 1
Figure 9: Appearance of hot sealed specimens (above) and sealed with FRIOFIX® ECOLINE (QND-011) (below) after 1000 hours in acetic salt spray.
N. 53 - SEPTEMBER/OCTOBER 2018 - international PAINT&COATING magazine
INNOVATIONS: PRESENT&FUTURE
Table 3. Comparative results with the reference hot sealing / hydration obtained during the approval process from the product FRIOFIX® ECOLINE (QND-011).
In order to find out how MEDSEAL® 08 accelerates the sealing process, Alsan studied the morphology of the anodic layer at different times during the sealing process by Scanning Electron Microscopy, with and without MEDSEAL® 08 at 85 ºC. With MEDSEAL® 08 the pore widening is very fast: after only 5 minutes the pore size has increased from 12 to 14 nm.”
CLARK TEST (M)
LOSS WEIGHT (mg/dm²)
DYE DROP
ADMITTANCE (μS)
Hydration Ecoline
Hydration Ecoline
Hydration Ecoline
Hydration Ecoline
15 μm-Bronze-1
0,7
0,8
8,6
7,9
---
---
17,1
7,7
15 μm-Bronze-2
0,4
0,6
8,9
7,7
---
---
25,7
8,1
15 μm-Bronze-3
0,6
0,4
9,4
7,8
---
---
37,9
8,6
20 μm-Bronze-1
1,3
0,3
9,1
8,9
---
---
24,4
11,9
20 μm-Bronze-2
1,8
0,2
8,1
9,9
---
---
45,3
11,8
20 μm-Bronze-3
0,5
0,8
8,7
9,9
---
---
36,3
9,2
15 μm-Natural-1
0,9
0,5
8,4
10,6
0-1
0
16,3
7
15 μm-Natural-2
0,4
0,6
8,9
9,2
1
0
23,2
6,6
15 μm-Natural-3
1
0,7
10,1
10,4
1
0
14,5
6,4
20 μm-Natural-1
0,3
0,6
11,4
10,4
0-1
0
14,2
7,1
20 μm-Natural-2
0,9
0,6
10,9
11,8
0
0
34,5
7,8
the disadvantages created by their toxicity.
20 μm-Natural-3
0,5
1,1
10,3
10,8
0
0
16,6
7,7
Therefore, it is now possible to replace nickel
Average
0,8
0,6
9,4
9,6
---
---
25,5
8,3
salts with a new process free of toxicity, without needing to make changes in your current anodizing line.
Once Alsan received the approval
range of finishes: polishing, brushing,
The results of the homologation process,
from QUALANOD, the industrial
electrolytic colouring, organic colouring,
where FRIOFIX® Ecoline was compared with a
implementation process started.
and chemical brightening. Tecanal
reference hot sealing product, are shown in
Last December, the process was
used to work with two baths of cold
Table 3. As we can see, the weight loss values
successfully incorporated in the
sealing with nickel; one of them with a
obtained were very low in both cases, below
Spanish company TECANAL, mainly
large amount of additive to avoid the
10 mg / dm on average. Regarding the dye
dedicated to decorative anodizing
typical appearance of nickel salts. In
drop test, by using FRIOFIX® Ecoline product,
and which is working with a wide
this sealing bath, the nickel salts were
the absorption power loss is greater than that shown with the reference hot sealing.
© Alsan
2
At the Clark’s abrasion test, thickness losses from anodic coating were on average lower with FRIOFIX® ECOLINE, probably because the hydration sealing at higher temperatures has a little negative effect on the abrasion resistance of the anodic coating. Regarding the admittance test, and opposite to what happens with the sealing by impregnation with nickel salts, the conductivity of the anodic layers sealed with FRIOFIX® ECOLINE is extremely low, and clearly below the values measured in the reference hot sealing. Finally, at the accelerated corrosion test, the presence of corrosion pits after 1000 hours of exposure was not observed in any case, only iridescences and small spots of similar size and extension appeared in both types of sealing (Fig. 9).
10 1
Figure 10: Scheme of the pre-treatment baths after the anodizing bath in Tecanal’s line using FRIOFIX® ECOLINE.
international PAINT&COATING magazine - SEPTEMBER/OCTOBER 2018 - N. 53
95
© Alsan
© Alsan
SP ECIAL ALUMIN IUM
11 1
12 1
Figure 11: Scheme of the pre-treatment baths after the anodizing bath in Anodicolor´s line using FRIOFIX® ECOLINE.
Figure 12: Evolution of loss weight with production in different colors using FRIOFIX® ECOLINE in Anodicolor.
replaced by FRIOFIX® ECOLINE
fields such as the cosmetic or
(Fig. 10). The behavior of the nickel-free sealing was excellent for all the aforementioned finishes, with no influence of the sealing on the final appearance of the material. It is worth mentioning that the touch in the sealed material, which is especially important in the decorative sector, cosmetic and pharmaceutical anodizing, turned out to be smoother in the material sealed with FRIOFIX
®
FRIOFIX® ECOLINE (QND-011) is the first and only free of nickel cold-sealing product approved by the quality label QUALANOD. This process ensures very similar working conditions to those used with the classic nickel salts, but without the disadvantages created by their toxicity. Therefore, it is now possible to replace nickel salts with a new process free of toxicity, without needing to make changes in your current anodizing line.”
pharmaceutical market where the pressure to avoid nickel salts is even higher. More recently, in April Alsan has introduced FRIOFIX® ECOLINE at the Spanish company ANODICOLOR, mainly dedicated to architectural anodizing (Fig. 11). ANODICOLOR has QUALANOD quality label and works with ageing at 60-65 ºC after the cold sealing process. As it can be seen in Figure 12, the
ECOLINE.
© Alsan
The sealing quality was checked continuously
sealing quality remained excellent as the bath
by means of the dye
was ageing. Besides, the
drop test, following the
final appearance of the
QUALANOD guidelines.
material was very good
Although the material was
(Fig. 13), in all finishes,
not aged in hot water, the
as long as a good
results of dye drop and
temperature control
weight loss, 24 hours after
and immersion times
the sealing process, were
were carried out.
satisfactory.
FRIOFIX® ECOLINE
The results obtained at
(QND-011), approved
the industrial test carried
by the quality label
out in TECANAL show the
QUALANOD and with
great potential of this new
proven results at
process for the sealing of anodic layer not only in the industrial or building sector, but also in other
96
13 1
Figure 13: Pictures of aluminium profiles sealed with FRIOFIX® ECOLINE in Anodicolor.
N. 53 - SEPTEMBER/OCTOBER 2018 - international PAINT&COATING magazine
industrial level, brings to the market the first and only free of nickel cold-sealing product.
One partner for your automated paint applications Preprogrammed centralized controls Easy integration Modular build User friendly interface (HMI)
DISCOVER OUR SOLUTIONS
graco.com/ďŹ nishing
© Luxe Coat
Opening photo: One of the stadium of Russia 2018 FIFA World Cup was built using prepainted aluminium by Luxe Coat.
FOCUS ON TECHNOLOGY
S P E C I A L ALU MINIU M
Advanced Technology, Process Renewal, and Industrial Research on Pre-Treatment: Luxe Coat’s Strategy for Its Business Relaunch Barbara Pennati ipcm®
I
n continuous coating processes, e.g. coil
to competitiveness. Luxe Coat Srl (Bazzano,
found in Italy, and especially in L’Aquila, the
coating operations, it is crucial to keep
L’Aquila, Italy) specialises in the continuous
ideal solution to increase production capacity
quality constant and ensure that the plant
coating of aluminium alloys. The company was
and expand into the European market.
is versatile enough to meet the market’s needs
founded by Luxe Perfil, a Valencian company
“Luxe Coat’s current corporate structure
without sacrificing high productivity, crucial
operating in the aluminium market, which
was created in March 2016, but many of
98
N. 53 - SEPTEMBER/OCTOBER 2018 - international PAINT&COATING magazine
FOCUS ON TECHNOLOGY
Innovative pre-treatment
its employees have over twenty years of experience and know-how,” explains Alfredo Calvano, the Technical and Plant Manager of Luxe Coat (Fig. 1). “Luxe Perfil’s interest has enabled the reactivation of two coil coating lines and to approach an ever-booming market thanks to targeted investments. This has allowed Luxe Coat to become one of the major players in the aluminium coil coating sector (ref. Opening photo) in relatively little time.” The first step for this business relaunch was the revamping of the coating systems, with the aim of making them as flexible as possible and increasing their production capacity. Two painting systems in L’Aquila (Abruzzo) have been acquired. Both lines had been stopped during the financial crisis and a turnover of different companies. Through a targeted intervention, not only have they been put back into operation, but also modernised and modified to meet the commercial and production goals set by Luxe Perfil,” says
In continuous coating processes, e.g. coil coating operations, it is crucial to keep quality constant and ensure that the plant is versatile enough to meet the market’s needs without sacrificing high productivity, crucial to competitiveness. Luxe Coat Srl (Bazzano, L’Aquila, Italy) specialises in the continuous coating of aluminium alloys. The company was founded by Luxe Perfil, a Valencian company operating in the aluminium market, which found in Italy, and especially in L’Aquila, the ideal solution to increase production capacity and expand into the European market.”
The pre-treatment stage employs chromefree acids and it is the same on both plants. “The chrome-free products used are Qualicoat approved. In the first phases of the process, the product is applied by spray and the interlocking tanks have a capacity of 10 m3,” explains DN Chemicals Sales Manager André Bernasconi. “The decision to adopt an acid product instead of an alkaline one was based on the technical experience of Luxe Coat, which found acid products ensured greater cleaning efficiency and better paint adhesion.” Thanks to the arrangement of the system, which includes 7 tanks devoted to pre-treatment, Luxe Coat and DN Chemicals were able to experiment and test different types of products without slowing down the coating process (Fig. 4). “Over the year, we have conducted a series of industrial tests to analyse and select the best products and © ipcm ®
Calvano. “Luxe Coat now has two continuous flow coating
application methods for an optimal preparation of coils
plants. The first one applies
without compromising their
liquid products and it is able
mechanical properties. After
to treat metal strips from 0.25
the application of various
up to 1.5 mm in thickness (Fig.
products on different alloys
2). The second one is the old
and at different speeds, and
machine: it was one of the first
after the performance of
continuous powder coating
mechanical tests such as
systems, dating back to 1989;
multiple bending and impact
we transformed into a unique
tests, data were collected
hybrid plant, able to coat coils
and analysed to see if it
up to 3.05 mm in thickness
was possible to apply the
with both powder and liquid
final conversion product
products or with countless combinations of them (Fig. 3).” The investment also involved updating the pre-treatment
by nebulisation rather than
1
by sprinkling, as it is done
Figure 1: From left to right: DN Chemicals Sales Manager André Bernasconi and Luxe Coat Technical and Plant Manager Alfredo Calvano.
phase. This was performed by
today,” says Bernasconi. “We then installed prototypes of spraying bars on both
DN Chemicals, a Milan-based
new application method that could ensure
company specialising in chemical products
greater treatment uniformity and, therefore,
fine-tuning to proceed to the final installation
for the treatment of metal surfaces. “We have
improved paint adhesion.” Together with DN
(Fig. 5).”
collaborated with DN Chemicals to identify
Chemicals, Luxe Coat conducted a series of
“These tests have ensured several benefits,
the pre-treatment process that best suited
industrial tests to assess the effectiveness of
especially in terms of quality consistency.
our needs and the different configuration
spraying bars, until then never implemented
The coil surface is in fact converted in a
of our systems,” explains Alfredo Calvano.
on a coil coating system, for the application
uniform way and the conversion layer was
“Above all, however, we aimed at developing a
of the no-rinse conversion product.
homogeneous regardless of speed (Fig. 6).
systems, which we are now
international PAINT&COATING magazine - SEPTEMBER/OCTOBER 2018 - N. 53
99
© ipcm ®
© ipcm ®
SP ECIAL ALUMIN IUM
2 1
3 1
Figure 2: The liquid coating system, able to treat metal strips from 0.25 up to 1.5 mm in thickness.
Figure 3: The hybrid plant can coat coils up to 3.05 mm in thickness with both powder and liquid products.
The only difference recorded was
competitive delivery times.”
meeting the most diverse specifications,”
determined by the type of aluminium
“With our expansion on foreign markets,
says Calvano. “Finally, we aim at helping
alloy, as different alloys have different
such the US, Canadian, and German
medium-small producers grow, since they
reactivity values and, therefore, different
ones, this need has increasingly become
are more receptive to market innovations
final conversion weights,” states Bernasconi.
stringent. In Germany, for example, the
and, therefore, they need a supplier
“Another advantage ensured by the
motorway barrier specifications require
that is equally capable of renewing
spraying bars was the substantial reduction
an aluminium thickness of not less than
itself to keep up with technological
of a problem arising in any process that
3.02 mm. This is one of the reasons that
developments.”
applies chrome-free products, that is,
led us to rethink our plants with the aim of
All these reasons led to a renewal of the production process to include
the nebulised product is always fresh, thus
two coating plants equipped with
© ipcm ®
sensitivity to dragged pollutants. Indeed, eliminating pollution. Finally, nebulisation
accumulators at both the entrance and
significantly reduces costs, because it
exit, which allow to continuously coat
uses much less product than spraying
without ever stopping the system, not
processes. At least 40% of the cost of the
even during the colour change or metal
conversion product is saved each year.”
cutting phase at the end of the process
In July, the last test was concluded to
(Fig. 7). “The liquid coating system, which
check the functionality of the system to
handles thicknesses between 0.25
be implemented with the final installation
and 1.5 mm, can treat 500/600 metres
stage.
of aluminium at a time. The hybrid system, on the other hand, was
Rethinking the production process
upgraded to treat coils up to 3.05 mm in thickness and can continuously apply
“Luxe Coat’s customers belong mainly to
both liquids and powders. This allows us
three categories: distributors, installers
to obtain various coating combinations
in the architecture sector, and panel
by simply activating or deactivating the
installation experts (e.g. honeycombs for
booths and ovens. Another peculiarity
the naval sector),” says Calvano. “This variety
of these plants, finally, is the ability to
allows us to be present in various industrial fields but, at the same time, it forces us to offer maximum production flexibility and
100
4 1
Figure 4: The pre-treatment tunnel.
N. 53 - SEPTEMBER/OCTOBER 2018 - international PAINT&COATING magazine
simultaneously apply more than one layer of paint on each side in one coat,” explains Calvano.
Top Quality Coil coatings Since 1978 coil coatings for building, industry, and packaging for
Aluminium closures
for for
TAB stock
Indoor
for for
Valve caps
Food containers
for
Pharma caps
• Antifinger for stainless steel • High gloss PE coating • Laminated system
for
Outdoor • Anti-skid coating • Copper imitation • PE coating • PUR/PA cycle • PVdF cycle • Wood effect • Wrinkled coating
Innovative coil coatings Worldwide market presence High performance paints and inks Salchi Metalcoat Srl Viale dell’Industria 3/A-3/B - 20875 Burago di Molgora (MB) ITALY Ph. +39 039 6251824 Fax +39 039 6251829 E mail: info@salchirh.it - www.salchimetalcoat.com
The hybrid system is vertical and it includes liquid application booths and
© ipcm ®
© ipcm ®
SP ECIAL ALUMIN IUM
two powder coating booths (Fig. 11). All the booths and their related ovens can be activated according to production needs: in this way, Luxe Coat has the ability to apply double layers and mixed powder + liquid systems. “This type of system is very versatile – and versatility is one of Luxe Coat’s distinguishing features,” states Alfredo Calvano. “However, this process can hide pitfalls. Therefore, it requires special measures and process control options. Continuous
© ipcm ®
powder coating is a very difficult process
5 1
7 1
Figure 5: Prototypes of spraying bars have been installed on the final part of the pre-treatment tunnel.
