The first international magazine for surface treatments
®
ISSN 2280-6083
ipcm digital on In this issue:
Special Issue
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INNOVATIONS IN SURFACE TREATMENTS FOR METAL ARCHITECTURE
& INTERNATIONAL PAINT&COATING MAGAZINE
INNOVATIONS IN SURFACE TREATMENTS FOR METAL WORKING
2018
9th Year - Bimonthly N° 50 - MARCH/APRIL
we
l UV you
UV coatings In how many ways can the love for beauty and colour be expressed? Arsonsisi does it through a line of state-of-the-art UVcuring coatings, thanks also to the experience and know-how of Tecnocolor, a specialized company that is part of our group. Arsonsisi UVcolor range includes solvent-based, water-based or 100% dry residue coatings, suitable for various types of applications among which high vacuum metallization, Sputtering or PVD, and hybrid “Dual Cure� coatings with mixed heat/UV curing for complex 3D objects. Italian colour technology at the service of all industries.
www.arsonsisi.com
100% made in Italy
Visit us at PaintExpo 2018, Hall 1 booth 1149 17-20 April 2018 - Karlsruhe Exhibition Centre
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© Brainflash/by Martin Lugger
CONTENTS MARCH/APRIL 2018
INNOVATIONS IN SURFACE TREATMENTS FOR METAL ARCHITECTURE
The Trend Towards Ever-Greater Colour Customisation In The Aluminium Industry: The Response Of ALUKON
© CMA Robotics
38
The Cube’s Flexibility
FOCUS ON TECHNOLOGY
© Sevalcon
18
HIGHLIGHT OF THE MONTH
INNOVATIONS IN SURFACE TREATMENTS FOR METAL ARCHITECTURE
48 05 06 10 14
FOCUS ON TECHNOLOGY
Impol: the Supplier of High Quality PVDF Pre-Painted Aluminium for the Infrastructure of the 2018 World Cup in Russia
EDITOR’S LETTER ANALYSIS
25 26
Lean Production: How to Reduce the Production Time and Cost of Special and Customised Mask
70
HIGHLIGHT OF THE MONTH
CMA Robotics Celebrates 25 Years of History at the Forefront of Technology in the Automatic Coating Sector
INNOVATIONS IN SURFACE TREATMENTS FOR METAL ARCHITECTURE
FOCUS ON TECHNOLOGY Alumero: An Investment in the Coating Quality of Aluminium Profiles
BRAND-NEW HIGHLIGHT OF THE MONTH
INNOVATIONS IN SURFACE TREATMENTS FOR METAL ARCHITECTURE
44
SUCCESS STORIES Asif Khan Reveals Super-Dark Vantablack Pavilion for Winter Olympics 2018
86 89 102
BRAND-NEW INNOVATIONS IN SURFACE TREATMENTS FOR METAL WORKING
FOCUS ON TECHNOLOGY When the Proper Design of a Two-Rail Conveyor Improves the Versatility and Productivity of a Coating Company: The Success Story of Franchini Snc
Paint Expo 2018 17 - 20 April Visit us at:
Hall 2 Booth 2140
zonamista.it
For over 150 years, we have developed paints and coatings that enhance the appearance and durability of our customers’ products. With a broad range of liquid and powder coatings, designed to meet the needs of a wide array of industries, you can trust Sherwin-Williams to be your coatings solutions partner.
Inver and Syntha Pulvin are brands of The Sherwin-Williams Company
oem.sherwin-williams.com
© Nordson
© Arneg Italia
CONTENTS MARCH/APRIL 2018
INNOVATIONS IN SURFACE TREATMENTS FOR METAL WORKING
FOCUS ON TECHNOLOGY
INNOVATIONS: PRESENT&FUTURE
Ready for “Industry 4.0” and The Smart Factory with Nordson Dense Phase Technology
DKcomposing © Fotolia
110
Arneg Italia’s New Coating Line: an Industry 4.0-Oriented Management System in Compliance with the Most Advanced Environmental Protection Requirements © Cabycal
90
INNOVATIONS IN SURFACE TREATMENTS FOR METAL WORKING
170 130
FOCUS ON TECHNOLOGY
A New Automatic Coating Line to Increase the Production Capacity of a Glass Objects’ Manufacturer: the Positive Result of the Industry Teaming Up with Craftsmanship
FOCUS ON TECHNOLOGY Shot Blasting 4.0 for a Flexible and Highly Efficient Pre-Treatment Process Prior to Coating
154
Energy Efficiency in Italy: the Implementation Decree on the National Fund Has Been Published
160 BRAND-NEW 164 INNOVATIONS:
184
NitroBoxSpray® Revolutionises the Nitrogen Coating Concept: Better Performance at Low Costs Both In-House and On Site
174
BRAND-NEW
STANDARD & LEGISLATION What Changes with the ISO 9001:2015 Quality Certification?
PRESENT&FUTURE
INNOVATIONS: PRESENT&FUTURE Dense Phase, Low Pressure (DPLP) Powder Application: Reduced Consumption and High Performance with the New Transport System NEA 415
188
STANDARD & LEGISLATION - UCIF Informs
190 TRADE FAIRS & CONFERENCES
192
ZOOM ON EVENTS
PAINTING ROBOTS & SYSTEM INTEGRATOR Articulated and cartesian robots for every painting need! LeBot C5: 5 axis cartesian robot with shape acquisition scanner system.
LeBot A6: 6 axis articulated robot with self-learning, point-to-point and 3D offline programming, g available also with overhead crane and carousel configurations.
LeCrob Production Manager STD RFID WEB: production management software with RFID tags and antennas for automatic recognition of production queue
LeBot IA6: articulated 6-axis industrial robots for point-to-point applications, controlled by our LeCRob K-Manager software.