Figure 7: Accumulators at both the entrance and exit allow to continuously coat without ever stopping the system.
The coating lines
thanks to the air blades. This also enables
The liquid coating system performs
to control thicknesses and to avoid any
a wet-on-wet application with the
quality problems during press-bending of
first coating head, which applies
painted aluminium (Fig. 12).”
the product simultaneously on two metre long oven with an air drying
A sustainable, 4.0-oriented future
segment and a cooling segment that
“Experience has taught us that the
uses demineralised water to bring the
control of the production process
metal to a temperature of 30 degrees.
affects the final quality of workpieces.
sides (Fig. 8). This is followed by a 15
Coming out of the cooling tunnel, the coil goes back into the same booth, where the second coating head applies the coloured or special effect layer, e.g. copper-like or wood-like,
6 1
Figure 6: A coated coil exiting the curing oven and passing through the quality control area.
through photoengraved rolls (Fig. 9).
DN Chemicals turned out to be a partner that shares this approach and is therefore able to develop solutions to meet such need, thus enabling us to give more guarantees to our customers. We have had the chance to
The plant also features a second
to control, as the guns’ mechanical
test different pre-treatment chemicals,
booth equipped with a coating head
movement and overspray can cause
but DN Chemicals’ technology offered
able to apply 20 to 25 microns per
pollution on the uncoated side.
the soundest solutions, in addition
side. After curing, the coil undergoes
Luxe Coat solved this problem by
to a fast and professional assistance
a final check to identify any surface
installing air blades to prevent excess
service. They were able to offer us
defects. The accumulator at the exit
powder from falling on the coil’s
a versatile, advanced, and unique
of the system allows to keep the plant
underside and by applying a liquid back
process, which will help improve
working even when cutting the metal
coat on surfaces that are clean and free
Luxe Coat’s product quality even
strip (Fig. 10).
from any powder residues precisely
further,” says Alfredo Calvano.
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N. 53 - SEPTEMBER/OCTOBER 2018 - international PAINT&COATING magazine
* patent pending
© ipcm ®
FOCUS ON TECHNOLOGY
8 1
Figure 8: A coating head with liquid products.
The pre-treatment stage employs chrome-free acids and it is the same on both plants. The chrome-free products used are Qualicoat approved. In the first phases of the process, the product is applied by spray and the interlocking tanks have a capacity of 10 m3. The decision to adopt an acid product instead of an alkaline one was based on the technical experience of Luxe Coat, which found acid products ensured greater cleaning efficiency and better paint adhesion.”
Light on rejects Light on waste Bright on application The must-have accessory for the Encore manual spray gun range
The Encore® nLighten™ LED Kit* Reduce or eliminate rejects or rework Effectively highlight and fix light powder areas on surfaces, deep recesses and cavities – on the fly. Reduce material waste Optimum light levels enable precisely targeted powder
© ipcm ®
application, to reduce waste and save on material costs. Increase efficiency This all-in-one application and inspection tool gives every operator the power to both spray and inspect at the same time. Improve safety Rated for use in all powder coating environments. For more information please visit www.nordsoncoating.com/nlighten ics.eu@nordson.com | www.nordson.com/powder 9 1
Figure 9: Coils painted with different effects: from the copper-like finish to the oxidised-like and matte ones.
Performance by design
© ipcm ®
© ipcm ®
SP ECIAL ALUMIN IUM
10 1
11 1
Figure 10: The final part of the plant, with a coil rewind system.
“Investments and innovations in the last few years have allowed us to grow a lot and give a second life to our old plants. The number of hires has increased exponentially and we have expanded by acquiring different neighbouring buildings and warehouses,” says Calvano. “We did not expect this success. Initially, the goal was ensuring greater production capacity for Luxe Perfil. However, our will to grow and
Figure 11: One of the two powder coating application booths.
will be presented at the
DN Chemicals has conducted a series of industrial tests to analyse and select the best products and application methods for an optimal preparation of coils without compromising their mechanical properties. After the application of various products on different alloys and at different speeds, and after the performance of mechanical tests such as multiple bending and impact tests, data were collected and analysed to see if it was possible to apply the final conversion product by nebulisation rather than by sprinkling, as it is done today. Then prototypes of spraying bars have been installed on both systems, which DN Chemicals is now fine-tuning to proceed to the final installation.
Aluminium 2018 fair in Düsseldorf on October,” states Calvano. “In future, we aim at further expanding our portfolio and at implementing an automatic process control that allows remote monitoring of all phases and process parameters, thus making intervention in case of any problems easier and more timely. Together with DN Chemicals, we are also developing a
old skilled and experienced
water recovery system.
© ipcm ®
start again together with our employees has enabled us to
This is a critical issue in
meet Luxe Perfil’s objective as
the Abruzzo region, which
well as to establish ourselves
entails significant costs for
on the national and foreign
our type of production.
markets with our own identity,
With a view to sustainability
in just two years.”
and respect for the
“The revamping of our
environment, therefore,
systems has ensured
we would like to adopt as
excellent quality consistency
soon as possible a system
while allowing us to expand
that allows us to exploit less
our range of products
and less drinking water by
and be flexible enough to experiment and develop new ones. Some of these
104
12 1
Figure 12: Powder dispensers.
N. 53 - SEPTEMBER/OCTOBER 2018 - international PAINT&COATING magazine
purifying and recirculating our process water,” says Alfredo Calvano.
Zaniolo CdA - 1.18
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© Elvial
Opening picture: The vertical plant in operation.
FOCUS ON TECHNOLOGY
S P E C I A L ALU MINIU M
Chromium-Free Pretreatment at ELVIAL. A Review of 18 Successful Years Thomas Sondermann Alufinish GmbH & Co. Kg, Andernach (Germany)
thomas.sondermann@alufinish.de
E
ven as early as the 1990s, Alufinish
in Europe was at the ELVIAL company in
success story started in 1990 as a
developed the first chromium-free
Kilkis, Greece in 2000. ELVIAL is one of the
manufacturer of profiles for the industrial
ENVIROX pretreatment systems
leading aluminium extruders and finishers
sector. Production is now carried out on
which were successfully approved by the
in Greece who develop, manufacture
three aluminium presses with an annual
GSB International and Qualicoat quality
and market coated systems for a wide
capacity of more than 25,000 tonnes.
communities.
variety of architectural requirements as
Thanks to continuous advancement,
One of the earliest practical applications
also industrial purposes. The company’s
plant modernisation and automation with
106
N. 53 - SEPTEMBER/OCTOBER 2018 - international PAINT&COATING magazine
© Elvial
FOCUS ON TECHNOLOGY
From the start in 2000, excellent coating results were achieved with this process. At the same time, Alufinish had the opportunity to gather valuable experience in dealing with the still new chromium-free technology. Based on their successful achievements with Alficoat 748/3, it was hardly surprising that ELVIAL again relied on this technology when building their new production location in 2005 (Fig. 1). The facilities that have since been built on the almost 40-acre site owned by the company include modern, vertical pre-treatment plant with surge technology in addition to robot-controlled transportation engineering and a large profile warehouse. The vertical line is made completely of 316 stainless steel. It is designed in tunnel form, has 12 process stages (Fig. 2) and is
1
capable of pretreating around 15 tonnes of Figure 1: The new production site of ELVIAL, built in 2005 in Kilkis (Greece).
aluminium profiles per shift.
robotic systems, the company is today able to fulfil even the most individual wishes of their customers. Besides extrusion lines, ELVIAL currently operate two coating lines (one horizontal and one vertical unit), both Qualicoat-Seaside class certified. The first chromium-free application using Alufinish products was implemented in a horizontal spray unit at the former production site in Kilkis. The Alufinish products used at the time were a simple combination of alkaline pickling and degreasing solution (Alfinal 273 – Alfisid 12), acidic pickling bath (Alfideox 74), and chromium-free pretreatment (Alficoat 748/3) (Table 1). This plant is still in operation.
Process
Products
Alkaline cleaning and pickling + rinsing
Alfinal 273 – Alfisid 12 + circular spraying nozzle, process water
Rinsing
Process water
Acidic pickling + rinsing
Alfideox 74 + circular spraying nozzle, process water
Rinsing
Demineralised water
Chromium-free pre-treatment, no-rinse
Alficoat 748/3 (ENVIROX NR process)
Draining and drying Table 1 - The first chromium-free application using Alufinish products, implemented in a horizontal spray unit at the former production site of ELVIAL.
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SP ECIAL ALUMIN IUM
conducted at the coastal location of Hoek van
The pretreated goods leave the long tunnel after the chromium-free pretreatment and are then dried in the retained water drier. This vertical installation is designed to allow maximum flexibility and currently has three acidic process stages. Cleaning and pickling are carried out simultaneously in zone 1 using Alfideox 74 and Alfisid 14. In zone 4, the same Alfideox product is used again for acidic post-pickling. The two-component product consists of Alfideox 74 – a pickling component with fluoride content – and the cleaning intensifier Alfisid 14. This method is particularly interesting whenever it is necessary to remove thicker oxide layers. Instead of having to implement the requirement in a single zone,
After 13 years of operation, the chromium-free ENVIROX NR process (Alficoat 748/3) is fully established in the vertical line at ELVIAL and provides the consistently high level of surface quality demanded by customers. More than 80,000 tonnes of aluminium have been treated in this installation to date. So, in the case of ELVIAL, one could definitely speak of a chromium-free model for success.”
Holland. Alficoat 748/3 generates colourless corrosion protection layers with titanium content which can be established, both on a quantitative as well as a qualitative level, by means of photometric layer determination and rapid test (staining). At ELVIAL, the product functions in a concentration range of just 4 – 6 g/l and is consequently very economical. Besides this, the continuous partial replacement of the bath solution also warrants consistent processing conditions and a guaranteed pre-treatment quality. In the vertical line (rif. Opening picture), the goods are treated by the surge method. In this case, pumps deliver the relevant process solution upwards into a surge box from which it
entailing a high consumption of chemicals, the necessary removal of the oxide layer has
ELVIAL are currently operating the line solely
flows down over the goods in a constant liquid
been divided between the two zones. In the
with acidic processing stages and achieve the
film (surge), thus performing the pretreatment.
event that the cleaning efficiency in the first
required surface qualities in this way.
The surge boxes are variable and can be
processing step is inadequate, the option is
The chromium-free ENVIROX NR implemented
adapted to the relevant profile sizes.
provided to intensify the cleaning performance
here is a single-component no-rinse system
Now, after 13 years of operation, the
in zone 4 by the addition of Alfisid 14.
that requires no downstream rinsing steps
chromium-free ENVIROX NR process © Alufinish
However, this variant is usually only needed for material which has been contaminated with oil
(Alficoat 748/3) is fully established in the vertical line at ELVIAL and provides the
and is not generally necessary.
consistently high level of surface
Further to that, in order to have
quality demanded by customers.
the ability to speed up the line
More than 80,000 tonnes of
without losing the etching rate
aluminium have been treated in
the system provides another
this installation to date.
acidic process stage in zone 8 in
So, in the case of ELVIAL, one
ambient temperature this time.
could definitely speak of a
In theory, the entire line could
chromium-free model for success.
also be operated with an alkaline pickling and degreasing step in zone 1 and one or two acidic pickling steps in zone 4 and/ or 8. At least two rinsing stages
Thanks to flexible plant
2 1
technology, established from the
Figure 2: Schematic diagram of vertical line with surge pre-treatment (Zones 1 – 12 are actually located in a linear tunnel).
very beginning, the company is also well equipped for the future and follows the new trends. A further anodizing process for
between the processing steps were planned by the plant manufacturer,
at all. Despite this, the option is provided to
pre-anodization and chromium-free methods
ensuring sufficient rinsing efficiency, even in
perform posttreatment by means of a water
is under construction. The innovative method
different operating modes. The combined
spray unit. The product used is Alficoat 748/3
from ELVIAL, allows to pretreat the profiles with
alkaline pickling and degreasing (Alfinal 276
which has attained all the necessary approvals
a flash oxide layer (between 3 and 8 microns)
and Alfisid 12, for instance, would be
of the Qualicoat and GSB International quality
ensuring that the aluminium and the coated
conceivable) and acidic pickling pretreatment
communities and has also been certified since
layer are excellently protected from corrosion.
(Alfideox) enable optimum cleaning and
the beginning of the millennium. The product
A fully automated and technology advanced
pickling as they remove residues that are
has also passed the GSB International 10-year
process that performs all the steps on the
soluble in both alkaline and acidic solutions.
outdoor weathering test which was successfully
same line.
108
N. 53 - SEPTEMBER/OCTOBER 2018 - international PAINT&COATING magazine
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© OMSG
Opening photo: The mechanical pre-treatment of extruded aluminium profiles significantly reduces the pickling time while creating a pleasant, uniform satin effect.
INNOVATIONS: PRESENT&FUTURE
S P E C I A L ALU MINIU M
Shot Blasting of Extruded Aluminium Profiles: Aesthetic Quality with Time and Cost Savings Enzo Dell’Orto OMSG – Officine Meccaniche San Giorgio Spa, Villa Cortese (MI), Italy
T
management@omsg.it
he most common surface treatment
make it difficult to employ alternative methods.
of precious material that must be recovered
used for finishing extruded aluminium
On the other hand, the use of caustic
with further processes.
profiles has always been chemical
soda-based chemicals entails a large number of
In a global context where the demand for
pickling in a basic bath. The profiles’ complex
disadvantages due to the need to handle toxic
aluminium products is constantly growing, all
shapes, their sensitivity, and the aesthetic
solutions and properly dispose of their related
of this calls for a change of paradigm in order
perfection required raise several issues that
waste water, as well as to the significant erosion
to increase productivity and reduce costs, of
110
N. 53 - SEPTEMBER/OCTOBER 2018 - international PAINT&COATING magazine
course without affecting quality. A solution
Š OMSG
INNOVATIONS: PRESENT&FUTURE
that has been successfully tested by major manufacturers of extruded aluminium profiles is a pre-treatment phase with a mechanical shot blasting process performed in an automatic turbine system, followed by a quick immersion in an alkaline bath to complete the finishing treatment. Shot blasting quickly eliminates most of the surface defects generated by extrusion and handling operations, while creating a pleasant, uniform satin effect (ref. Opening photo). The subsequent pickling phase, therefore, has a mere finishing function, thus being much more delicate. Some product characteristics, however, make it difficult to get optimal results. First of all, profiles have complex shapes and, therefore, they require careful positioning of the
1
Figure 1: OMSGâ&#x20AC;&#x2122;s LAUCO 80/30 shot blasting machine eďŹ&#x20AC;ectively treats numerous types of extruded aluminium parts.
turbines in order to obtain a uniform finish. Secondly, the parts are generally very thin
of abrasive per minute. The turbines are
its dispersion with the dusty air flow, thus
and thus susceptible to shot peening-induced
mounted on the central body of the shot
minimising waste.
deformation when subjected to mechanical
blasting machine and they are specially
At the exit of the machine, the workpieces are
stresses. Finally, in order to preserve their
arranged and inclined so that the whole
automatically transferred sideways on a special
aesthetics, any contact of the profiles with the
workpiece is perfectly treated.
hydraulic lifting system parallel to the exit roller
machineâ&#x20AC;&#x2122;s metal elements should be avoided.
A special conveyor made of rubber rollers
conveyor. This device tilts them to remove all
In order to meet all these requirements,
(Fig. 2) moves the workpieces through the
the abrasives stuck in their internal grooves and
OMSG â&#x20AC;&#x201C; Officine Meccaniche San Giorgio Spa
shot blasting chamber. Two pressure rollers
channels (Fig. 3); the stainless steel abrasive
(Villa Cortese, Milan, Italy) has developed a
block them from above, maintaining their
is then automatically returned to the shot
special range of shot blasting systems called
position, alignment, and distance. If needed, a
blasting machine. The choice to move the parts
LAUCO 80/30 (Fig. 1), able to effectively treat
third pressure roller can be added to enable
sideways maximises the productivity of the
any type of extruded aluminium part. As
the treatment of particularly short profiles,
plant, quickly freeing up the exit roller conveyor
always, the core of the shot blasting plants are
up to a minimum of 2 metres. Due to the
and concealing the time required for the tilting
four high-performance centrifugal turbines
need to use a fine, stainless steel abrasive
of pallets and the removal of abrasives. In this
patented by OMSG, each with an installed
composed of very small-sized spherical grains,
way, the pitch between batches can be limited
power of 15 kW, projecting more than 900 kg
the suction system is suitably sized to avoid
to a few seconds.
/D 0,*/,25( WHFQRORJLD SHU LO 782 ULYHVWLPHQWR
9LVLWD LO VLWR
ZZZ WHFQRVXSSO\ FRP ZZZ KDQJRQ LW
# &+8+5+10 1(
ĹĞĜ ħĜ ĹĞĹ&#x201E;Ĺ Äś ÄŽ ĨĜĹ&#x2021;ĞĜ ÄžĹ&#x192; ĥĜġĹ&#x2021;ĞĜğĹ&#x201E; ÄÄ&#x153;
įĺŠĥĜĹ? Ĺ&#x152;Ĺ&#x152;Ĺ&#x152; Ĺ&#x2030;ĺĸĹ&#x192;Ĺ&#x201E;Ĺ&#x2C6;Ĺ&#x160;Ĺ&#x2026;Ĺ&#x2026;Ĺ Ĺ&#x17D; ĸĹ&#x201E;Ĺ&#x201A; ÄžĹ&#x192;ÄťĹ&#x201E;#Ĺ&#x2030;ĺĸĹ&#x192;Ĺ&#x201E;Ĺ&#x2C6;Ĺ&#x160;Ĺ&#x2026;Ĺ&#x2026;Ĺ Ĺ&#x17D; ĸĹ&#x201E;Ĺ&#x201A;
#0%+ g 664'<<#674# g #5%*'4#674# g 2'55+/'64+ g 7.+5%+ #6'0#
© OMSG
SP ECIAL ALUMIN IUM
reduces the pickling time. Although this can
Mechanical pre-treatment significantly reduces the pickling time. Although this can vary greatly depending on the type of finish required, it is decreased by about 80%. In other words, if a chemical-only treatment takes 20 minutes, the finishing pickling process after shot blasting may last only 4 minutes.”
vary greatly depending on the type of finish required, it is decreased by about 80%. In other words, if a chemical-only treatment takes 20 minutes, the finishing pickling process after shot blasting may last only 4 minutes. This evidently ensures three benefits: - limited size of the plant and production area; - reduced total processing time; - reduced dispersion related to the material corrosion. This increases productivity and overall efficiency. In particular, it is possible to obtain
2 1
As per OMSG’s tradition,
a production increase of over 15%, while a
normally very fine and with a high percentage
recurring cost reduction of around 20% (for
of aluminium, the most effective safety systems
the same tonnage produced) can be expected.
have been adopted to avoid explosion.
Besides these economic advantages, another
An effective two-stage argon fire extinguishing
significant advantage of this solution is its
system can be added to also avoid fire.
much lower environmental impact, as it greatly
Now, what are the real advantages of
reduces the amount of sludge to be disposed
the combined cycle compared with the
of. The combined treatment proves therefore
conventional, chemical-only treatment? This is
to be a simple, modern, and feasible way to
the main question asked by customers before
innovate and make the treatment of extruded
deciding to purchase this turbine shot blasting
aluminium profiles more competitive while
machine. Mechanical pre-treatment significantly
saving and avoiding giving up quality.
© OMSG
Figure 2: A special conveyor made of rubber rollers moves the workpieces through the shot blasting chamber.
Given the characteristics of the particulate,
this shot blasting system is extremely robust, built with the highest quality materials, and advanced in terms of engineering solutions. It is equipped with a PLC that accurately sequences the work phases, sophisticated sensors for positioning control, and effective field diagnostics based on a PROFINET interface. A practical and user-friendly touchscreen interface enables the operator to manage the system effectively, check its performance, and watch synoptic graphics about the system status. Particular attention was paid to the dust extraction system.
112
3 1
Figure 3: At the exit of the machine, a special hydraulic lifting system tilts the parts to remove all the abrasives, which are automatically returned to the shot blasting machine.
N. 53 - SEPTEMBER/OCTOBER 2018 - international PAINT&COATING magazine
G R
T
© Metra
Opening photo: The new BNL headquarters in Rome with curtain walls supplied by the Metra group.
FOCUS ON TECHNOLOGY
S P E C I A L ALU MINIU M
Metra Color: an Italian History of Quality and Innovation in Powder Coating to Conquer the US Market Ilaria Paolomelo and Alessia Venturi ipcm®
114
N. 53 - SEPTEMBER/OCTOBER 2018 - international PAINT&COATING magazine
FOCUS ON TECHNOLOGY
© ipcm ®
I
n some aluminium
In order to help these
markets, such as the US
(few) applicators
one, powder coating is
tenaciously using
still uncommon, whereas
powders compliant
liquid and especially PVDF
with AAMA2605 , some
coatings are preferred
systems are being
thanks to their excellent
developed to optimise
outdoor and colour retention
the application
characteristics. However, the
process and avoid
trend is now being reversed,
significant investments
with an increasing number
for complete plant
of architectural projects
updates. An example
requiring powder-coated
of this is Eurosider’s
profiles for curtain walls (ref.
POLIFLUID® device
opening photo).
(Fig. 1), recently
In most cases, the suppliers of
installed by Metra
these profiles are European
Color in Rodengo
an, in particular, Italian,
Saiano.
since the local market lacks the necessary in-depth
Metra Holding has
knowledge of the powder
focused on innovation
coating process. However,
to achieve maximum
these projects’ specifications
quality levels since its
continue to call for
establishment in 1962.
compliance with the AAM2605
The Group has always
certification, requiring
specialised in the
powders with the same
aluminium extrusion
resistance properties of PVDF
and finishing field,
liquid paints, that is at least 10
quickly becoming an
years of outdoor resistance
industry leader both
in Florida Test. These powder
in Italy and abroad.
coatings compliant with AAMA2605 and that could be certified Qualicoat Classe 3 without this being a necessary
Currently, the Group
1
has three production
Figure 1: The control panel of one of the three machines featuring POLIFLUID®, a technology patented by Eurosider.
condition – are also called
plants located in Italy, including its subsidiary company
“hyper durable” and have been
Metra Color (Rodengo Saiano, BS),
available on the European market
which performs the whole finishing
for some time now. Nonetheless, such powders have a few critical issues in terms of formulation and application. These limit their colour range to a few shades and require a very high-quality application process, as well as its continuous monitoring and the protection of the workpieces against contamination with powders of different chemical nature.
process of aluminium profiles with an
Metra Holding has focused on innovation to achieve maximum quality levels since its establishment in 1962. The Group has always specialised in the aluminium extrusion and finishing field, quickly becoming an industry leader both in Italy and abroad.”
anodic oxidation line and a vertical powder coating plant (Fig. 2). In line with the Group’s philosophy, last year the latter was integrated with a new advanced technology offered by Eurosider, which enabled the company to solve a few quality issues and to achieve excellent aesthetic performance by modifying the powder application phase.
international PAINT&COATING magazine - SEPTEMBER/OCTOBER 2018 - N. 53
115
© ipcm ®
SP ECIAL ALUMIN IUM
2 1
Figure 2: The unloading area of the vertical coating plant.
The innovative pre-treatment and coating cycle In Metra Color, extruded aluminium from the other factories of the Group enters the spray pre-treatment tunnel that performs the following stages: • degreasing with an acid solution • double rinsing with demineralised water • pickling with an alkaline solution • double rinsing with demineralised water • neutralization with an acid solution • double rinsing with specific demineralised water • surface conversion based on chrome-free zirconium-titanium • double rinsing with specific demineralised water.
116
“We chose to add an alkaline stage in order to achieve excellent performance
Last year Metra Color decided to integrate the coating line with a new advanced technology offered by Eurosider, which enabled the company to solve a few quality issues and to achieve excellent aesthetic performance by modifying the powder application phase. ”
N. 53 - SEPTEMBER/OCTOBER 2018 - international PAINT&COATING magazine
and quality results. Thanks to this acidalkaline-acid pre-treatment cycle, all our aluminium products have obtained the Qualicoat Seaside certification: in this way, our profiles can be installed anywhere in the world, even in the marine areas most subject to corrosion (Fig. 3),” says Metra Color technical manager Biagio Scopel (Fig. 4). After pre-treatment, the aluminium bars are dried and sent to the application station, composed of three vertical coating booths provided by Euroimpianti. “The first one of the three booth is devoted to the
© Hufton + Crow
FOCUS ON TECHNOLOGY
3 1
© ipcm ®
Figure 3: The “Dollar Bay” towern in London’s Ciry.
The reason behind the choice to add an alkaline stage is to achieve excellent performance and quality results. Thanks to this acid-alkaline-acid pre-treatment cycle, the aluminium profiles manage to obtain the Qualicoat Seaside certification: in this way, they can be installed anywhere in the world, even in the marine areas most subject to corrosion.”
application of hyper-durable coatings as well as metallic colours and special products (Fig. 5); the second one of light shades, and the third of powders with conventional RAL colours (Fig. 6). The choice to devote each booth to a particular type of powder prevents any problems of contamination among different colours and chemical natures, as happened in the past. Also this choice is aimed at high quality and it avoids disputes over our products. In June, we decided to further improve the coating quality of our profiles by installing Eurosider’s POLIFLUID® system on all three coating booths.”
POLIFLUID®: Powder coating with nitrogen POLIFLUID® is a powder coating technology patented by Eurosider that exploits the nitrogen contained in compressed air through the selective permeation principle and uses it as a carrier in all application stages. The use of 96% pure nitrogen instead of
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Figure 4: The touch screen panel managing the POLIFLUID® devices.
international PAINT&COATING magazine - SEPTEMBER/OCTOBER 2018 - N. 53
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© ipcm ®
S P E C I A L A L UM I NI UM
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Figure 5: Close up of the powder coating application in typical vertical coating booth.
compressed air enables this generator to prevent powder from accumulating in the gun and from producing lumps that could compromise surface uniformity. “Thanks to the installation of these generators, precisely a POLIFLUID® 150 and two POLIFLUID® 200 systems, we have solved the aesthetic problems that we encountered in the past, especially in terms of coating distension. Hyper-durable powders are very difficult to spread compared with other powders on the market and
Each one of the three vertical coating booths, provided by Euroimpianti, is devoted to the application of a different powder coating, in particular: the first of hyper-durable coatings as well as metallic colours and special products; the second of light shades; the third of dark shades and conventional RAL colours. The choice to devote each booth to a particular type of powder prevents any problems of contamination among different colours and chemical natures.”
FOCUS ON TECHNOLOGY
POLIFLUID® is a powder coating technology patented by Eurosider that exploits the nitrogen contained in compressed air through the selective permeation principle and uses it as a carrier in all application stages. The use of 96% pure nitrogen instead of compressed air enables this generator to prevent powder from accumulating in the gun and from producing lumps that could compromise surface uniformity.” they created orange peel issues; moreover, they are difficult to control during application and they require more than uniform thicknesses,” says Scopel. “POLIFLUID® ensures numerous advantages: more uniform thicknesses on profiles, better distension and therefore reduced orange peel effect, better yield, greater coverage with lower thicknesses, and about a 10% saving on coating products (Fig. 7). POLIFLUID® has allowed us to solve all our application issues without having to change the whole application system of our coating plant: with a small investment, we have been able to continue to use the equipment already present on our line without replacing it.” “Eurosider technicians have worked in close cooperation with the Italian customer: we were very willing to find the best solutions for them and solve any problem found” Ottavio Milli (Fig. 6), CEO of Eurosider in Grosseto, Italy, explains. “During the first month, we would
POLIFLUID® ensures numerous advantages: more uniform thicknesses on profiles, better distension and therefore reduced orange peel effect, better yield, greater coverage with lower thicknesses, and at least a 10% saving on coating products.”
© ipcm ®
SP ECIAL ALUMIN IUM
Figure 6: Ottavio Milli, CEO of Eurosider (Grosseto, Italy).
receive from the customer a weekly report with application parameters
© ipcm ®
6 1
and production data (Fig. 7), which made us realise that they had reduced their powder consumption. Given the high cost of hyper durable coatings, which they use on a stable basis, this also translates into significant economic savings.”
Metra Color’s choice “Investing in an unusual pre-treatment cycle, in new advanced technologies, and in more expensive but better performing powder coatings has proved to be a winning choice. It has enabled us to provide our customers with excellent-quality aluminium profiles and to become the supplier of choice on the US market,” says Scopel.
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Figure 7: Process parameters of POLIFLUID® equipment.
N. 53 - SEPTEMBER/OCTOBER 2018 - international PAINT&COATING magazine
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Micro-Gloss Robotic: Automatic Online Gloss Control
B
YK-Gardner, a global leader in
The long-term stable LED light source
mounting track for fast calibration
the field of measuring colour
of the micro-gloss provides not only
on a regular basis. The intelligent
and appearance and testing
highly repeatable results for many
auto diagnosis of the micro-gloss
physical properties of plastic, coatings and
readings and years, but also will
notifies when the standard is
cosmetics is introducing a new member
never burn out. A 10 years warranty
dirty or damaged, which ensures
of the well-proven micro-gloss family.
on the lamp life is guaranteed. Due
reliable measurement at any time.
The new micro-gloss 60° robotic enables
to advanced temperature control, the
Power supply occurs via the USB
automatic measurement of surface gloss
micro-gloss assures highest stability
interface, as well as control of all
(Fig. 1). Matte, satin-finished or glossy
of the gloss values. A high-tech,
measurement functions. The smart
- uniform appearance stands for high
automated calibration procedure
data communication allows direct
quality. A stable running process is the
on a complete range of gloss tiles as
and fast data transfer to the smart-
key for uniform and consistent quality.
final step in the meter’s production
chart software.
Therefore, gloss needs to be measured on
process guarantees outstanding
a routine basis in the production process
technical performance including
For further information:
and the measurement results need to be
repeatability, inter-instrument
www.byk.com
documented for clear communication.
agreement and temperature stability.