WWW.LESTA.IT 17/04/2018 – 20/04/2018 Karlsruhe, Germany
We invite you to visit our Booth: Hall 3 - Booth 3525
LESTA S.r.l. LEST
Via D. D Chiesa, 42 - 20020 Dairago (MI) - Italy +39 0331.430817 0 +39 0331.1581053 info@lesta.it info@
EDITOR’S LETTER
Richiedi la versione in italiano a info@ipcm.it
From Product Customisation to Individualisation
W
Alessia Venturi Editor-in-chief Direttore Responsabile
e are living in the era of mass customisation, a very strong trend facilitated by the logics of the fourth industrial revolution. However, a new era is already on the horizon, that of “market of one”. Although the two terms are often used as synonyms, there is a profound difference between “customisation” and “individualisation”, at least in the framework of industrial production. Mass customisation uses modularisation to increase product variety and at the same time maintain the logics (and benefits) of mass production. In this paradigm, consumers can choose the personalised configuration of their product within a series of options pre-set by its manufacturer and designer. Mass customisation, therefore, does not allow to create exclusive, unique, and individualised products. In order to do so, consumers must co-design and cocreate the product they are going to buy. In the spectrum of individualisation, the manufacturers of hard goods are at the lowest point, whereas at the highest point there are the producers of soft goods that can be configured and provided electronically, such as service companies1. At the industrial level, single-product batches are already a reality. What is new is the idea of creating unique products with the same logics of mass production. The Industry 4.0 will offer new forms of personalisation. Companies will be able to manufacture exclusive products in shorter cycle times, with efficiencies and costs normally associated with standardisation. Finishes are the “skin” of products and one of the parameters that influence purchase behaviour. That is why they are one of the most used elements for customisation. In future, companies performing coating tasks will have to be able to offer products with unique and exclusive finishes for each consumer, without sacrificing productivity and efficiency but at the same time implementing a just-in-time approach. If I have to find the common thread of the numerous articles included in this issue of ipcm® – which is a special edition for the PaintExpo 2018 trade fair, which in a few years has become the unmissable event for the world of industrial coating – it is precisely this: how companies are gradually transforming their production structure to meet the “market of one” needs and produce single-product batches, and how digital innovation is helping them. This transformation involves the whole value chain of coating processes: from paint suppliers, which must offer always new and customisable finishes and colours but also be able to produce them in very small lots and in a short time, to plant builders, whose management software must automate production to the point where it is possible to coat in sequence single-products batches with different colours and effects without sacrificing productivity, up to manufacturers of hooks and masks, which are gearing up to reduce their sampling times in the name of efficiency. Most case studies included in this issue portray Industry 4.0-ready factories with high levels of human-machine interaction and an optimal system integration to reduce production downtimes (e.g. colour change operations) and waste. These are factories ready to mass-produce highly customised products. These are factories of the future. 1
Wang, Y., Ma, HS., Yang, JH. et al. Adv. Manuf. (2017) 5: 311. https://doi.org/10.1007/s40436-017-0204-7
international PAINT&COATING magazine - MARCH/APRIL 2018 - N. 50
05
© Hang On
Opening photo: Masks, hooks and hanging systems are just a small part of industrial coating processes, but they have a greater impact on results than one might think.
ANALYSIS
The New Explorers Adriano Antonelli IBIX S.r.l - TECNO SUPPLY DIVISION, Santa Maria in Fabriago (RA), Italy
H
adriano.antonelli@tecnosupply.com
istory cannot be seen as a mere
the Republics that dominated the so far crucial
The economic and financial balance has
sequence of facts and dates. It is
trade routes. What fears and perplexities did
certainly changed, as have the behaviour of
always interesting to study it by
those communities perceive in such complex
consumers, who no longer buy things in a
delving into the people’s lives, the society
historical periods? What solutions did they
“cold” way, but prefer products with a high
of their time, and the mysteries behind the
conceive to counter the new events?
added value; the rules of communication and
continuous “cause and effect” cycle. Many
In a sense, history is now repeating itself.
marketing; and the production world – that
historians, for example, are intrigued by the
The recent crisis was not a part of a classic
is under everyone’s eyes. Planning methods
feelings, the enthusiasm and the motives of
economic-financial cycle. A negative economic
and even the just-in-time approach are
the first European explorers in the New World.
cycle has not just ended to be replaced by a
obsolete. The markets’ frenzy calls for quality
New lands to explore, new opportunities, and
new growth one. It is now clear that we are
at competitive prices, technology and skills.
new populations and cultures to deal with in
living in a New Economic Era. The world has
Market penetration can no longer be left to
seemingly infinite countries. All this changed the
profoundly changed in a way that we do not
chance. The value chain has become crucial:
equilibrium in the Old Continent, too, with the
fully understand, yet. One can feel lost and
we need to understand it and analyse it in its
loss of centrality of the Mare Nostrum and of
doubtful like the explorers of the New World.
specific aspects; such systematic study can
06
N. 50 - MARCH/APRIL 2018 - international PAINT&COATING magazine
ANALYSIS
© Hang On
Figure 1: HQS tree frames can be made up of different metal sheet shapes: 8 versions and different length.
and flexible hanging equipment is needed, which can be used with workpieces with similar shapes. This should always be not only available, but also analysed and tested in a short time, which is sometimes not reasonable for a technical and productive department.
protect companies from new problems such as
In this New Economic World, production stocks
fiscal and social dumping. Whole productions
and buffers are minimised and only exactly
with their satellite activities can disappear or be
what the market is currently asking for is
moved without any warning and in anomalous
produced. All efforts are directed at hanging
ways. A key concept has become crucial to
components in a smoother and faster way,
compete globally: productivity. In this article, we
while reworking and touching up operations
would like to apply it to the coating sector. In our field, “productivity” could be translated into the increase of workpiece hanging density while maintaining the same finishing quality. The greater the number of parts that can be hung onto the line, the higher the productivity of the plant, with countless advantages (ref. Opening photo). Some of them are immediate, such as less operation hours for the same number of hung parts and less waste of paint, energy, pre-treatment solutions, and so on. For this purpose, efficient
© Hang On
1
2 1
Figure 2: HQL bars are ready for use and feature already inserted 1 mm hooks; they can be integrated on HCF universal frames.
The economic and financial balance has certainly changed, as have the behaviour of consumers, who no longer buy things in a “cold” way, but prefer products with a high added value.”
© Hang On
operations with a minimum contact point. They can be integrated on HCF universal frames,
A HQS shaft can reach a 2400 mm length, while the distance between two hooks is adjustable according to production needs. In this way, the hanging point is minimised and the part is stable.”
3 1
which offer the great advantage of being able to implement all the three bar types of the HangOn range (Fig. 3). As well as HQL bars, H11B bars can also be integrated (Fig. 4): these enable to always protect the contact point, since the hooks are inserted in cavities. Flexibility and robustness are their two main characteristics. It is also possible to insert a second identical hook to make the hook stable as if it were soldered. HCL bars feature hook-holders (“socket”) welded on a wire with a diameter of 6 or 8 mm. “Each ‘socket’ is covered by a silicone cap to ensure maximum electrostatic force even if it is not used (Fig. 5). It can accommodate springs, sheet-cut hooks, and arrows. Countless arrangements can be created by using one bar
© Hang On
Figure 3: HangOn’s HCF universal frame is designed to flexibly accommodate different types of bars, depending on the hanging and coating requirements.
and changing only its accessory. The reduced cleaning needs of bars and frames are another important advantage.
are not acceptable. It is therefore important
Other interesting new hanging solutions will be
to avoid any disputes due to the presence
soon launched, especially suitable for coating
of corrosion or other surface defects caused
small parts: flexible frames that can be adapted
by improper pre-treatment or coating.
to various needs, standardised, economical, and
Tecno Supply, division of Ibix, and its partner
ready for use as always.
HangOn are offering hanging and masking © Hang On
solutions aimed at facilitating the work of coating line operators while meeting the growing demands for lean manufacturing processes. HQS tree frames (Fig. 1), for instance, feature 1.5 mm thick plates with different arrangements to be selected depending on the workpiece; 8 versions are currently available. There can be a 4 or 5 mm central hook. The frame is very durable and it can bear 30 kg per hanging point and 100 kg overall. The plates can be arranged with a
4 1
Figure 4: Suspension system (H11B, HB, H2B, H25B, H3B) bars are flexible and robust; they are punched to protect the contact points, since the hooks are inserted in cavities.
zigzag pattern, on one side only, or in parallel bends. This frame has been the subject of
to production needs. In this way, the hanging
an in-depth study to be produced at a cost
point is minimised and the part is stable.
equivalent to that of a box of hooks; on
Another particularly economical and efficient
the other hand, despite costing like a hook
hanging system for small components are
box, it ensures a 3 times higher hanging
HQL bars (Fig. 2). They are ready for use
and unloading speed. A HQS shaft can
and feature already inserted 1 mm hooks
reach a 2400 mm length, while the distance
in harmonic steel. These automatically
between two hooks is adjustable according
produced bars allow for fast hanging
08
N. 50 - MARCH/APRIL 2018 - international PAINT&COATING magazine
5 1
Figure 5: HCL bars feature “sockets” covered by a silicone cap to ensure maximum electrostatic force even if they are not used.
®
SPECIAL
BRAND-NEW
Ready2spray Painting Solutions for General Industry: Dürr Introduces Robot System At Paint Expo In Karlsruhe
P
this new combination at the Paint Expo
for customers in general industry.
the ready2spray paint robot EcoRP
Karlsruhe in hall 3 at booth 3218.
The robot lines into the new concept
10 R1100 (Fig. 1) contains fully
Dr. Hans Schumacher, CEO of Dürr
of ready2spray and ready2integrate
compatible, tried-and-tested components
Systems AG, says: “General industry has
sets which are a true innovation in this
and offers a unique combination in
seen a growing need for fully automated
market segment.”
the market. It is perfectly suited for the
paint application of the highest quality. The
The automated painting robot system
requirements of general industry. Areas of
new painting robot system offers a perfect
consists of a small six-axis robot
application include the painting of wood,
complement to Dürr’s product portfolio
equipped with state-of-the-art paint
plastics, glass and metal. Dürr presents
in the form of a compact painting robot
application technology. This technology
© Dürr Systems AG
re-installed and ready-to-spray,
1
Figure 1: Equipped with application technology, ready to spray: While the robot comes from Kuka, Dürr provides the paint application technology.
10
N. 50 - MARCH/APRIL 2018 - international PAINT&COATING magazine
SPECIAL
© Dürr Systems AG
BRAND-NEW
receive all components from a single source. These include the four product categories of pump and fluid-handling equipment, conventional application technology (spray guns), two-component systems as well as solutions for electrostatic application. The EcoBell high-speed rotating atomizers are ideally suited to industry, thanks to their variable spray jet. Therefore, Dürr offers perfectly coordinate solutions as ready2spray or ready2integrate solutions. The ready2spray systems are preinstalled, manual or automated solutions to be put directly into operation by the customer himself. The ready2integrate sets are automatic painting sets or paint supply sets, ready to be integrated into existing customer facilities. Dürr offers global support for the ready2spray and ready2integrate systems with assistance for all components and an international 24/7 hotline. For further information: www.durr.com
2 1
Figure 2: The new painting system is fully Industry 4.0-ready.
is available in different configurations, tailored to each individual customer project. The system, with all its different components, is completed and pre-commissioned at Dürr. It is thus ready to use (“ready2spray”), can be quickly installed at the customer’s site, and ensures efficient processes and a consistently high-quality paint finish. The ready2spray robot enables the application of solvent- and waterbased one- and two-component paints. It can be equipped with matching dosing pumps, paint pressure regulators and color changers. Depending on the requirements, it comes with automated spray guns (air-atomizing or airless) from the EcoGun range or with electrostatic high-speed rotating atomizers from the EcoBell range, both by Dürr. The compact industrial robot is an innovation in industrial painting. Its integrated concept also includes the motion control of the robot and the process control for the applications, housed together in one control cabinet. Furthermore, the new painting system is fully Industry 4.0-ready (Fig. 2). Dürr is the world leader in automotive painting and car body sealing through its painting and sealing robots as well as its application technology. As in the automotive industry, Dürr also covers the entire spectrum of paint application in the industrial sector. Customers
VACUDEST vacuum evaporator. An effective treatment of industrial wastewater. Thanks to innovative VACUDEST technology you get high quality rinsing water, resulting
in excellent results in your surface technology processes. Are you interested?
Visit us at the international trade fairs: PaintExpo: 17th to 20th March 2018, Karlsruhe IFAT: 14th to 18th May 2018, Munich H2O GmbH | info@h2o-de.com | www.h2o-de.com
SPECIAL
BRAND-NEW
© H2O
H2O Gmbh Presents the Answer to Higher Coating Requirements at Paintexpo
1
Figure 1: H2O at PaintExpo in Hall 1, booth 1611.
C
and reducing the disposal costs enormously.
ustomers are placing higher and
the world’s leading trade fair for coating
higher demands on consistent
technology, will take place from 17 to 20 of
Companies that produce a wastewater volume
cleanliness and low costs for part
April 2018 in Karlsruhe.
of 180 to 30,000 cubic metres per year stand
cleaning – processes need to be ever cleaner,
VACUDEST systems boast patented,
to enjoy the greatest savings. Wastewater
better and more cost-efficient. To respond to
innovative technology that sets high
can be treated coming from various different
these demands, H2O GmbH, which is based
standards in rinsing water treatment. For
manufacturing processes, such as paint pre-
in Steinen, Germany, has developed efficient
example, Clearcat technology produces
treatment, degreasing, electroplating, stainless
solutions that simultaneously improve rinsing
crystal clear, oil-free distillate that allows
steel pickling and many more.
water quality and reduce costs. H2O GmbH
surface technology processes to achieve
will demonstrate how it works at PaintExpo
excellent cleaning results. Thus it is ideally
For further information:
in Hall 1, booth 1611 (Fig.1). PaintExpo,
suitable for recycling in the rinsing process
www.h2o-de.com
12
th
N. 50 - MARCH/APRIL 2018 - international PAINT&COATING magazine
th
© ipcm ®
Opening photo: The new flat cutting machine purchased by Euromask.