The new micro-gloss robotic allows
The reference tile for calibration
automated gloss control to increase the
is supplied in a special
sampling rate. With its robust mounting fixture, the meter can be integrated into a © BYK-Gardner
measuring cell, on a xy-table or similar set-ups. Thus, readings are always taken on the same sample area, which ensures repeatable positioning and reliable results. The lightweight of the unit and the fast data collection allow measuring a high number of parts. This provides complete and representative data for statistical process control enabling proactive reaction to process changes.
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N. 53 - SEPTEMBER/OCTOBER 2018 - international PAINT&COATING magazine
1
Figure 1: The new micro-gloss 60° robotic enables automatic measurement of surface gloss.
BRAND-NEW
S P E C I A L ALU MINIU M
T
© AGTOS
New High-Performance Turbines for Aluminum Components he increasing processing of aluminum
requires new developments in surface technology. What is needed are economical concepts for deburring, cleaning and finishing the aluminum workpieces. Aluminum workpieces are increasingly being processed with aluminum abrasive. For this application, AGTOS engineers and technicians have developed new highperformance turbines (Fig. 1). One turbine can be seen as an exhibit at the AGTOS booth of the ALUMINUM fair in hall 12, booth 12I20. In addition to the blasting processing, the gentle handling of the workpieces is important. Only if both is matched to the aluminum workpieces the quality of the surfaces can meet the
1
requirements. The AGTOS exhibition team is happy to inform the visitors
Figure 1: The new high-performance turbine from AGTOS
about shot blasting machines specially
blasting machines. These are
Trade fair ALUMINIUM, 09. – 11.
designed for the processing of
as well delivered in a technically
Oktober 2018 Düsseldorf, Hall 12,
aluminum workpieces.
perfect condition, modernized and
Booth 12I20.
Generally, AGTOS offers many
tailored to customer requirements.
different types of new blasting
An extensive service program
For further information:
machines and deals with used
completes the range of services.
www.agtos.de
international PAINT&COATING magazine - SEPTEMBER/OCTOBER 2018 - N. 53
123
© All.co
Opening photo: All.co Group, an industrial group founded in Pisa (Italy) in 1973, has established itself among the most successful companies in the sector of aluminium extrusion and processing.
FOCUS ON TECHNOLOGY
S P E C I A L ALU MINIU M
All.co Group: A Wide Choice of High-Quality Finishes and Colours from a Well-Established Company Barbara Pennati ipcm®
i
pcm® has already presented several
right strategy to remain operational and
All.co Group is an industrial group established
examples of Italian companies that have
relaunch their products. The solutions
in Pisa (Italy) in 1973 by the Vecoli family
had (and been able to) innovate in order
adopted up to now have involved plant
(Fig. 1). It has managed to consolidate its
to overcome the economic crisis that hit the
investments, close collaborations with
presence on the Italian and foreign markets,
Country in 2008. In the last few years, there
suppliers, widening of the product ranges,
establishing itself among the most successful
has been a slow recovery, but some markets
and export to foreign markets. Very often,
companies in the sector of aluminium
are still struggling to get back on track and
the winning strategy is just a combination of
extrusion and processing and achieving a
numerous company still have to look for the
all these practices.
turnover of 162 million Euros in 2017.
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N. 53 - SEPTEMBER/OCTOBER 2018 - international PAINT&COATING magazine
FOCUS ON TECHNOLOGY
our production more versatile, we have
The success of this company is due to several factors, including its ability to present itself as a specialised aluminium extrusion centre. Its production cycle starts with the purchase of raw material and it continues with melting, extrusion, coating, and distribution operations – a process involving seven production plants and thirteen distribution centres located in Italy and abroad (ref. Opening photo). Besides presenting itself as a singlesource supplier, over the years All.co has been able to cope with market fluctuations by adapting its production to the current demand and thus ensuring constant growth and affirming itself on the international markets. “All.co designs and manufactures aluminium extrusions for the industrial and construction sectors, handling all phases in-house,” says Luigi Vecoli, the coating manager of the All.co Group. “In 1991, we even insourced the coating process to offer an extra service to our customers. We mainly paint material for the construction sector. This has enabled us to meet the needs of the market in terms of finishing, which, especially in recent years, has
All.co Group is an industrial group established in Pisa (Italy) in 1973 by the Vecoli family. It has managed to consolidate its presence on the Italian and foreign markets, establishing itself among the most successful companies in the sector of aluminium extrusion and processing and achieving a turnover of 162 million Euros in 2017. The success of this company is due to several factors, including its ability to present itself as a specialised aluminium extrusion centre. Its production cycle starts with the purchase of raw material and it continues with melting, extrusion, coating, and distribution operations – a process involving seven production plants and thirteen distribution centres located in Italy and abroad.”
become increasingly important for the
on foreign markets, which have become our main target, as the Italian aluminium market is still slow,” states Vecoli. All.co has been actively collaborating for more than ten years with Inver, a manufacturer of industrial coatings belonging to the Sherwin-Williams Group, as well as the main supplier of the Syntha Pulvin® branded polyester powders used by All.co. For even greater production flexibility, also the vertical coating plant designed by Trasmetal (Milan, Italy) underwent a revamping in the 2014, with the installation of a new coating booth equipped with two OFB disks, able to treat profiles up to 6 metres and with an overall capacity of 40 tonnes per day.
Combining production versatility and quality consistency “Our collaboration with Inver began in 2004. The first few years have been a trial stage for both parties: since we previously had other suppliers, Inver had to analyse our colours and adapt its products to our needs,” explains Luigi Vecoli. “Much of the material painted in our Pisa plant is sent to © All.co
construction field and
also succeeded in establishing ourselves
therefore for us too.
our other factories and distribution
In the past, the most
centres. This
used colours were
allows us to be
white and ivory and
more competitive
the most common
on the market
finish was the glossy
and ensure fast
one; nowadays, in the
delivery times to
world of aluminium
our customers.”
and in particular of
The powders
window and door
applied on all All.
frames, there is
co products are
the possibility to
Syntha Pulvin®
experiment with
polyesters
many shades,
specifically
whose demand
designed for the
varies according to the destination market. By making
1
Figure 1: The Vecoli family, which founded the All.co Group.
architectural sector, which are Qualicoat and
international PAINT&COATING magazine - SEPTEMBER/OCTOBER 2018 - N. 53
125
© ipcm ®
SP ECIAL ALUMIN IUM
Figure 2: Inver is the main supplier of polyester powders of the All.co Group.
In Germany and France, for example, greys are in high demand, whereas in Italy the palette is much wider, from white and ivory to green and gothic brown (Fig. 4).” “All.co performs 4 to 6 colour change operations per day. With such special and varied requests, for us it was crucial to find the right powder supplier, able to guarantee extreme versatility without compromising quality standards. Inver showed
2 1
perseverance and expertise in meeting all our needs and it proved
GSB-INTERNATIONAL approved (Fig. 2).
Marco Canola (Fig. 3). “Now, not only
to be the perfect technological
Thanks to the joint efforts of Inver and All.co,
quality must be high, but suppliers
partner for All.co,” says Vecoli. “When
the company is able to offer different
must also be able to cope with the most
we replaced our coating booth in
finishes and effects while maintaining a
diverse requests in terms of colours
2014, they were also able to modify
high quality standard. These skills have
and finishes. Matte finishes prevail
their formulations to perfectly
helped establishing the firm on both
everywhere, while the colours requested
adapt them to our new application
the building and industrial market as
vary depending on the Country.
parameters.”
application sectors of its products – which currently
© ipcm ®
well as expanding the
include road, naval, and air transport. “Today’s market requires attention to detail and very high quality levels, even in industries where a lot less attention used to be paid to possible defects and imperfections, such as the building one,” explains Sherwin-Williams architectural sales representative
Figure 3: From left to right, Marco Canola from Sherwin-Williams and Luigi Vecoli from All.co.
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© ipcm ®
FOCUS ON TECHNOLOGY
The coating process The coating plant was designed by Trasmetal and it integrates into the fully computerised production flow of All.co (Fig. 5). “The plant has two loading areas: one for packaged materials that must be handled by an automatic unwrapping machine, the other devoted to the baskets containing ready-to-be-coated profiles,” explains Luigi Vecoli. “Our production system is completely computerised. The operators use barcode reading guns to manage the whole cycle: in this way, not only have we eliminated paper, which is an advantage in terms of both eco-friendliness and
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Figure 4: Some colours and finishes produced by All.co.
SP ECIAL ALUMIN IUM
© ipcm ®
Figure 5: The vertical coating plant.
© ipcm ®
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Figure 6: The profile loading area and the entrance to the 10-stage pre-treatment tunnel.
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N. 53 - SEPTEMBER/OCTOBER 2018 - international PAINT&COATING magazine
FOCUS ON TECHNOLOGY
cost efficiency, but we have also minimised the possibility of any order management errors. Moreover, all information related to profiles is linked to the coating parameters, so that the operators have a complete overview of production and All.co can analyse the various data to improve its painting process. Monitoring every process phase has also resulted in a substantial reduction in
PAINTING ROBOTS & SYSTEM INTEGRATOR We are able to provide the full range of articulated and cartesian robots for every painting need!
production waste, as we are able to intervene promptly to solve any problems and prevent them from happening again.” Coating starts with a 10-stage pre-treatment
All.co has been actively collaborating for more than ten years with Inver, a manufacturer of industrial coatings belonging to the Sherwin-Williams Group, as well as the main supplier of the Syntha Pulvin® branded polyester powders used by All.co. For even greater production flexibility, also the vertical coating plant underwent a revamping in the 2014, with the installation of a new coating booth equipped with two OFB disks, able to treat profiles up to 6 metres and with an overall capacity of 40 tonnes per day.”
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.
process (Fig. 6). The chemicals are applied through spray nozzles. After drying, the profiles enter the new coating booth (Fig. 7) installed by Trasmetal in 2014 and featuring two
LeBot C5: 5 axis cartesian robot with 3D Lesta shape acquisition system. acqui ystem.
OFB disks. “The OFB technology is the most suitable for our type of production flow, which involves processing large quantities of material, and it enables us to perfectly coat all our profiles, as they loop around the disk to obtain uniform
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.
application over their entire surface. In the past, only visible parts had to be painted, but now we prefer to coat our products on all sides,” says Vecoli. “After coating,
the profiles reach an IR gelling oven (Fig. 8), again provided by
WWW.LESTA.IT
Trasmetal. It is located before the polymerisation oven to ensure greater control over colour and reduce contamination among different process phases.” “The profiles then reach the polymerisation oven (Fig. 9), operating at a temperature of 180-190°C. A storage buffer allows for effective cooling before unloading (Figs. 10 and 11). During the revamping process of 2014, we also lengthened the unloading bench (Figs. 12 and 13),” states Vecoli. “In the past,
LESTA S.r.l.
Via D. Chiesa, 42 - 20020 Dairago (MI) - Italy +39 0331.430817 0331.1581053 +39 0331.158 info@lesta.it
© ipcm ®
SP ECIAL ALUMIN IUM
the material was unhooked, gathered, and loaded on forklifts for weighing. This much longer unloading station allows us to manage orders according to our current needs, postponing or anticipating operations without ever stopping production or slowing down the weighing and packaging procedures, which are performed automatically to minimise the possibility of damaging the material.”
A high-performance future “Although coating is not the core business of All.co, our company is very attentive to the quality of its products and it strives to offer a reliable and complete service to its customers,” explains Vecoli. “Our activity is certified according to the international quality
© ipcm ®
standard ISO 9001 and the environmental standard ISO 14001,
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Figure 7: Trasmetal’s coating booth paints the profiles with two OFB disks.
The powders applied on all All.co products are Syntha Pulvin® polyesters specifically designed for the architectural sector, which are Qualicoat and GSB-INTERNATIONAL approved. Thanks to the joint efforts of Inver and All.co, the company is able to offer different finishes and effects while maintaining a high quality standard. These skills have helped establishing the firm on both the building and industrial market as well as expanding the application sectors of its products – which currently include road, naval, and air transport.”
130
N. 53 - SEPTEMBER/OCTOBER 2018 - international PAINT&COATING magazine
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Figure 8: The IR gelling oven installed before the polymerisation oven for greater control over colour and contamination.
© ipcm ®
FOCUS ON TECHNOLOGY Figure 9: Profiles entering the polymerisation oven.
and our pre-treatment phase is Qualicoat Seaside certified. During production, we take samples of each colour at the beginning, in the middle, and at the end of the coating cycle. We then perform the tests required by the certification – scratch, impact, tear-off, and bending tests – as well as a salt spray test to ensure a 1000-hour resistance value.” “Before working with Inver, we already had our own tints, which Inver has managed to reproduce and adapt to its products,” says Vecoli. “This may seem a secondary factor, but finding the right colour is never easy and quality can be affected if the formulation is not correct. For instance, door and window profiles are often coupled and even a minimal
9 1
© ipcm ®
shade difference is not tolerated. Inver was able to faithfully
10 1
Figures 10 and 11: The storage buffer for cooling the profiles and the unloading area.
© ipcm ®
Coating starts with a 10-stage pre-treatment process. The chemicals are applied through spray nozzles. After drying, the profiles enter the new coating booth installed by Trasmetal in 2014 and featuring two OFB disks. The OFB technology is the most suitable for All.Co’s type of production flow, which involves processing large quantities of material, and it enables them to perfectly coat all the profiles, as they loop around the disk to obtain uniform application over their entire surface. In the past, only visible parts had to be painted, but now they prefer to coat the products on all sides. After coating, the profiles reach an IR gelling oven. It is located before the polymerisation oven to ensure greater control over colour and reduce contamination among different process phases.”
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international PAINT&COATING magazine - SEPTEMBER/OCTOBER 2018 - N. 53
131
© ipcm ®
SP ECIAL ALUMIN IUM
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reproduce the colour chart developed
© ipcm ®
Figures 12 and 13: The storage buffer for cooling the profiles and the unloading area.
over the years by All.co and to further enrich it, guaranteeing at the same time the quality level required by the certifications that distinguish our group’s production.” “The Italian market still prefers Class 1 powders. However, as increasing attention is paid to quality, the request for Qualicoat Class 2 certified products is raising,” states Marco Canola. “In future, we plan to further strengthen our collaboration with All. co and offer to the Italian market an added value for conventional products, that is, better performing powders (as proved by our accelerated tests), already widespread in Germany and England.”
132
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N. 53 - SEPTEMBER/OCTOBER 2018 - international PAINT&COATING magazine
Š Karl Bubenhofer AG
Opening photo: Karl Bubenhofer AG has invested in a new high-tech powder coating plant supplied by Wagner.
HIGHLIGHT OF THE MONTH
New Technical Centre For Powder Coating Strengthens Karl Bubenhoferâ&#x20AC;&#x2122;s Market Position Michael Loretan, Karl Bubenhofer AG Gossau SG, Switzerland
T
pulver@kabe-farben.ch
he family-owned company Karl
curing options, the company can carry
reason, the family-owned company invested
Bubenhofer AG has upgraded its
out practical coating tests, evaluate newly
in a modern powder coating system at its
technical centre for powder coating
developed products and provide
site in Gossau (ref. Opening photo). The
in Gossau and invested in a new high-tech
high-quality training.
new powder coating plant is designed and
powder coating plant, which is the only one
At the former powder coating plant
developed for their specific requirements and is
of its kind in the industry. With state-of-
of Karl Bubenhofer AG real tests of
equipped for all types of automatic and manual
the-art application equipment and flexible
coating processes were limited. For this
powder coating application processes.