HIGHLIGHT OF THE MONTH
Lean Production: How to Reduce the Production Time and Cost of Special and Customised Mask Francesco Stucchi ipcm®
T
the creation of samples and prototypes,
A flat cutting machine for the production of masks in hard materials
labour and waste: substantially, this
two activities with a strong impact on the
Finishing Group Srl (Solaro, Milan, Italy)
means to reduce the flow time of a
delivery times of companies offering tailor-
operates in the coating market with the well-
product along a manufacturing line. An
made products.
established brand Euromask for the production
14
he industrial philosophy of lean
exemplary lean production measure is
production focuses on creating
the reduction of the time required for
value with as little as possible
N. 50 - MARCH/APRIL 2018 - international PAINT&COATING magazine
HIGHLIGHT OF THE MONTH
Finishing Group Srl (Solaro, Milan, Italy) operates in the coating market with the well-established brand Euromask for the production of masks and hanging hooks.” of masks and hanging hooks. In the last three years, all its investments have been aimed at achieving greater flexibility and versatility and reducing process times, in line with the lean production philosophy. The most recent investment was a flat cutting machine (ref. Opening photo) enabling to cut harder materials with rather high thicknesses for manufacturing special and customised masks. “Our new machine can cut silicone, EPDM, foams with different densities, adhesives, and coupled materials with a thickness ranging from 2 to, currently, 15 mm,” says Simeone Maitan, the owner of this Group now operating worldwide with distributors in the main European countries and a branch in Mexico. “We have installed the new system to reduce almost completely the flow time of our normal production process, from sampling to manufacturing through prototyping.” “For conventional machines, we need two weeks to produce samples and at least three weeks to create the final production mould. Our new system, a sort of a flat plotter, enables us to switch from sampling to manufacturing in one day with similar or lower costs, since the moulds’ amortisation cost is eliminated,” states Maitan. This investment has made Euromask’s production not only very fast but also flexible and versatile also in terms of quantities. “The machine has no production quantity limits: it can range from 200 to 500,000 workpieces. Of course, for large-volume productions, we will require an economic assessment to determine if this machine is preferable to conventional systems,” says Maitan. From a technical point of view, the system has a well-defined flat surface of 100x60 cm. “It is possible to display different outlines on this surface (Fig. 1),” states Luca Bonin, the new machine’s manager at Euromask. “New outlines can be
Euromask has installed the new system to reduce almost completely the flow time of the normal production process, from sampling to manufacturing through prototyping.” international PAINT&COATING magazine - MARCH/APRIL 2018 - N. 50
© ipcm ®
Besides the already-mentioned advantages in terms of lean production, this new flat cutting machine, particularly appreciated in the leather and shoe sectors, enables Euromask to produce special masks even in peculiar materials such as foams.”
Applications
are more flexible and adaptable
Besides the already-mentioned
to complex shapes, thanks to
advantages in terms of lean
their lower density and hardness
production, this new flat
properties compared with
cutting machine, particularly
silicone,” says Simeone Maitan.
appreciated in the leather and
“With this new machine, we can
shoe sectors, enables Euromask
also produce masks in silicone
to produce special masks even
foam, which is high-performing like
in peculiar materials such as
silicone because it resists up to
foams. “Liquid coating does
300 °C, but less hard.”
not call for high temperature
1
resistant masks, but it requires
Figure 1: Examples of masks with special shapes that can be produced with the new machine.
large components or with very large holes to be protected. Foams are therefore the most suitable material, because they
program or, if they are particularly complex, with a 3D CAD drawing program. In this
© ipcm ®
drawn directly with the system’s 2D drawing
case, the drawings are then transferred to the machine and converted into its software language. The machine projects the realsize shapes on the worktable, showing different arrangement options to optimise production. Once the drawing is correctly positioned on the work surface, the machine’s pump creates vacuum to lock the material in its cutting position and a rotating spindle equipped with different types of blades cuts the shapes (Fig. 2).”
This investment has made Euromask’s production not only very fast but also flexible and versatile also in terms of quantities.”
16
2 1
Figure 2: A technical detail of the flat plotter.
N. 50 - MARCH/APRIL 2018 - international PAINT&COATING magazine
© Brainflash/by Martin Lugger
Opening photo: Saturated and unsaturated edrizzi® paint mist separators. They are assembled in the modular system to an optional size of separation area.
HIGHLIGHT OF THE MONTH
The Cube’s Flexibility Andrea Zanier Azett Kommunikation, Lienz, Austria
15
andrea@azett-kommunikation.com
years ago, Michael Eder revolutionized
first to entirely avoid filter mats extracted from
ergonomic finishing in numerous international
the surface processing industry with
mineral oil.
painting companies. Through the conversion
a cardboard box. In long time development he
In 2003 Brainflash, Eder’s company, launched
from wet to dry absorption, chemicals
pursued his vision of changing the varnishing
the trend-setting invention: paint mist
are eliminated in the separation process
process in an economical and sustainable
separators in the form of cubes, made from
and energy costs are lowered accordingly.
way: to eliminate chemicals in the separation
100% recycled paper. The major stroke lies
Saturated edrizzi® dry scrubbers are practically
process by the alteration from wet to dry
secretly within the inconspicuous boxes:
disposed of just like ordinary domestic waste,
separation. From the very first of his processing
complex, smart labyrinth systems made
and thus reduce the amount of harmful paint
Eder focused on physics, technology and 100%
of corrugated paper. Those can, with the
scrap, which is a cost-intensive special waste.
recycled paper. He never considered the mere
help of the centrifugal force, hold up to 100
The flexibility of the edrizzi® system is another
enlargement of filter surface – which doesn’t
kg overspray/m² and more and provide
benefit for plant operators, regardless of
even exist in the edrizzi® system and he was the
economical, environmentally friendly and
which industry or factory size.
18
N. 50 - MARCH/APRIL 2018 - international PAINT&COATING magazine
The modular system enables an individual
© Seliba S.L
HIGHLIGHT OF THE MONTH
to absorb all of the overspray.
application in any
Figure 2 shows
kind of surface
a plant in the
processing.
automotive
The manageable
industry with
cubes are
the edrizzi®
assembled in the
system in air
modular system
circulation
to an optionally
mode and thus
large separation
with several
area – no matter if used horizontally, vertically, or a combination of the
secondary
Figure 1: In spray gun facilities of every dimension the edrizzi® system may reach perennial service life. Since 2003, the system was further developed twice and adjusted for every application of surface treatment.
filters: the
to retrofit existing systems or install new
and ergonomic replacement. In consideration of
systems in a shortage of space - adaptions in
the designated air flow slow down zone, the first
measurements are possible in special-purpose
secondary filter is installed behind the edrizzi dry
solutions. Eight different types of edrizzi® dry
scrubber system. Pocket filters can be found in
scrubbers and five types of complementing
the exhaust air area as the next set of secondary
®
filters. Recirculated air flows
secondary filtrations cover all areas of
through the recuperator and
industry. All modules within the
incoming air vent fitted with
edrizzi® system can be changed
Viledon® filter mats, into the
separately and economically when
paint shop.
saturated.
edrizzi® became synonymous
Due to the flexibility of the system,
for dry separation with a
edrizzi® is effectively applied in
“cardboard box” and has
a variety of surface processing companies. From the smallest spray gun facilities with multi-year service life to ambitious automated
© Freudenberg Filtration Technologies
application in the surface processing
since encouraged several
PaintExpo 17. - 20. April 2018 Halle 2, Stand 2512
replications. In consideration of environmental aspects, the trend towards dry absorption is to
within the plant determines
be welcomed. Due
the modular assembly of
to the existing patent
the edrizzi system: the
protection of edrizzi®,
®
paint mist separator level
guarantee the best solutions for our customers around the globe.
manufacturers to produce
The individual situation
Especially in air circulation
Worldwide leading and innovative technologies
vertically in the subsurface area, which allows for a quick
several follow-up filtrations.
… and always close to you
are built in
photo). Different sized modules make it easier
can be complemented by
worldwide
edrizzi® cubes
two (ref. Opening
paint shops (Fig. 1).