134
N. 53 - SEPTEMBER/OCTOBER 2018 - international PAINT&COATING magazine
HIGHLIGHT OF THE MONTH
High-tech solution
Special equipment for coating heat-sensitive substrates
the engineers can carry out practical
The new plant, which was supplied by the application system manufacturer
The markets for alternative and heat-
products and in-depth evaluations
J. WAGNER GmbH, meets all of the
sensitive materials are becoming
of the behaviour of powder coatings
company’s needs. The spacious
increasingly important for Karl Bubenhofer
in automated systems in order to
plastic spray booth is fitted with the
AG. These include plastics and, in particular,
improve their quality even further.
latest type of recovery system. Three
wood. The new coating plant is fitted with
At the same time, existing and
automatic spray guns on reciprocators
counter-electrodes and a software system
potential customers can benefit from
are arranged vertically on each side
that allows high-quality coating tests to be
high-quality training using the latest
of the booth. If necessary, this can be
carried out on components made from
application technology. The amount
increased to five guns on each side. A
MDF, which is used in furniture production
of preparation and cleaning involved
light curtain detects the size of the parts
for example, and other types of materials.
has been significantly reduced, which
to be coated and adjusts the movements
The curing oven has been specially
allows more tests to be completed
of the guns accordingly. The application
designed to specifications drawn up by
in a short time and leads to higher
system, conveyor and batch oven can
the engineers at Karl Bubenhofer AG.
quality results.
be controlled from a central location by
The coated parts are transported directly
The newly modernised powder
touch screens.
from the booth to the batch oven, where
coating technical centre at Karl
The powder is supplied by a semi-
the powder coating is cross-linked using
Bubenhofer AG is unique. The family-
automated powder centre with an
medium-wave infrared emitters.
owned company has made a major
integrated control system and an
The heaters can be replaced with long-wave
investment in its future success and a
ultrasonic sieve which all the new and
infrared emitters or UV lamps, if necessary.
clear commitment to the production
recycled powder passes through. The
In addition, the oven can operate in air
site in Arnegg (Switzerland).
interior of the powder centre is made
recirculation mode or
from chrome steel and this ensures that
in combined mode. An
the frequent cleaning processes needed
integrated infrared camera
in the technical centre can be carried out
analyses and documents
quickly and without leaving any powder
the cross-linking process.
residues. The closed circuit system
The flexibility of the plant
allows the experts at Karl Bubenhofer
allows the development
AG to obtain reliable information about
engineers to control the
the behaviour of standard products and
cross-link procedure and
of high-tech bonded metallic powder
test all types of powder
Leader group in wastewater treatment for metal finishing line and ZLD is looking
coatings.
coatings including the result
for new addiction to our winning team located in the south of Milan.
As well as being equipped with the latest
logging.
application and control systems, the A cleverly designed exhaust air ducting
Investing in a successful future
system and a cyclone with an optimised
The newly installed
air flow allow the use of a compact
plant in the technical
extraction filter with very low energy
centre belonging to Karl
consumption.
Bubenhofer AG functions
The plant is ideally suited for practical
both as a practical training
user training. From the central control
facility and as a test lab
module, the course participants
for the development of
can follow the settings made by the
new products. The plant’s
engineers in the lab in real time and
modern technology allows
evaluate their impact on the final coating,
powder coating systems
which makes the learning process more
to be cross-linked under
effective.
ideal conditions. As a result,
new plant is also highly energy efficient.
tests of their newly developed
JOB OFFER
Open positions for CIE: 1 CHEMICAL OR MECHANICAL ENGINEER (or comparable preparation) 1 DESIGNER AUTOCAD 2D/3D, 3D SOLIDWORK 1 QUALITY, SAFETY AND MANUAL OFFICERS 1 SOFTWARE TECHNICIAN, AUTOMATION (Siemens, Allen Bradley) Open positions for MST CHEMICALS: 1 TECHNICAL - SALES MANAGER CHEMICAL SPECIALTIES for wastewater treatment
What you need to succeed: - Aged preferably under 35; - Good knowledge of MS Office and order management systems; - Written and spoken english (min. level required: B2); - Availability to travel abroad for medium-term periods; - Candidates coming from Metal Finishing sector appreciated.
Please send detailed CV to silvia.tamburini@cieeng.com www.cieeng.com
BRAND-NEW
Gardner-scrub ECE 43 – Scrub Abrasion Tester Designed to Comply with Economic Commission for Europe Regulation on Safety Glazing
B
YK-Gardner - worldwide partner of
liquid containers, and pre-cut wiper
The tester has a compact size to save on
the automotive, paint and plastic
blades. The Abrasion Tester simulates
counter space. The instrument comes
industries for quality control
on-road abrasive conditions.
with a two-year warranty and supported
of colour, appearance and physical
Dry condition testing is also possible.
by BYK-Gardner’s worldwide offices and
properties - is introducing the Gardner-
Gardner-scrub ECE 43 has a touch-screen
distributor channels.
scrub ECE 43.
display for easy operation. Cycle speed
Safety glass for use in cars and other
and time are user selectable. Proven
For further information:
motorized vehicles has to withstand
drive mechanism for long-term usage.
www.byk.com
different conditions than conventional glass products. In order to ensure the quality of vehicle glass the United Nations Economic Commission for Europe (ECE) has issued regulation R43 that specifies standards for safety car glass. The new Gardner-scrub ECE 43 allows for a quick and reliable determination of scratch resistance according to this regulation. To determine the scratch resistance of glass or plastic © BYK-Gardner
materials and coatings used for motorized vehicle windshields, a windshield wiper blade under a specific force and cycle time scrubs the sample. A standardized abrasive liquid solution accelerates the test results. The Gardner-scrub ECE 43 runs two samples simultaneously. The abrasion tester comes with two blade holders, sample holders,
136
Figure 1: The new Gardner-scrub ECE 43 allows for a quick and reliable determination of scratch resistance.
N. 53 - SEPTEMBER/OCTOBER 2018 - international PAINT&COATING magazine
BRAND-NEW
C
Š Chemtec
Chemtec Improves Customer Service With the Acquisition of a New Building hemtec has bought the building
adjacent to its already-existing one in Corbetta (Milan, Italy). With this acquisition, it will have more than 1,000 m2 available to devote to commercial and administrative offices, an R&D laboratory, a warehouse, and a production unit for water-based products. The aim was giving the
1
Figure 1: Chemtecâ&#x20AC;&#x2122;s premises in Corbetta (Milan, Italy).
company the chance to continue the growth path that is leading
allow the firm to meet the needs
it to acquire ever larger market shares in
of end customers requiring more
Italy, France (where its subsidiary company
and more specific and customised
Aertech SAS is based), other European
products.
countries, and North and South America
Thanks to this acquisition, by 2019
(where the Chemtec North & Latin
Chemtec will be able to rapidly
America branches are located).
produce medium/small and medium/
Thanks to the new logistics structure,
large-sized batches of its products
Chemtec will improve customer service
for metal surface pre-treatment and
by shortening delivery times and thus
waste water treatment. It will also be
meeting the increasingly demanding
able to ship them more quickly. For
requests of end customers, distributors,
the company, production and logistics
and retailers. The new production unit,
efficiency is in fact a key to constant
on the other hand, will enable Chemtec
growth in the short, medium, and
to insource an important part of its
long-term future.
processes with the aim of shortening lead-time and increasing flexibility and
For further information:
production efficiency. This, in turn, will
www.chemtecitalia.it
BRAND-NEW
Industry Leading Performance With AGM’s Genable® 3000 Series, Graphene Based, Active Non-Metallic, Anticorrosion Additives
E
arlier in 2018 Applied Graphene
on another extensive test programme
Genable® 3000 series dispersions are
Materials (AGM) launched their
looking at the performance of a higher
available initially in epoxy resins but with a
latest, ground-breaking, dispersion
build primer system. The thickness of this
range of solvent and water based dispersions
range – the Genable 3000 series. Genable
high build primer is around 110 microns,
under near-term development. All AGM’s
3000 dispersions are graphene based,
and is therefore typically thinner than many
Genable® dispersions are formulated
active non-metallic, anti-corrosion additives,
comparative industry standard systems in
for long term stability and engineered
which are proven capable of delivering
the C4/C5 category (ISO12944).
to aid easy incorporation into existing
leading performance through numerous
The properties of the Genable® 3000
manufacturing processes. The new range
extensive test programmes. Like all Genable
series make it an ideal tool-box additive
follows on the heels of the recent launches
dispersions, they are formulated to enable
for formulators seeking to significantly
of the Genable® 1000 series (for enhancing
the full benefit of graphene materials to be
enhance coating performance in a range
existing anti-corrosive additive performance)
accessed by coating industry formulators
of environments. As an additive capable of
and the Genable® 2000 series (specifically
seeking a step change anti-corrosion
offering metal free systems with extended
for corrosion inhibition on aluminium
performance.
durability it is anticipated that the
substrates).
AGM is now reporting results from further
Genable® 3000 should find multiple
testing, which not only underlines the
applications in industrial areas subject to
Prohesion Testing
potential for significant anticorrosion
high humidity and aggressive atmosphere,
Over 5 times extension to the primer coating
performance gains but also the products
including inshore areas of medium to high
lifetime under cyclic salt spray (ASTM G-85-94
commercial attractiveness – particularly under
salinity. Extended durability and thinner
Prohesion) with the use of Genable® 3000,
harsher C4/C5 corrosive environments.
flexible coatings are directly equitable
AGM’s formulation ready active corrosion
Incorporated into the formulation of an
to significant cost savings in both initial
inhibitor, in place of Zinc Phosphate.
industry standard C3 epoxy primer system,
coating system application, as well as
and tested under representative cyclical salt
maintenance and repair for commercial
Fur further information:
spray testing (ASTM G-85-94 Prohesion),
end users.
www.appliedgraphenematerials.com
®
®
®
Genable 3000 series materials have been ®
© Applied Graphene Materials
shown to deliver a 5- fold extension in coating lifetime, based on a single 60 micron dry film thickness (Fig. 1). These exciting results are supported by a detailed mechanical dataset and studies incorporating combination with a PU topcoat exploring intercoat adhesion and overcoating intervals. All results confirm the products attractiveness for development into commercial anti-corrosion systems. Further investigating Genable® 3000 series potential for applications in harsher C4/C5 environments, AGM has embarked
138
1
Figure 1: Genable® 3000 series materials have been shown to deliver a 5-fold extension in coating lifetime, based on a single 60 micron dry film thickness.
N. 53 - SEPTEMBER/OCTOBER 2018 - international PAINT&COATING magazine
BRAND-NEW
T
Š Cabycal
Cabycal Provided an Infrared Oven to Istobal he Spanish multinational choose Cabycal
reader located before the gelling zone. Depending
to improve the powder
on the information
paint line of its factory in
collected by these
Valencia.
measurement
Cabycal has designed,
barriers, the
manufactured and
IR carriage
assembled an infrared (IR)
automatically
gas oven, also known as
approach or
gelling zone, forbIstobal,
move away from
a leading company in the
the frame with
design and manufacture
anbaccuracy of
of solutions for the
5 millimetres.
automotive sector. This IR
In addition, the
oven has beenbadapted
automation of this
to the existing convection
system also allows
ovenbby combining a
the activation of
mixed system by intelligent control. This IR short wave heating area aims tobimprove the powder coating
only the infrared
1
plates of the area
Figures 1 and 2: The new IR oven installed by Cabycal at the Valencia production site of Istobal.
application linebthat
of the frame in which parts have been detected (upper zone or
Cabycal installed in the Istobal
lower zone), which gives
plantbin 2009. Among the
anbimportant saving of energy
advantages of the new system
for the client.
is the increase in speed of
Istobal is the leading Spanish
the production, the rise of the
company in the design,
temperature of pieces with high
manufacture and marketing of
thickness and the elimination
automotive washing solutions.
of the contamination of colours
They export their products to
in the polymerized oven. In
more than 75 countries, have
addition,bthe space occupied has
seven subsidiaries and two
been minimizedbsince the system
assembly plants in Europe and
has been installed between the
two other subsidiaries and
paint booth and the entrance to
assembly plants in the US and
the existing polymerization oven.
Brazil.
thebrecognition of the dimensions of the framebthanks to a parts
2 1
Š Cabycal
The new system allows For further information: www.cabycal.com
international PAINT&COATING magazine - SEPTEMBER/OCTOBER 2018 - N. 53
139
BRAND-NEW
W
ithin three months
© BASF
Groundbreaking Expand!™ Coatings Pigment From Colors & Effects® Portfolio Off To Strong Start With Customers of its official launch, the eXpand!™ Red
EH 3427 stir-in pigment for automotive coatings from the Colors & Effects® pigment portfolio has received its first commercial sales order from a major automotive coatings manufacturer. “This is our fastest introduction of any new pigment in automotive applications and demonstrates that we are well prepared to meet customer demand quickly and successfully,” said Paul Verhoeven, eXpand!™ business leader. “This technology underwent an intensive customer testing phase and we are very glad about the
1
early demand.” The eXpand!™ Red pigment is the first in the eXpand!™ line and is the result of
Figure 1: The eXpand!™ Red pigment is the first in the eXpand!™ line and is the result of the strategic partnership stablished in 2017 between BASF and Landa Labs.
the strategic partnership stablished in 2017 between BASF and
“A very close collaboration between the
researching and developing more pioneering
Landa Labs. The blue-red shade stir-
technical units of the Colors & Effects®
pigments.
in pigment is compatible with modern
team and our customer underscored the
In addition, Morcillo Ruiz will be at the 2018
automotive coating systems and offers
innovation and benefits that eXpand!™ Red
Pigment Color & Science Forum at the Marriott
intense shades, colour depth and
offers,” said Javier Morcillo Ruiz, technical
Copley Place in Boston, Massachusetts, on
sparkle thanks to its high transparency,
director of eXpand!™ at BASF. “We were able
October 4, presenting “On the Road to New
low scattering and tinting strength. It is
to demonstrate its outstanding coloristic
Dimensions in the Golden to Red Color Space”
the first of its kind suitable for outdoor
properties as well as its efficient stir-in
at 3 p.m. during the Advancements in Pigment
applications and is easily dispersible,
characteristics within a very short timeframe.”
Technology session.
cutting the time involved in the production
Looking ahead, the eXpand!™ team currently
process compared to traditional milling and
has more than 20 projects running with
For further information:
dispersion methods.
automotive coatings suppliers globally and is
www.colors-effects.basf.com
140
N. 53 - SEPTEMBER/OCTOBER 2018 - international PAINT&COATING magazine
SUCCESS STORIES
Electric Vehicles from Sokon Will Be Painted Using Highly Flexible Seven-Axis Robots
D
ürr acting as general contractor for
investment and maintenance costs in the
for the sealing stations. The seam sealing
the construction of complete paint
spray booth and also enables a better
and insulation materials will be applied to
shop in Chongqing (Fig. 1).
view of the booths.
the bodies by 20 robots from the EcoRSi
In total, 60 Ecopaint robots from the
series (Fig. 3).