Paint stripping
replicas lack important Figure 2: The edrizzi® system is implemented in international paint shops.
features of the original. Manufacturers of replications use filter
mode and top paint shops, those secondary
mats as alternative to the patented edrizzi®
filters are essential and important with regard
corrugated paper labyrinth, which leads to
to the development of emission control laws
restrictions in function and in disposal.
and environmental protection. There are indeed
Due to the sales cooperation with Freudenberg
facilities which run without secondary filtration
Filtration Technologies, edrizzi is being
though, because edrizzi® dry scrubbers are able
distributed globally since 2016.
®
info @ abl-technic.de www.abl-technic.de ABL-Germany | ABL-Austria ABL-France | ABL-Italy ABL-Turkey | ABL-Czechoslovakia ABL-Poland | ABL-Slovakia ABL-Hungary | ABL-Portugal ABL-USA
SPECIAL
BRAND-NEW
TMC Develops Special Self-Lubricating, High Temperature Resistant Bearings for the Chains of Coating Systems
T
MC, based in Cesana Brianza (LC, Italy) and established in 1964, specialises in
the production of high precision mechanical components for automation and coating systems. It has recently designed and developed special self-lubricating bearings able © TMC
to withstand high temperatures up to 250 °C. “Through our research activity on new materials and processes, we have tried to increasingly diversify our production in order to meet
1
the demands of the market and the different technical needs of each industry and type of users,” explains
Figures 1 and 2: An overhead conveyor chain featuring bearings treated with TMCoat.
TMC owner Lorenzo Mauri. “For the industrial coating sector, we have developed special bearings that can withstand high operating temperatures, compared to the conventional ones that are used at room temperature or in refrigerated environments.” TMC’s bearings are
© TMC
especially employed in conveyor chains (Figs. 1 and 2). They meet the standard requirements for corrosion resistance and they are characterised by excellent lubrication, which can triple the service life of the chains themselves.
2 1
20
“In TMC, we firmly believe
N. 50 - MARCH/APRIL 2018 - international PAINT&COATING magazine
A NEW DIMENSION IN EFFECT POWDER COATINGS • • • • • • • •
Liquid paint-like 3D effects in one-coat Brilliant and bright effects Visible from all angles of observation New design effects for architects For multi-coater projects Easy-to-apply: minimal equipment influence Considerable reduction of rework Very good batch consistency
www.tiger-coatings.com
© diversepixel - Fotolia.de
TIGER Drylac®
3D Metallics
TIGER Drylac® 3D Metallics Until now, one-coat powder coatings could not match the visual performance provided by liquid effect paints. However, TIGER is now opening completely new spheres with its TIGER Drylac® 3D Metallic products: the coating features a breathtaking, wet paint-like 3D effect with stunning depth, spatial clarity and unsurpassed brightness – still visible at a considerable distance and from different perspectives. With TIGER Drylac® 3D Metallics, many areas of industrial surface finishing may now draw on the “green” technology of powder coating and move away from solvent-based wet paints. TIGER Drylac® 3D Metallics are subject to the strict quality and test regulations of GSB International and QUALICOAT and available in Series 68 superdurable quality.
For more information or color cards please contact your TIGER representative or visit our website:
©mariana_designer - stock.adobe.com
www.tiger-coatings.com TIGER Drylac Italia s.r.l. 24122 Bergamo via F.lli Calvi 2/g Italy Phone: +39.035.413 35 80 E-Mail: 3DM@tiger-coatings.com
Experience TIGER Drylac® 3D Metallics live at
PaintExpo | Karlsruhe | Germany April 17 to 20, 2018 Hall 1 |Booth 1641
SPECIAL
BRAND-NEW
in the quality and reliability of our
materials and treatments that could
“The strength of this new product
product over time. Our experience
ensure greater resistance to wear and
is its versatility and adaptability to
has shown that the major problems
corrosion. This has resulted in the
all types of system and intended
of conveyor systems are often related
development of a special material that
use. It combines corrosion
to their bearings’ lubrication, which
we are considering patenting, able to
resistance and functionality
in turn affects the durability of their
self-lubricate and extend the life of
without affecting the chain
chains,” states Lorenzo Mauri. “We have
a chain up to three times compared
range and the plant efficiency,
focused on the choice of construction
with standard bearings (Fig. 3).”
while significantly reducing maintenance costs,” says Mauri. This new technology and the TMC product range will be
© TMC
presented during the PaintExpo exhibition, Hall 1, booth 1412 to be held in Karlsruhe from April 17 to 20. For further information: www.tmc-italia.com
3 1
TMCOAT
WITHOUT TMCOAT
Figure 3: Bearing rings compared after a 200-hour salt spray test.
CALDAN conveyor solutions - simply perfect.
Visit us here:
Hall 1, Stand #1530
SPECIAL
BRAND-NEW
Under the Slogan “Your Efficiency Our Innovations”, the Wagner Group Will Present Innovative Products and Solutions for Increasing Efficiency
I
n addition to the latest products for powder and liquid coating, adhesive and © Wagner Group
marking solutions, Wagner will present
the following highlights at PaintExpo 2018, the leading trade fair for industrial coating technology: Automation concepts for highly efficient liquid coating will be showcased, such as the new TOPFINISH Bell 1S highrotation atomizer for reciprocators and linear axes, which is available in many variants, for example with integrated 2- or 4-colour change discs or 2-component It ensures
mixers. It complements the TOPFINISH
flawless, sharp-
RobotBell 1 for robot applications, which has been on the market since 2017. All models of the product family have adjustable shroud airs and can be used with different bell
Figure 2: Layer Check LC 1000.
edged markings 2 1
in OK/NOK component marking, alphanumeric labelling
plate combinations. Fast rinsing processes
and in the metalworking industry.
and short colour change times support fast
For powder coating, Wagner will present
cycle times for coating workpieces. Walther
innovative system solutions which can
Pilot, a subsidiary of the Wagner Group, will
considerably increase the productivity of
demonstrate the PILOT GA 9010 Marking
coating systems. In addition, Wagner’s
(Fig. 1), a fully automatic
Industry 4.0 solutions create transparency
spray gun for single
with regard to productivity, maintenance and
and multi-coloured
quality information - on the PC, smartphone
spot and line
or tablet. In this way, industrial customers
marking.
can identify unused potential in production at a glance. The trade visitors’ interest is also likely to be attracted by the Layer
© Wagner Group
Check LC 1000 (Fig. 2) for layer thickness measurement, which can be used to measure the layer thickness of powder and liquid paint before curing or drying without
1
22
N. 50 - MARCH/APRIL 2018 - international PAINT&COATING magazine
Figure 1: PILOT GA 9010 Marking, a fully automatic spray gun for single and multi-coloured spot and line marking.
contact and with micrometer accuracy. For further information: www.wagner-group.com
Meet the world’s most experienced rookie.
Say hello to a remarkable business partner: We combine decades of expertise with the enthusiasm and dedication of a start-up. With the united powers of Silica products, TEGO® additives, and specialty additives of former Air Products, we offer innovative and tailor-made solutions that deliver real value for your coating formulations.