Electric cars will be manufactured using
© Dürr
state-of-the-art technology in the Chongqing Sokon Industry Group,
Lower investment and maintenance costs
within the next weeks. It is the first
Dürr’s third generation of robots
time that the extremely mobile,
is modular in structure. This
seven-axis painting robot EcoRP
means that the EcoRP E/L033i
E043i from Dürr’s new generation of
and EcoRP E/L133i models
robots will be used in China (Fig. 2).
with their 6-axis kinematics
It can paint differently sized bodies
can be used both for painting
of the fully electric SUVs flexibly and
and for opening the hoods.
without the previously required
The modular concept has been
displacement rail. The complete
applied throughout the 6-axis
new electric vehicle plant of the
paint shop with Dürr as the general contractor also includes an Ecopure air purification system with heat recovery. The new plant will therefore also set standards when it
and 7-axis kinematics. The
1
only difference between the
Figure 1: Dürr is constructing the entire paint shop for Sokon as general contractor.
comes to air pollution control.
variants is the additional axis of rotation in the main arm. The otherwise universally identical components simplify spare
latest generation are being used in the
parts management, save storage costs, and
development of electric mobility with its new
primer, top coat, and clear coat lines for
make maintenance work easier. The control
plant at the company’s site in Chongqing.
interior and exterior painting at Sokon.
technology of the robots for applying paint
The production technology itself is also
As well as the 36 EcoRP
pioneering. It will be the first time that a
E043i painting robots,
third-generation painting robot from Dürr will
16 SCARA door openers
be used in a Chinese car factory. The EcoRP
and the six-axis models
E043i has seven rotary axes, making it much
as a hood opener are
more mobile than previous painting robots
being sent to China.
with six axes. The additional joint extends
In addition, Dürr is
the robot’s working area. As a result, it
supplying the robots and
reaches even hard-to-access areas with ease
application technology
© Dürr
Sokon is dynamically promoting the
when painting the interiors of the bodies. Up to now, painting robots often moved on horizontal rails. The EcoRP E043i no longer needs these thanks to the high mobility of its 7-axis kinematics. This greatly reduces the
142
Figure 2: Ready to go: Dürr’s latest robot generation will soon be painting electric SUVs in China.
N. 53 - SEPTEMBER/OCTOBER 2018 - international PAINT&COATING magazine
2 1
© Dürr
SUCCESS STORIES Figure 3: The seam sealing and insulation materials will be applied to the bodies by 20 robots from the EcoRSi series.
the building structure, saves space, and enables intelligent material flow control, making it a key part of Dürr’s Eco+Layout. Among other things, the technical scope of services includes the RoDip rotational dip process in pre-treatment and electrocoating, all robots and applications
3 1
Further milestones
for the sealing and painting processes, and
towards the
the EcoDryScrubber dry separation system
digitization of
(Fig. 4). This binds the paint overspray in
the plant are
a process involving no water or chemicals,
reached with the
and can therefore be operated with up to
MES software
90% recirculated air. The result is an energy
and high-viscosity material is also universal.
for production control developed by Dürr.
The modular design of the control cabinets
Monitoring, tracking, and individually
enables the optimal configuration for the
configurable reporting are important elements
respective application process of a painting or
in efficient process control and optimization.
Energy-efficient exhaust air purification
sealing station at the customer.
This solution is the basis for further advances
When it comes to emission protection,
With EcoScreen 3D-OnSite 4, a universal
in the area of Industry 4.0.
Sokon will comprehensively meet all legal
software package is available for
saving of up to 60% in the spray booth.
requirements and also realize maximum
Dürr’s painting and sealing robots. In
One-stop shop for a complete paint shop
addition, all relevant process data can be
The mechanical and plant engineering
zones will be purified by a combination of
parameterized. The software supports the
company Dürr is constructing the entire paint
the adsorptive process of the Ecopure®
programming, simulating, and optimizing
and is compatible with the previous
solvent emissions from the application
KPR VOC concentration
© Dürr
new generation of robot controllers
energy efficiency. The large volume of
system and the Ecopure® RTO
version. It can be connected online
regenerative thermal oxidation
to multiple robot controllers directly
system. The gaseous pollutants
via the network. As a result, changes
in the exhaust air from the
to teach programs and process data
booth first undergo adsorptive
can be transferred to the production
concentration before being
process in the shortest possible time.
disposed of in the downstream oxidation system with minimal
Fit for Industry 4.0
energy consumption.
The new coating and sealing robots
The latest generation of the
are prepared for the intelligent
Ecopure® TAR recuperative
factory of the future. Sensors detect temperature, operating hours, and the degree of wear of the components, among other things. The also newly developed EcoRCMP2
thermal air purification system
4 1
is used to purify the hot
Figure 4: EcoDryScrubber: dry paint separation without using water and chemicals.
process and motion controller
exhaust air flows from the various paint drying processes. This process purifies the exhaust air and at the same
transfers the information to the higher-level
shop for Sokon and, as general contractor, is
time makes all the heat available for
maintenance and control system. Thanks to
also responsible for the construction of the
heating the oven.
this technology, the data from multiple spray
building and for three high-bay warehouses.
booths or even complete paint shops can be
These high-bay warehouses mean that various
For further information:
combined and evaluated.
surface storage is not needed. This simplifies
www.durr.com
international PAINT&COATING magazine - SEPTEMBER/OCTOBER 2018 - N. 53
143
© RoyalbDSM
1
144
N. 53 - SEPTEMBER/OCTOBER 2018 - international PAINT&COATING magazine
SUSTAINABILITY
Uralac® Ultra Technology: A Better Solution for Coating Heat-Sensitive Substrates Sjoerd de Jong DSM Coating Resins, Waalwijk, The Netherlands
uralac.ultra@dsm.com
R
oyalbDSM is a globalbscience-
performance, environmentally friendly
based company active in health,
alternative to traditional solvent-borne paints.
The evolution of powder coatings for heat-sensitive substrates
nutrition and materials with
These attributes, together with the unique
From the first commercial attempts in the
solutions that nourish, protect and
aesthetic options that are available with
early 1990s until only a few years ago, powder
improve performance in a wide range of
powder, have made it the preferred coating
coatings available for heat-sensitive substrates
end markets. Fortune Magazine recently
have provided a viable solution to drive a shift
ranked DSM number two in its 2017
away from liquid coatings. However, the new
‘Change the World’ list of 50 companies that are making an important social or environmental impact through their profit-making strategy and operations. Additionally, DSM has consistently been recognized by the Dow Jones Sustainability World Index for integrating sustainability into its business, having been named among the global leaders in each of the last 13 years, and holding the number one position in the sector seven times. One of its business units in particular, DSM Coating Resins, has made a significant contribution to the transformation to sustainable technologies in the field of paints and
technology came with a significant degree of uncertainty about the results that this shift For metalwould yield. based products, powder In terms of thermally-cured technologies, coating is well established as a several factors hindered the widespread high-performance, environmentally adoption of powder coatings; most friendly alternative to traditional prominently, limitations associated with solvent-borne paints. These attributes, together with the unique aesthetic options cure temperature/duration imposed by the poor chemical storage stability that are available with powder, have of catalyzed systems. With regard to made it the preferred coating technology UV-cured powders, the inability to cure for many products. With the launch of complex shapes, difficulty curing some Uralac® Ultra technology by DSM, the colors, limitations on coating thickness benefits of powder coating are now (including poor intercoat adhesion when available for products made with applied in multiple coating layers), have heat-sensitive materials such made the technology unsuitable for many as engineered and natural applications. Aesthetic properties also imposed woods as well.”
coatings. Specifically, the business has
limits, as the available technologies struggled
promoted the shift away from traditional
to achieve the smoothness and gloss versatility
solvent-based coating technologies by
technology for many products. With the launch
requirements of several market spaces.
providing the propositions necessary
of Uralac® Ultra technology by DSM, the
In addition to the limitations imposed by the
for the segment to evolve towards a
benefits of powder coating are now available
available material technologies, advancements
sustainable future.
for products made with heat-sensitive materials
in application and curing process technologies
For metal-based products, powder
such as engineered and natural woods as well
were necessary for powder coatings to gain
coating is well established as a high-
(Fig. 1).
extensive acceptance. The electrostatic
Figure 1: With the launch of Uralac® Ultra technology by DSM, the benefits of powder coating are now available
for products made with heat-sensitive materials.
international PAINT&COATING magazine - SEPTEMBER/OCTOBER 2018 - N. 53
145
© RoyalbDSM
SUSTAINABILITY
????????? ???????
2 1
Figure 2: Uralac® Ultra offers superior aesthetic qualities in many colors, gloss levels, textures and finishes, even on unusual shapes, edges, hollows and contours, allowing imaginative new substrate designs and semi-assemblies that could not easily be finished with liquid coatings.
variables associated with non-metal substrates made it difficult to control film thickness, and conventional ovens lacked a mechanism to direct and control heat with adequate precision.
The revolution of powder coatings for heat-sensitive substrates Thanks to recent advances in application
Powder coatings based on Uralac® Ultra technology create competitive advantage: - Tougher - Greener - Safer - Greater production efficiency - More design flexibility - Technical support, from start to finish
that hindered the advancement of powder coatings in non-metal applications in the past have been overcome. The technology has advanced to such a degree that, for those who have taken a close look at the possibilities, converting to powder coatings is no longer a questionable proposition. Rather, as those who have made the conversion in recent years will attest, converting to powder coating for heat-
and curing equipment technologies,
sensitive substrates is steadily developing into
together with the recent introduction of
a competitive necessity.
the Uralac Ultra binder chemistry (based
development of regulated counter electrodes
on unsaturated polyester, which imparted
provided an important step forward. Oven
The commercial launch of
flexibility, and urethane, which improved
technology, with the advent of catalytic
Uralac® Ultra in 2014 further established the
durability), powder coating technology has
infrared curing systems, now provides an
viability and added value of powder coatings
bridged the technology gap and become
efficient and reliable way to cure powder on
for heat-sensitive substrates, offering a
a reliable proposition for heat-sensitive
heat-sensitive substrates. Finally, with the
competitive advantage to manufacturers by
substrates.
commercial launch of Uralac® Ultra based
improving both their operational solutions
In the field of application technology, the
powder coatings in 2014, the obstacles
and the final product.
®
146
N. 53 - SEPTEMBER/OCTOBER 2018 - international PAINT&COATING magazine
SUSTAINABILITY The revolutionary process of coating by powder The powder production process involves mixing, extrusion, milling and sieving steps, after which the powder is typically applied electrostatically, followed by curing under heat to allow it to flow and ultimately harden. The powder coating formulation consists of a binder (resin and crosslinker), pigments and additives. Powder coatings are mainly used for the coating of metals, such as household appliances, aluminium extrusions and automobile and bicycle parts due to the high temperature that is required
significant efforts towards reducing the curing temperature: this has been the driving force to further reducing the required energy of an already ecological, low-footprint process. This creates an increased demand for low-temperature curing powder coatings without adverse effect on the curing times, which are also important for lowering manufacturing costs. DSM has been a pioneer in developing polyester resins since the 1960s, and, through its ongoing commitment to resin quality, consistency and sustainable growth, has become the world’s leading
© RoyalbDSM
to harden the coating, which is typically
160-170°C. For years, there have been
Thanks to recent advances in application and curing equipment technologies, together with the recent introduction of the Uralac® Ultra binder chemistry (based on unsaturated polyester, which imparted flexibility, and urethane, which improved durability), powder coating technology has bridged the technology gap and become a reliable proposition for heat-sensitive substrates.”
3 1
Figure 3: Uralac® Ultra reduces the environmental footprint and guarantees a higher chemical and physical resistance than traditional coating solutions, enabling a reduction in the cost and fuel consumption involved in transportation and storage.
148
N. 53 - SEPTEMBER/OCTOBER 2018 - international PAINT&COATING magazine
SUSTAINABILITY
MDF was intended for. Next, low-temperature
imaginative new substrate designs and semi-
UV-curable powder coatings were often
assemblies that could not easily be finished
proposed for coating heat-sensitive substrates.
with liquid coatings (Fig. 2).
However, UV technologies also have a
The coated surfaces also possess impressive
number of drawbacks, including an inability
resistance against abrasion and moisture,
to produce thick or matte coatings, shade
broadening the scope of market opportunities.
specificity, higher material costs and higher
For example, IKEA noted in their 2016 Annual
capital equipment requirements. The powder
Report that, as more of their customers are
coatings using Uralac® Ultra system enables
now living in humid climates, the powder
fully powder coated MDF objects, without
coating technique has helped improved the
exposing the MDF to excessive heat loads
humidity resistance of the HEMNES bathroom
and it provides an opportunity to differentiate
series. The versatility of Uralac® Ultra also
finished products by offering superior
allows for a greater design freedom, being
aesthetic qualities in many colors, gloss levels,
able to be applied on real wood, MDF, HDF
textures and finishes that are still challenging
and alternative substrates, offering opaque,
for other powder coating technologies for
transparent or glazed surfaces for every design
heat-sensitive substrates.
material.
Superior aesthetic offering
Robust, efficient processing
As products made from heat-sensitive
Uralac® Ultra not only allows manufacturers
supplier of high-quality, consistent powder
substrates such as MDF gain a bigger
to broaden their market reach, and raise the
coating polyester resins. These high-quality
and bigger market share, both in interior
performance standards of their products,
resins, such as Uralac® Ultra, are combined
architecture and furniture manufacturing, the
it also enables significant cost savings in
In line with the market demand for “mass customization”, Uralac® Ultra provides an opportunity to differentiate finished products by offering superior aesthetic qualities in many colors, gloss levels, textures and finishes, including hammer tones, veins and speckles. What’s more, it does so even on unusual shapes, edges, hollows and contours, allowing imaginative new substrate designs and semi-assemblies that could not easily be finished with liquid coatings.”
with Uralac Ultra crosslinkers, pigments
design possibilities and color choice of powder
the manufacturing process compared to
and other additives, to determine the
coatings become increasingly important
incumbent coating technologies. The powder
specific properties of the powder coating,
properties. In line with the market demand for
coating process offers many advantages
and then applied by electrostatic spray to a
“mass customization”, Uralac® Ultra provides an
compared to the application process of a
pre-heated substrate. The coating is cured
opportunity to differentiate finished products
liquid finish, requiring fewer operational steps
in a specialized catalytic infrared curing
by offering superior aesthetic qualities in many
and enabling a higher line density. Depending
chamber at a high temperature.
colors, gloss levels, textures and finishes,
on the substrate, the powder coating
For Uralac Ultra, this curing process takes
including hammer tones, veins and speckles.
processing can take place up to ten times
place at 130°C (265°F) for three minutes.