Coating Additives of Evonik. Home of ACEMATT®, AEROSIL®, SURFYNOL®, and TEGO®. And much more.
8
ALUMINIUM 2018 12th World Trade Fair & Conference
9 – 11 October 2018 Messe Düsseldorf, Germany www.aluminium-messe.com
Organised by
Partners
INNOVATIONS IN SURFACE TREATMENTS FOR METAL ARCHITECTURE
26
FOCUS ON TECHNOLOGY Alumero: An Investment in the Coating Quality of Aluminium Profiles
38
FOCUS ON TECHNOLOGY The Trend Towards Ever-Greater Colour Customisation In The Aluminium Industry: The Response Of ALUKON
44
SUCCESS STORIES Asif Khan Reveals Super-Dark Vantablack Pavilion for Winter Olympics 2018
48
FOCUS ON TECHNOLOGY Impol Sevalcon: the Supplier of High Quality PVDF Pre-Painted Aluminium for the Infrastructure of the 2018 World Cup in Russia
56 58
BRAND NEW
FOCUS ON TECHNOLOGY How Cutting-Edge Technologies and Targeted Interventions Have Made Sepal One of the Most Advanced and Flexible Aluminium Processing Companies in Europe
64 70
BRAND NEW
HIGHLIGHT OF THE MONTH CMA Robotics Celebrates 25 Years of History at the Forefront of Technology in the Automatic Coating Sector BRAND NEW
FOCUS ON TECHNOLOGY Extrusiones Metálicas: Loyalising a Powder Coating Supplier to Consistently Meet the Quality Requirements of Very Different Markets
86
BRAND NEW
VTT Studio © Fotolia
74 76
© ipcm ®
INNOVATIONS IN SURFACE TREATMENTS FOR METAL ARCHITECTURE
26
N. 50 - MARCH/APRIL 2018 - international PAINT&COATING magazine
INNOVATIONS IN SURFACE TREATMENTS FOR METAL ARCHITECTURE
FOCUS ON TECHNOLOGY
Alumero: An Investment in the Coating Quality of Aluminium Profiles
T
© ipcm ®
Alessia Venturi ipcm® he biggest
specialises in the design
problem that many
and construction of
manufacturers
customised aluminium
from different sectors
structures. “Such
face when it comes
problems were due
to finishing, if it is
partly to the big
outsourced, is related
changes occurred in
to quality consistency
the formulations of
and to the possibility to
chemical products
obtain different quality
and powder
levels for products with
coatings to meet
different intended uses.
the more restrictive
This is especially true in
environmental
industries where surface
regulations, and partly
treatment products and
to our difficulties in
technologies evolve so rapidly that contractors do not always manage to keep pace with innovations and their
maintaining constant
1
and timely control
Figure 1: The new powder coating plant installed by Euroimpianti Srl of Valeggio sul Mincio (Verona, Italy).
on the work of our providers. That is why in 2017 we decided to insource all our coating
related investments.
activities, installing a technologically advanced
Let us consider the aluminium profile
“In the last five years, we had found an
sector. With the banning of Chromium VI,
increasing number of quality issues in our
horizontal line,” says Šlamberger (Fig. 1).
the introduction of the REACH chemical
suppliers’ coated parts,” states Boris Šlamberger,
“Alumero’s coating quality level is too
substance monitoring register, and the
the plant manager of Alumero d.o.o.
important to accept even the slightest defects.
increase in performance requirements, which
This company, based in Bistrica (Slovenia) and
We paint both profiles and sheets for doors,
more and more often must comply with the
belonging to the Austrian Group ALUMERO,
curtain walls, fences, and so on. Coating
Qualicoat 2 specifications
aluminium sheet
for architecture, keeping
components, especially if intended for private
control over the quality of coated profiles is a challenge for the manufacturers that chose to entrust their finishing treatments to third parties (ref. Opening photo).
With the banning of Chromium VI, the introduction of the REACH chemical substance monitoring register, and the increase in performance requirements, which more and more often must comply with the Qualicoat 2 specifications for architecture, keeping control over the quality of coated profiles is a challenge for the manufacturers that chose to entrust their finishing treatments to third parties.”
homes, is even more difficult than treating profiles: they require the highest aesthetic quality level possible. For all these reasons, we decided to install
Opening photo: Application of powder coatings on profiles at Alumero d.o.o of Bistrica (Slovenia).
international PAINT&COATING magazine - MARCH/APRIL 2018 - N. 50
27
© ipcm ®
INNOVATIONS IN SURFACE TREATMENTS FOR METAL ARCHITECTURE
2 1
Figure 2: In the wide range of Alumero’s products, indoor and outdoor doors are very important.
Alumero paints both profiles and sheets for doors, curtain walls, fences, and so on. Coating aluminium sheet components, especially if intended for private homes, is even more difficult than treating profiles: they require the highest aesthetic quality level possible. For all these reasons, Alumero decided to install a coating line able to ensure maximum quality, chosing Euroimpianti, to support them in this insourcing project.”
a coating line able to ensure maximum
compromise that could jeopardise quality.
had the plant certified by a German
quality: Euroimpianti, the Italian company
This was one of the most difficult plant
body and our line reached the maximum
we have chosen to support us in this
design projects handled by Euroimpianti
values in all the parameters tested:
insourcing project, did not make any
in the last few years. The final solution was
polymerisation, pre-treatment, powder
compromise during the design phase.
the result of a precise joint work between
coating, colour change flexibility and
We can now safely state that the installed
the customer and the supplier. Alumero
speed, and workpiece handling.”
production needs,” says Boris Šlamberger. “The analysis, design and creation process
© ipcm ®
line was the best solution for our quality and
of the final layout of Alumero’s plant was very long and complex,” states Dean Bassi, the East Europe sales manager of Euroimpianti. “We revised the initial project over twenty times, precisely because we were required to avoid any technical
Alumero d.o.o, based in Bistrica (Slovenia) and belonging to the Austrian Group ALUMERO, specialises in the design and construction of customised aluminium structures.”
28
3 1
Figure 3: The 7-stage pre-treatment tunnel.
N. 50 - MARCH/APRIL 2018 - international PAINT&COATING magazine
FOCUS ON TECHNOLOGY
The Alumero Group The Alumero Group is a complete partner for the design, development and production of aluminium structures: curtain walls and components, windows, outdoor doors, roofing systems, sunblinds, fences, and even profiles for furnishings and kitchens, for solar panels, and for the industry (Fig. 2). Established in 1992 by Manfred Rosenstatter in Seeham (Austria) the Group now includes a branch in Poland, an extrusion company in Helmond (Netherlands), and the branch of Bistrica
The Alumero Group is a complete partner for the design, development and production of aluminium structures: curtain walls and components, windows, indoor and outdoor doors, roofing systems, sunblinds, fences, and even profiles for furnishings and kitchens, for solar panels, and for the industry.”
(Slovenia), which has recently inaugurated the Group’s first in-house coating line. Alumero specialises in the machining of precision profiles with thicknesses down to 0.4 mm, cross sections up to 500 mm and lengths up to 15 m. In its four sites, it vertically integrates the whole profile production process: extrusion,
Faster and Stronger Coat twice - bake once
machining, and coating, as
Powder-in-Powder solutions from FreiLacke
well as the processing and
www.powder-in-powder.com www.freilacke.com
painting of aluminium sheets intended for curtain wall doors and panels. “The Bistrica plant coats the entire Group production,” says Andreja Kurež, the
general manager assistant. “We receive extruded profiles from different suppliers and we machine them with 3, 4 and 5-axis CNC centres, weld them with various technologies, and assemble them. Assembly occurs after coating. Our customers are architects, construction companies, and final consumers.”
Improving quality: an imperative for Alumero The primary reason that lead Alumero to install a horizontal profile coating line was the need to improve its products’ finishing quality and resistance levels. “After a careful assessment, we concluded that we had to invest in quality in order to grow on the European profile market,” says Boris Šlamberger. “At the same time, we noticed that our contractors had not invested in new technologies for years: this prevented them from improving the quality of their surface treatments. Therefore, the only possible solution was insourcing our coating stage. The Slovenian plant was chosen to accommodate this new process phase.”
Visit us for more system coatings und applicationsolutions from one source!
Hall 1; booth 1420
© ipcm ®
INNOVATIONS IN SURFACE TREATMENTS FOR METAL ARCHITECTURE
Inaugurated on October 19, 2017, the horizontal powder coating plant for aluminium profiles and sheets required an investment of almost 2 million Euros, aimed at enhancing the added value of the firm’s products and completing its manufacturing process.”
Whereas the first requirement of the new plant was a high treatment quality level, the second one was flexibility: Alumero coats profiles with very different sizes and thicknesses, as well as plates and fences requiring different technical choices than profiles.”
Inaugurated on October 19,
Plant features
2017, this horizontal powder
Whereas the first
coating plant for aluminium
requirement of the new
profiles and sheets required an
plant was a high treatment
investment of almost 2 million
quality level, the second
Euros, aimed at enhancing
one was flexibility:
the added value of the firm’s
Alumero coats profiles
products and completing its
with very different sizes
manufacturing process. “Buying
and thicknesses, as well as
a coating plant is not like buying
plates and fences requiring
a car: you must speak the
different technical choices
same language as the supplier,
than profiles. “The spray
carefully assess all the machines all finding a partner that listens
pre-treatment tunnel was
4 1
included in the line, and above
designed to easily achieve
Figure 4: Entry of the pre-treatment tunnel.
the Qualicoat 3 and GSB 3
to your needs. Euroimpianti
certification levels.
ticked all the boxes,” states Boris
It currently includes 7
Šlamberger. “We required a
stages, but it is ready for the
tailor-made plant and wanted to actively contribute to its design, especially to verify that our requirements were always met and our goals always considered. The design phase lasted over a year: not many companies are willing to invest so much time on a potential customer.” “Once the goals were established accurately, Euroimpianti showed Alumero the way to reach them,” says Dean Bassi, “providing them with all the
introduction of a further stage in future to
Alumero required a tailor-made plant and wanted to actively contribute to its design, especially to verify that the requirements were always met and the goals always considered. The design phase lasted over a year.”
support possible.”
30
N. 50 - MARCH/APRIL 2018 - international PAINT&COATING magazine
increase the line productivity (Fig. 3),” says Dean Bassi from Euroimpianti to describe the constructive characteristics of the plant. “The cycle uses chemicals provided by Alufinish GmbH and it includes the following stages (Fig. 4): acid attack, pre-cleaning, a rinse with mains water, two rinses with demineralised water, nebulisation of a chrome-free no-rinse passivating product, and nebulisation of demineralised water. The pre-treatment
© ipcm ®
INNOVATIONS IN SURFACE TREATMENTS FOR METAL ARCHITECTURE
5 1
Figure 5: The power&free conveyor supplied by Futura Convogliatori Aerei of Robecco Pavese (Pavia, Italy).
plant also includes a demineralisation unit and
to strategically create several storage
The colour change operation has an
a chemical-physical water treatment system for
buffers, used for optimising the colour
impact of 10 to 20 minutes on productivity,
continuous discharge; this ensures constant
change times and, above all, ensuring
compensated for by two storage buffers
concentration and pollution levels
– one after the drying tunnel,
in the baths during plant operation,
also used for cooling the parts,
without changing the quality of the
and the other after the coating
pre-treatment results.” The pre-treatment tunnel is followed by a blow-off station and a drying oven. As for logistics, Alumero had initially chosen a one-rail conveyor. It then
The spray pre-treatment tunnel was designed to easily achieve the Qualicoat 3 and GSB 3 certification levels. It currently includes 7 stages, but it is ready for the introduction of a further stage in future to increase the line productivity.”
booth (Figs. 6 and 7). Another storage buffer is located inside the polymerisation oven to compensate for the different curing times of products (due to different sizes and thicknesses – Fig 8).
opted for a power&free one that could provide the line with greater productivity, flexibility and treatment
maximum treatment quality for every
The coating booth is the machine with the
accuracy. Futura Convogliatori Aerei
workpiece during both pre-treatment and
highest colour change automation offered
developed this power&free conveyor in order
polymerisation (Fig. 5).
by Gema, featuring a conventional Venturi
32
N. 50 - MARCH/APRIL 2018 - international PAINT&COATING magazine
© ipcm ®
FOCUS ON TECHNOLOGY
to enter the oven is also the first to leave it: this ensures uniformity of the polymerisation time for the whole length of each profile. “With a conventional U-shaped oven, on 6-7 metre long profiles there may be a polymerisation time difference of up to 1 minute,” says Bassi. “The Z-shaped oven we installed in Alumero eliminates this problem. This is the only possible choice for a company seeking the highest level of finishing quality, since, as is well known, an excessive polymerisation time causes colour issues whereas too
6 1
short a time creates film resistance problems.”
Figure 6: The storage buffer before the coating booth.
A storage buffer located after the polymerisation oven is used to cool the parts and to
application system and 10 automatic guns (Fig. 9). It is also equipped with two double preand post-retouching stations to ensure perfect coverage of workpieces with any shape (Fig. 10). The automatic guns are adjusted by the system
Futura Convogliatori Aerei developed a power&free conveyor in order to strategically create several storage buffers, used for optimising the colour change times and, above all, ensuring maximum treatment quality for every workpiece during both pretreatment and polymerisation.”
completely empty the oven at the end of the work shift; once again, this ensures that the cycle meets the minimum or maximum polymerisation time requirements of each workpiece type.
which changes the coating parameters depending on the input received during loading
© ipcm ®
management software,
without any operator intervention. In theory, every load bar on the chain could be automatically coated with different parameters. The polymerisation oven located afterwards features a powder gelling pre-chamber. “Instead of an oven dedicated solely to gelling, with consumption values sometimes almost equal to those of polymerisation ovens themselves, we chose to create a pre-chamber exploiting the energy recovered from the oven to gel the powder. Only one load bar at a time stays in this pre-chamber, in order to avoid any colour contamination between parts,” explains Dean Bassi from Euroimpianti. “This design choice ensures minimum energy consumption for gelling the coating at almost zero cost.” Alumero’s production flow is based on the FIFO (First InFirst Out) principle; therefore, the first part of a workpiece
7 1
Figure 7: A storage buffer is positioned after the powder application booth and before the polymerization oven.
international PAINT&COATING magazine - MARCH/APRIL 2018 - N. 50
33
© ipcm ®
INNOVATIONS IN SURFACE TREATMENTS FOR METAL ARCHITECTURE
8 1
Figure 8: A storage buffer is located inside the polymerization oven.