What’s more, it does so even on unusual
faster than liquid coating, and cost savings can
Once the powder coating has been
shapes, edges, hollows and contours, allowing
reach 45%.b
®
®
In particular, the fully automated one-step
successfully cured, the finished product is taken off the racks. MDF is an excellent example of a heat-sensitive substrate that can be coated using the described technology. Different powder coating technologies can be used to coat MDF, including hybrid technology, epoxy powders or UV powder coatings. However, when exposed to temperatures above 140°C, temperatures needed to harden for hybrid systems, for a relatively short time MDF shows warping and cracks. This is clearly unacceptable for any decorative or structural application the
It’s possible to use just three minutes of oven time with powder, rather than the 30 minutes with liquid paint. Powder coatings are also faster to process because there is no priming and less sanding involved. But make no mistake, this increased speed does not impact at all on quality.” – Paul Maeyninckx, company owner.
application of powder coatings based on Uralac® Ultra technology results in reduced rework and minimized sanding. Color changes on the production line can be implemented in a quick and efficient way, without the requirement of additional floor space. From start to finish, the process can be completed in 20 to 30 minutes, with all surfaces covered in just one step. What’s more, as the overspray is in solid form, it is easy to collect and re-use, resulting in material utilization of over 90%, and also proves to be less toxic to operators handling the product.
international PAINT&COATING magazine - SEPTEMBER/OCTOBER 2018 - N. 53
149
SUSTAINABILITY A greener, more sustainable coating solution With increasing environmental awareness, and air pollution standards becoming more stringent, the demand for environmentally friendly coatings is also increasing. A conversion to powder coatings based on Uralac® Ultra allows manufacturers
With increasing environmental awareness, and air pollution standards becoming more stringent, the demand for environmentally friendly coatings is also increasing. A conversion to powder coatings based on Uralac® Ultra allows manufacturers significant environmental advantages, as their environmental footprint will be reduced by integrating a low-temperature bake and a nowater process. The powder coating process also prevents harmful chemicals from damaging the environment, as it involves no VOCs. ”
On-hand technical product support DSM provides comprehensive technical support to manufacturers in adopting the Uralac® Ultra powder coating technology at every stage. This ranges from fine-tuning the best coating and curing process for your applications in laboratory testing, to equipment selection, coating line configuration and general project management.
significant environmental advantages, as their environmental footprint
Blue Wool Scale (discoloration tests) and
With five manufacturing centers in the
will be reduced by integrating a low-
hinge hole benchmarking (known as swelling
Netherlands, Spain, the United States and
temperature bake and a no-water process.
test or the Ledro test). These tests confirmed
Greater China, as well as marketing and sales
The powder coating process also prevents
the solution’s excellent humidity, UV light
hubs on three continents, DSM can provide
harmful chemicals from damaging the
and chemical resistance, and its other
technical support to coating manufacturers
environment, as it involves no VOCs. In addition,
high-performance qualities. Furthermore,
across the world, and for a broad range of
powder coatings based on Uralac® Ultra
the Uralac® Ultra architectural range comes
industrial sectors.
have higher chemical and physical resistance
withbEnvironmental Product Declarationsbthat
than traditional coating solutions, enabling a
contribute towards LEED credits.
reduction in the cost and fuel consumption
Uralac® Ultra also enables manufacturers
The right time to convert to powder coating
involved in transportation and storage (Fig. 3).
to meet increasingly stringent workplace
The operational, environmental and
A comprehensive Life Cycle Assessment for
regulatory standards. Since this technology
performance benefits of Uralac® Ultra powder
Uralac Ultra measures a carbon footprint that
is solvent-free, it reduces fire and application
coating technology make it a better choice
is five times lower than solvent-borne coatings.
risks, and offers a better disposal of waste.
than the incumbent coating technologies for a
The eco-footprint for Uralac Ultra, which
It also reduces the health risks for operators, as
wide range of applications, including children’s
indicates the impact on resource depletion and
any powder can easily be washed off and there
furniture, bathroom furniture, office furniture,
climate change, is equally reduced.b
are fewer hazardous materials.
outdoor furniture, and kitchen furniture.
As manufacturers across the world try to
By converting to Uralac® Ultra powder coating
implement safer operational practices,
technology, manufacturers can lower operational
®
®
Meeting higher regulatory standards
Uralac Ultra technology provides an
costs, increase end-product value and provide a
The eco-friendliness of powder coatings
SHE-compliant solution for a wide variety of
mechanism for meaningful differentiation.
based on Uralac Ultra also enables
markets.
In fact, given the considerable advantages of
®
®
compliance with tighter and tighter industry
this coating technology, converting to powder
restrictions. Since 2005, the coating industry
coating for heat-sensitive substrates such as
in Europe has been subject to the strict environmental guidelines of the Kyoto protocol of 1997, and in recent years these industry guidelines have become even stricter. In light of this, Uralac Ultra-treated products offer a high ®
level of compliance with all major regulatory requirements, and have been submitted to key industry standard tests, such as
We made the switch to the one-layer coating quickly and efficiently. Moreover, since adopting the new coating technology, our supplier has continued to work closely with us and has developed a wide range of colors and effects specially for us.” – Walter Schweiger, company owner.
NEN-EN 12720 (resistance to cold liquids),
150
N. 53 - SEPTEMBER/OCTOBER 2018 - international PAINT&COATING magazine
Uralac® Ultra is quickly becoming a competitive necessity. With the adoption of Uralac® Ultra technology by leading manufacturers in both North America and Europe already well on its way, few coating companies can afford the late integration of this superior powder coating solution. For further information: www.dsm.com
BRAND-NEW
BYK-Gardner Seminar – the Complete Solution for Paints Control
L
earn how to test objectively the physical
Day 1: Physical Properties 101
The seminar content applies to all
properties of wet to dry coatings. Then,
- Viscosity Measurement in CQ
industries and is appropriate for users at
experience how practical colour and gloss
- Wet film preparation
all levels and for those who want to expand
measurements will improve product quality and
- Temperature control of production ovens
their knowledge.
communication along the supply chain.
- Hardness, Abrasion and Flexibility control - Film Thickness measurement on different
Prices
When: November 07-08, 2018 Where: CDH Hotel Parma & Congressi, Parma, Italy
Day 2: Color and Gloss in practice
Both days: 795,00 € per person
During both seminar days, the subject will cover
- Visual and instrumental gloss evaluation
Prices include certificate, lunch and training
theoretical basis and advices of international
- Fundamentals of gloss measurement and its
materials.
standards. The presentations will be integrated
substrates
Day 1: 495,00 € per person Day 2: 495,00 € per person
limitations
with interactive workshops and all the
- Fundamentals of color measurement
attendees will have the chance to operate with
- Which geometry is suitable for my application?
For further information:
the instruments.
- Color system and color tolerancing
www.byk.com
Aluminium Wheel Painting
Excellence in surface finishing For the painting of aluminum wheels, Dürr delivers powerful technologies along the whole process, starting with wheel surface cleaning and chemical conversion for effective corrosion protection, painting and curing, to the purification of air exhaust. Dürr offers their own application technology with specially patented features that fit best with the requirements of quality-oriented aluminum wheel surface painting. www.verind.it
BRAND-NEW
Automation Made Easy
T
he new SprayPackE control unit from
system. This also sets it apart from other
guns. The powder supply is switched off
WAGNER facilitates the changeover
solutions on the market. For example, the
in the gaps. In addition, the innovative
from manual to automated powder
powder quantity can be easily determined
height control system, which previously
coating (Fig. 1). Due to its great user-
via a central touch screen (Fig. 2) - for
only existed for larger WAGNER systems,
friendliness, the operators can efficiently
all guns, in groups or individually. With
is now optionally available for the
achieve a high coating quality. Existing powder
comparable devices, the guns must be set
entry-level model. Michael Topp
coating systems can also be brought up to
individually via the corresponding control
explains: “The height control optimizes
date.
modules. This costs time - and money, as
the coating of parts of different heights
Full order books quickly push companies
an example shows:
by switching off guns that would spray
While an operator
past the workpiece. This works via a
the limits of their capacities. One
needs around ten
continuous light bar at the entrance
seconds to change
to the powder booth. Spaces in the
the parameters
workpiece, for example in window frames,
with conventional
are also omitted in this way.” This creates
controls, new
maximum efficiency and minimizes
solution is to switch to automated applications. In addition to the
© Wagner
that do manual powder coating to
powder booth, powder preparation, motion systems and guns, this includes an intelligent control
settings can be made
powder consumption.
system that is easy to install and
with the SprayPackE
The guided colour change process
operate. This saves time and
in just two seconds.
makes operation even easier. An easyto-understand step-by-step guide helps
guarantees a high coating quality. With the new SprayPackE automatic
Figure 1: SprayPackE automatic control unit, the CPE module for controlling the power supply and safety interlocking of the motion technology, the MCE module with intuitive menu navigation for easysystem control.
control unit, WAGNER has brought a solution onto the market that meets all these requirements. It controls up to 20 automatic guns and the motion systems in the powder booth. “Thanks to its integrated design and high user-friendliness, the SprayPackE offers an ideal introduction to automatic powder coating. Even outdated plants can be
1
to avoid errors and, as a result, timeconsuming reworking or downtimes. Furthermore, a maintenance counter records the operating hours per component and thus enables an optimal maintenance routine for a long service life of the control unit.
Entry into automated powder coating or upgrade of obsolete systems
easily modernised,” explains Michael Topp,
With an average of four setting changes
The new automatic control unit is suitable
Global Senior Product Portfolio Manager at
per hour, extrapolated on the basis of a
for all industries. Be it for users who
WAGNER.
conventional eight-hour day, this results in
switch to automatic coating, but also for
an efficiency gain of several thousand euros
upgrading outdated coating systems.
per year.
“Controls in older powder coating systems
Sophisticated user guidance saves time and money
can be easily replaced by the SprayPackE,”
its predecessor model, this new product
Material savings through intelligent gap and height control
scores above all through its simple operation.
Customers also benefit from WAGNER’s
Instead of numerous individual components,
automatic gap and height control. The gap
it consists of a central control unit that can
control ensures that spraying only takes
For further information:
be used to control the entire powder coating
place when a workpiece is in front of the
www.wagner-group.com
With the SprayPackE WAGNER replaces the PrimaTech-CCM control unit. Compared to
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N. 53 - SEPTEMBER/OCTOBER 2018 - international PAINT&COATING magazine
says Michael Topp. “In principle, the booth and powder supply unit can continue to be used without restriction, as can guns up to a certain age.”
BRAND-NEW
Tikkurila Protects Steel Structures of the World’s Largest Indoor Ski Centre
T
he world’s largest indoor ski
the roof structures, will comprise of
anti-corrosive Temacoat Primer and
centre is under construction at
150 components and weigh about
high-solids polyurethane topcoat
Lørenskog, Norway, approximately
500 tonnes. The complex has been
Temathane PC 50. The combination
20 kilometres east of Oslo. The
designed by Norwegian Halvorsen &
provides excellent weather and
six-story skiing complex houses a
Reine AS and the opening is scheduled
abrasion resistance for steel, stainless
downhill ski slope over 500 meters
for early 2020.
steel, aluminium and zinc surfaces.
long and a suspended cross-country
Over 60 companies are involved in
ski track. Tikkurila partners with Ruukki
building the EUR 105 million ski centre.
High-performance protection
Construction in providing the steel
Ruukki Construction, a subsidiary
The quality standards for the ski
structures for the site.
of SSAB, is in charge of designing,
centre’s steel structures and protective
The ski centre has a snow-covered
manufacturing and installing the steel
coatings are very high. The minimum
area of around 40,000 square meters,
frame and load-bearing sheets.
structural steel grade was S355, but
which is the equivalent of five football
The steel structures are manufactured
certain structures of longer span
pitches. The downhill ski slope,
in Ruukki’s Peräseinäjoki and Oborniki
distances required S550 high-strength
equipped with three ski lifts, will be
units, where they are also coated
steels. Protective coatings had to meet
accompanied by a cross-country ski
with Tikkurila’s polyurethane system
corrosivity category C3-H according to
track. The ski track, suspended from
TP131. The paint system includes
EN 12944-2.
© Tikkurila
“These standards are exceptionally high for indoor steel structures. All outside structures had to be galvanized steel”, explains Mika Jäsperlä, Design Manager of Ruukki Construction. “In protective coatings, we must consider not only the final purpose of use, but also logistics. An element made for indoors has to withstand varying weather conditions during transport, such as overseas shipping. Our epoxy primer gives steel structures excellent chemical and abrasion resistance and our polyurethane topcoat protects them from the weather and ultraviolet radiation. This ensures, that the final structures fully match the architects’ vision”, says Mikko Soini, International 1
Figure 1: The steel structures of the world’s largest indoor ski centre are coated with Tikkurila’s polyurethane system TP131. The paint system includes anti-corrosive Temacoat Primer and high-solids polyurethane topcoat Temathane PC 50.
Key Account Manager at Tikkurila Oyj. For further information: www.tikkurila.com
international PAINT&COATING magazine - SEPTEMBER/OCTOBER 2018 - N. 53
153
STANDARD & LEGISLATION - UCIF Informs
Cybersecurity Act and Industrial Applications: Taking Stock of the Situation Marcello Zinno UCIF – Italian Surface Treatment Equipment Manufacturers’ Association, Milan
T
info@ucif.net
he issue of cybersecurity is
That is why much attention is being and will
by pointing out that the legislative framework
increasingly important for companies.
be increasingly paid on this issue as related to
for cybersecurity would significantly
In Italy, thanks to the Industry 4.0
deviate from the existing, well-supported
and their ever-greater capacity to interconnect
New Legislative Framework. Orgalime
able to interact with each other have
goods and systems. This phenomenon is
also intends to suggest other regulatory
increased up to a two-figure percentage
under close observation in Brussels. Both the
instruments to cope with cybersecurity
in the year 2017 only. One of the essential
European Council and the ITRE Committee
in industrial applications and plants. In
requirements for plants to be considered
of the European Parliament formalised their
addition to a document that describes
4.0-oriented and able to benefit from tax
position on the EU Cybersecurity Act in June.
in depth the current state of IT security
exemption is interconnection, which is
The European Parliament held a specific
in Europe and in industrial plants (which
closely linked to the machines’ ability to
and formal vote on September, 13 2018.
the ANIMA Federation has sent to all its
produce data and information. Cybersecurity
Negotiations should start at the end of
member companies highlighting pros
does not focus so much on the intended
September to reach a final agreement on the
and cons of such analysis), Orgalime has
use or nature of these data, but rather on
law by the end of 2018.
organised a survey on the results expected
their protection, for which the data owner is
Orgalime (European Engineering Industries
from the Cybersecurity Act and on possible
responsible.
Association) has expressed an official position
suggestions on alternative regulations.
© iconimage ©Fotolia
the technological development of machines
Plan, investments in plants and machines
Figure 1: Attention will be increasingly paid on cybersecurity as related to the technological development of machines and their ever-greater capacity to interconnect goods and systems.
154
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N. 53 - SEPTEMBER/OCTOBER 2018 - international PAINT&COATING magazine
WORLD IN NUMBERS
MAGAZINES
MONTHLY VISITS - 55.000 YEARLY VISITS - 650.000
45%
BRAZIL
35%
MEXICO
20%
ARGENTINA, COLOMBIA, VENEZUELA, CHILE, PERUâ&#x20AC;&#x2122;
AVERAGE PAGES PER VISIT - 23
AVERAGE VISIT DURATION - 23 mins
BOUNCE (users that exit immediately after accessing home page) - 26%
sector average: 10
sector average: 8 mins
sector average: 47.5%
+13
+18 mins
-21%
WEBSITE
MyIPCM NEWS - 12
NEWSLETTER
LINKEDIN - 48
TRADE FAIRS & CONFERENCES
OCTOBER 2018 PROFINTECH
LONDON BUILD
Brno, Czech Republic October 01-05, 2018 www.bvv.cz/en/profintech/
London, UK October 23-24, 2018 www.londonbuildexpo.com
POWDER COATING SUMMIT Columbus, USA October 02-03, 2018 http://www.powdersummit.com/
PARTS2CLEAN
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MAKTEK EURASIA
Moscow, Russia October 23-25, 2018 www.expocoating-moscow.ru
ALUMINIUM
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Hanover, Germany October 23-26, 2018 www.euroblech.com
ORGATEC
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MTA HANOI
Cologne, Germany October 23-27, 2018 www.orgatec.com/ORGATEC/index-2.php
ANKIROS
Hanoi, Vietnam October 16-18, 2018 www.mtahanoi.com
Istanbul, Turkey October 25-27, 2018 www.ankiros.com/home-en/
IOT SOLUTIONS
Barcelona, Spain October 16-18, 2018 https://www.iotsworldcongress.com/
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EUROBLECH
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BIMU
Milan, Italy October 09-13, 2018 www.bimu.it/en/home/
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Istanbul, Turkey October 02-07, 2018 http://maktekfuari.com/en/
Düsseldorf, Germany October 09-11, 2018 www.aluminium-messe.com
Stuttgart, Germany October 23-25, 2018 www.parts2clean.de/home
KOREA METAL WEEK
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Goyang, South Korea October 30 - November 02, 2018 www.korea-metal.com/en/
NORTH AFRICAN COATINGS CONGRESS Casablanca, Morocco October 17-18, 2018 www.coatings-group.com/nacc
NOVEMBER 2018 COMPOSITES EUROPE Stuttgart, Germany November 06-08, 2018 www.composites-europe.com
Madrid, Spain November 13-16, 2018 www.ifema.es/veteco_01/
FABTECH USA
CONSTRUTEC
EIMA
EQUIPBAIE - METALEXPO
Atlanta, USA November 06-08, 2018 www.fabtechexpo.com
Bologna, Italy November 07-11, 2018 www.eima.it/en/index.php
156
VETECO
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Madrid, Spain November 13-16, 2018 www.ifema.es/construtec_06/
Paris, France November 20-23, 2018 www.equipbaie.com
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NOVEMBER 2018 INDUSMACH TANZANIA
ALL4PACK
Dar Es Salaam, Tanzania November 22-24, 2018 www.expogr.com/tanzania/indexpo/
Paris, France November 26-29, 2018 www.all4pack.com
EMAF
Porto, Portugal November 21-24, 2018 www.emaf.exponor.pt
THE BIG 5
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Dubai, UAE November 26-29, 2018 www.thebig5.ae
DECEMBER 2018 BUILD ASIA
COATING JAPAN
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Tokyo, Japan December 05-07, 2018 www.coating-japan.jp/en/
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JANUARY 2019 STEEL FAB
IMTEX
Sharjah, UAE January 14-17, 2019 www.steelfabme.com
Bangalore, India January 24 -30, 2019 www.imtex.in
BAU
Munich, Germany January 14-19, 2019 www.bau-muenchen.com
OPTI
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ASTEC
AUTOZUM
Salzburg, Austria January 16-19, 2019 www.autozum.at
Munich, Germany January 25-27, 2019 www.opti.de
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IPCC 2019
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international PAINT&COATING magazine - SEPTEMBER/OCTOBER 2018 - N. 53
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ZOOM ON EVENTS
© Lechler
Lechler Presented Its Color Design Project in a Workshop on New Colour Trends
1
Figure 1: The exhibition of Lechler’s colour ranges at the premises of the company, in Como (Italy).
L
echler, a well-established company
for wood and glass furniture.
products (Fig. 3). In fact, all surfaces
in the coating industry, organised the
This very relevant topic once again turned
interact with each other within their given
second half if its two-day workshop
out to be of great appeal for companies,
space, as well as with something able
on the Color Design project on 11 July, in
decision makers, style centres, architects,
to change and affect their look: artificial
its Como headquarters. Color Design is
and designers working on products and
or natural light. In “The Way of Effects”
the concept that the firm has developed
environments (Fig. 2). The evolution of
exposition, light was indeed presented
to link the progress of chemistry with the
colour language in the last few decades
as a controlled and essential element
evolution of colour language (Fig. 1). After
was analysed, highlighting that Lechler’s
in the design of domestic and contract
the success of the first workshop, held on
range has always been advanced in relation
environments; in particular, “The Way of
20 June, Lechler again invited designers
to fashion trends – which, today more
Effects” was inspired by the company’s
and architects to present its project, started
than ever, is a key trump card for any
new projects Acromatica, Synergía,
in collaboration with industrial designer
player in the design industry, a competitive
CTH Edition 2, and Color Trainer.
Francesca Valan who specialises in colour
advantage that often decides the
The presentation of the colour collections
design. The aim is offering directions,
commercial success of their projects.
began with the range CTC Acromatica.
suggestions, and technical information
As previewed at the Milan Fuorisalone in
This includes five new finishes, from glossy
to help users select tints and finishes.
April, for this event Lechler focussed on
to matte and with different visual effects,
The project is organised in three sectors:
the rules for combining trendy colours
all in an achromatic shade to enhance the
“Decorative” for home walls, “Industry” for
featuring special effects specifically
finishes’ combinations (Fig. 4).
metal and plastic materials, and “Habitat”
created for wood, plastic, glass, and metal
This new perspective goes beyond the
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N. 53 - SEPTEMBER/OCTOBER 2018 - international PAINT&COATING magazine
© ipcm ®
© ipcm ®
ZOOM ON EVENTS
2 1
3 1
Figure 3: Cube Effects is a range of metallic and pearly-effect colours in glossy and opaque versions, created and developed for the Industry and Habitat sectors. © ipcm ®
Figure 2: The project presentation during the event of 11 July.
conventional approach to the metallic
Effect and Steel IVE base coats enable
effect: colours, and not effects, are
to obtain the following effects:
the real protagonists, thanks to less
• Steel Ive;
noticeable lamellar particles and to
• Steel Ive Anodic;
the combination with soft effects. This
• Brush metal;
creates three different effects. Starglass
• One-layer 40-gloss metallic, in open
is obtained by dispersing glass fibres
and closed-pore versions;
in the transparent paint to give metal
• Starglass.
a diamond-like look when hit by light.
This overview on the latest projects
On-Off is a glossy and semi-gloss effect
developed by the company ended
obtained with specific formulations
with the presentation of Color Trainer.
4 1
using Lechsys Effect standard base coats, in which the aluminium pigment
This online counselling program
Figure 4: The colour panels of the Acromatica range.
is mixed with significant, well-adjusted
has been specifically conceived to help users choose the most suitable colours and products for the different
in diffused light conditions, as with pastel
environments of their home, with a
shades, but with direct light they create a
© ipcm ®
quantities of white: they have no effect
focus on wellbeing.
sparkling effect. Silk is a matte and semigloss effect obtained with transparent
The interesting excursus and the
coatings already used in particular
presentation of colour ranges held the
niches for a soft and silky appearance.
attention of the numerous participants,
ThebSynergía range integrates perfectly
including journalists and design
with the Acromatica collection, allowing
experts from the major Italian firms
the users to expand the range of
in the sectors of furniture, lighting,
colour/effect solutions with the different
domestic appliances, motorcycles,
shades offered.
architecture, and design (Fig. 5).
The colour and finish range CTH Edition 2 was updated with new shades and effects for furniture design. The Acrylack
5 1
Figure 5: Some of the workshop participants.
For further information: www.lechler.eu
international PAINT&COATING magazine - SEPTEMBER/OCTOBER 2018 - N. 53
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ZOOM ON EVENTS
© Aluminium
Recycling: Aluminium Scrap is Becoming More and More Valuable
1
Figure 1: ALUMINIUM will present the latest developments and potential of aluminium recycling from 9 to 11 October in Düsseldorf.
A
luminium recycling is gaining in
latest developments and potential of
made from the primary metal and those
importance as a source of raw
aluminium recycling from 9 to 11 October
made from recycled aluminium.
materials. Today, aluminium scrap
in Düsseldorf.
is already one of the most economically
Its significance is increasing in a time
valuable secondary raw materials.
of shrinking raw material reserves and
Important raw material source
Around 20% of the world’s aluminium
scarce, and above all expensive, energy.
Scrap supply is the bottleneck
requirements are covered by post-
Recycled aluminium is produced in the
for the aluminium material cycle,
consumer scrap. ALUMINIUM - the world’s
form of cast and wrought alloys. There are
since aluminium is used mostly in
largest industry event - will present the
no qualitative differences between alloys
products with long service lives, e.g. in
160
N. 53 - SEPTEMBER/OCTOBER 2018 - international PAINT&COATING magazine
ZOOM ON EVENTS
construction applications like windows or
aluminium. Today, about 20% of
cycle as a valuable resource. The pool of
in cars. Windows, e.g., can have a service
aluminium demand is covered by old
aluminium scrap will grow exponentially,
life of well over 50 years. That makes it
scrap – i.e. metal from products that
toughening the requirements for
necessary to wait a long time before the
have served their purpose. Another
processing and sorting, on the one hand,
scrap can be recycled. Not least for this
source of raw materials besides old
and the metal trade as the link between
reason, about 75% of all aluminium ever
scrap is new scrap. New scrap refers
the collection and melting down of old
produced is still in use, meaning it’s not
to, for example, waste generated
scrap, in particular, on the other.
yet available for recycling.
in the production of semi-finished
Long before the need for sustainable
goods, sprues from casting foundries,
development became a widely discussed
or shavings from the mechanical
Recycling Pavilion at ALUMINIUM 2018
topic, the global aluminium industry
processing of semi-finished goods and
From 9 to 11 October, the ALUMINIUM
had already been running its material
other products. Initially, increasing
trade fair in Düsseldorf will present
through a largely closed-loop cycle of
aluminium demand leads to higher
the latest developments and potential
metal production, processing, use and
demand for semi-finished goods,
of light metal recycling. The world’s
recovery. Product-related material cycles
which results in a higher volume of
largest industry event for the aluminium
from production to processing and use
scrap – unless process optimisation
industry will dedicate its own exhibition
to recovery of the metal are already
steps can be implemented to reduce
space to the subject of recycling. A total
largely closed today – depending on
the amount of accrued scrap. This is
of around 1,000 exhibitors and 27,000
the application market. This has always
done to the extent possible, in part
visitors from 100 nations are expected.
been true for long-lived applications in
because it’s economically beneficial
This year, the exhibition area will grow to
cars and buildings – with recycling rates
to companies: more scrap means
80,000 square metres - a record and a
of about 95% – and now for relatively
less product and thus less efficient
clear sign of the current dynamism in the
short-lived product applications in
production.
aluminium industry.
packaging. Recycling rates of more than
Aluminium scrap is among the most
In six exhibition halls, global players,
80% have been reached in this segment
economically valuable secondary raw
specialists and young innovative
in Germany, and recycling rates continue
materials. Recovering and recycling it
companies will present the complete
to rise in the EU area, as well.
conserves resources and makes an
range of the industry, from aluminium
The aluminium industry is by no means
important contribution to limiting the
production to machines and plants for
resting on its laurels; instead, it continues
rise of greenhouse gases. For that
processing, semi-finished products,
to work on filling existing gaps in the
reason alone, using existing scrap is
products for the application industries
circular economy. In order to recycle the
in the aluminium industry’s very own
and recycling.
raw material even more intensively in
interest. The goal therefore must be to
In addition to the aluminium producing
Germany, German aluminium companies
keep end-of-life aluminium products
and processing industry, the fair will
are investing in the expansion of their
– whether they’re from construction,
also focus on processes and product
recycling capacities, drawing on ultra-
transport or packaging – in the
innovations for the most important
modern plant engineering technology.
reusable material cycle by leveraging
aluminium application industries:
appropriate collection systems,
Automotive, mechanical engineering,
including end-of-life vehicle recycling,
construction, aerospace, electronics,
proper upgrading and dismantling,
packaging and rail transport.
According to estimates by the
and deposit systems and/or recycling
The fair is organised by Reed Exhibitions
International Aluminium Institute, about
bins.
with the support of the German
17 million tonnes of post-consumer
Thanks in particular to the lightweight
Aluminium Industry Association (GDA)
scrap accumulated worldwide in 2016.
construction megatrend, more and
and the European Aluminium Industry
This volume will increase to about 21
more aluminium is demanded and
Association.
million tonnes in 2020, representing
processed into a wide range of
a share of more than one third of
products. Once these are used up,
For further information:
today’s global production of primary
they must be kept in the economic
www.aluminium-messe.com
Post-consumer scrap covers 20% of aluminium demand
international PAINT&COATING magazine - SEPTEMBER/OCTOBER 2018 - N. 53
161
ZOOM ON EVENTS
SFCHINA2018 Guangzhou Offers Opportunities to Learn About Future of The Industry
S
FCHINA2018 will open its gate to
surface finishing industry. The increasing
Raschig, Joihey, Zi Yi, Nordson, Yu Tung,
global trade visitors from 4th to 6th
application areas and end-user industries,
Ramseier, Super Polish, Yinhe, Dazhi,
December 2018 at Area A of the
such as automobile, construction,
Electron Coating, Guanghua, Anest Iwata,
China Import and Export Fair Complex
aerospace, industrial equipment, electricals
Meibao, Dafeng, Pinnuo Machinery, C· RAY,
in Guangzhou, P.R. China, covering 1.5
& electronics, have become dominant
Jadechem, WIN-WIN Technology, ODM,
exhibition halls (Halls 4.1 & 5.1).
factors for promoting market growth.
JINCO, Uyemura, Liush, Runma, Dürr, etc.
Total gross exhibition area will be over
South China has been a prosperous region
regions are going to present
Alongside the exhibition,
their novel technologies and
a ‘Coating Applications
new products in three exhibit
& Product Finishing
zones, namely ‘Electroplating
Forum’ and a series of
& Finishing Technology’,
Technical Seminars will
‘Environmental, Safety &
be organized to provide
Protection’ and ‘Coating
valuable opportunities
Applications & Coating
for visitors to network
Products’. Highlight this year
with industry leaders
includes total net exhibition
and to share knowledge
rise of 7% against last 2016 Guangzhou show). Over 280
© SFCHINA
exhibitors from 19 countries/
Attractive concurrent technical programmes
15,000 square metres (a
area and number of exhibitors of the ‘Environmental, Safety & Protection’ exhibit zone has expanded by 189% and 71% respectively in comparison with 2017 Shanghai show. These
on latest technology
1
trends and industry
Figure 1: SFCHINA2018 will open its gate to global trade visitors from 4th to 6th December 2018 at Area A of the China Import and Export Fair Complex in Guangzhou, P.R. China covering more than 15,000 square metres.
policies.
Visitor registration is now open!
remarkable figures are likely fueled by
for surface finishing industry and a major
Visitors can now pre-register on SFCHINA’s
increasing stringent government regulations
production base for personal protective
official website www.sfchina.net to
and growing awareness on workplace safety,
equipment, as well as witnessed a rapid
receive visitor pass in advance to avoid
thereby creating more opportunities in the
expansion in the environmental industry.
queuing during opening hours. Other
industry.
SFCHINA2018 will once again be an
registration methods such as WeChat
international meeting place featuring
and onsite registration are also available.
world-class exhibitors from across the
Follow SFCHINA on Facebook, Twitter and
Exciting showcase for innovative solutions and products
surface finishing industry, offering visitors
LinkedIn to receive first-hand information
Expanding industrialization, escalating heavy
a broad range of solutions and expertise.
or to get in touch with us.
machinery demand and deepening progress
A sampling of participating companies
of urbanization in APAC countries come
includes Finishing Brands, Parker, Atotech,
For further information:
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Gema, Wagner, Bostar, Hante, Zhenhua,
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