Fully automatic management
A green field project
The plant is completely digitalised.
The new coating plant installed by Alumero’s
During loading, the operator selects
Slovenian branch belonged to a green
the complete treatment sequence for
field project: the company expanded its
each hung part, choosing the type of
production site by building a new plant
pre-treatment, the colour of the coating
devoted only to coating. “The numerous
The coating booth is the machine with the highest colour change automation offered by Gema, featuring a conventional Venturi application system and 10 automatic guns. It is also equipped with two double pre- and postretouching stations to ensure perfect coverage of workpieces with any shape. The automatic guns are adjusted by the system management software, which changes the coating parameters depending on the input received during loading without any operator intervention.”
of the guns, and the polymerisation times (Fig. 11). In case a colour change
© ipcm ®
to be applied, the operating parameters
is needed, the system management software commands the spray booth to stop the chain. After cleaning, the operator can restart production with the new colour. Thanks to the buffer created inside the polymerisation oven, the system ensures that there is no over- or under-polymerisation, even with parts requiring different process times. Again in order to achieve maximum treatment quality, the plant prevents any load bar to remain inside the pre-treatment tunnel at the end of a shift or in case of any sudden production interruptions. In the same way, the management system prevents any coating process to start on a load bar if there is not enough time for to complete at least the pre-treatment and drying stages.
34
9 1
Figure 9: The fast colour change coating booth, with the powder centre on the left, is equipped with 10 automatic guns, all supplied by Gema.
N. 50 - MARCH/APRIL 2018 - international PAINT&COATING magazine
© ipcm ®
FOCUS ON TECHNOLOGY
10 1
Figure 10: The booth is equipped with two double pre- and postretouching stations.
Instead of an oven dedicated solely to gelling, with consumption values sometimes almost equal to those of polymerisation ovens themselves, Alumero chose to create a pre-chamber exploiting the energy recovered from the oven to gel the powder. Only one load bar at a time stays in this prechamber, in order to avoid any colour contamination between parts. This design choice ensures minimum energy consumption for gelling the coating at almost zero cost.”
INNOVATIONS IN SURFACE TREATMENTS FOR METAL ARCHITECTURE
requirements and it is efficient in terms
systems described were located in a space perfectly designed for this purpose,” states Dean Bassi. “Since this was in a new building, involving further costs for the company in addition to the technology investments, the challenge was to minimise the space needed to accommodate each machine, including the water treatment plant, the demineralisation unit, the compressors, and the quality control
The plant is completely digitalised. During loading, the operator selects the complete treatment sequence for each hung part, choosing the type of pre-treatment, the colour of the coating to be applied, the operating parameters of the guns, and the polymerisation times.”
of environmental impact. In Slovenia, we have one of the most stringent legislations in Europe and controls are constant and frequent.” “Compliance with Slovenian regulations was a true “stress test” for this plant, but we are proud to say that we have passed it,” states Dean Bassi, “especially because this is not a zero liquid discharge system: its water discharge is perfectly in line with the legal requirements.”
laboratory, as well as spaces for the
“Euroimpianti supported us not only
internal and external logistics.” “I
in terms of design, but also of plant The system has been in operation for
management and operation,” says Boris
plant to have the exactly necessary
a few months now. “Currently, we are
Šlamberger. “Their experience in terms of
dimensions, no more and no less,”
using about 20% of the plant’s production
operating costs enabled us to make a very
states Boris Šlamberger, “also due to
capacity, because we are still in the
accurate comparison between different
quality reasons: the less the space
learning phase,” says Šlamberger. “We are
solutions and understand how different
dispersion, the less the external
very pleased with the work of Euroimpianti.
technological choices would have affected
contamination.”
The plant meets all our quality
our investment and management costs.”
© ipcm ®
wanted the new building hosting this
11 1
Figure 11: The loading area with the storage buffer before the pre-treatment tunnel.
36
N. 50 - MARCH/APRIL 2018 - international PAINT&COATING magazine
© Alukon
Opening photo: Alukon KG is one of the leading suppliers in Central Europe in the sectors of shutters, window screens, sun protection systems, and garage doors
FOCUS ON TECHNOLOGY
INNOVATIONS IN SURFACE TREATMENTS FOR METAL ARCHITECTURE
The Trend Towards Ever-Greater Colour Customisation In The Aluminium Industry: The Response Of ALUKON Francesco Stucchi ipcm®
P
roduct customisation is one of the
lifestyle and consumption behaviour leads
also in the building sector, for example for
mega trends of our time. We have
to the demand for increasingly customised
window and door frames and awnings.
already dealt with it on this magazine1,
products. The quickest way to customise
This mega trend forces manufacturers to
analysing how the will to distinguish through
a product? Requiring an exclusive
be increasingly flexible in terms of coating
the originality and individualisation of one’s own
colour and finish. This is already a well-
to stay competitive, while pushing paint
established practice in the car market, but
suppliers to focus on R&D to meet individual
it is becoming more and more common
non-standard requests.
1
ipcm®_International Paint&Coating Magazine, Vol. No. 39, May/June 2016, page 03
38
N. 50 - MARCH/APRIL 2018 - international PAINT&COATING magazine
FOCUS ON TECHNOLOGY
Established as a distributor of aluminium shutters,
products, this company is still growing. With its new
Alukon KG is now one of the leading suppliers in Central
development project, Alukon expanded the space at
Europe in the sectors of shutters, window screens, sun
its headquarters in Konradsreuth, near Nuremberg
protection systems, and garage doors (ref. Opening
(Germany), by 50% (Fig. 2). The implementation
photo). It is currently expanding its plant by over
of a vertical warehouse (Fig. 3) and an advanced
12,000 m ;
coating plant
by 2019, it will be updated to the
© Alukon
2
that will come into operation in
latest construction
2019 will enable
and technology
it to optimise
standards (Fig. 1).
its production
Alukon is in fact
flow and reduce
constantly striving
delivery times.
for progress and
“Our focus for
improvement,
the future is to
as proven by its
confirm ourselves
evolution in its fortyyear history. A lot has happened since its establishment in 1974: it went
as reliable
1
suppliers for
Figure 1: Aerial view of the factory of Konradsreuth, near Nuremberg (Germany).
Spare Parts for Industrial Plants 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
an increasing number of customers while
keeping innovating our products,” says Alexander
expanded its product range up to the production
Winkler, the Head of Product Management and
and sale of textile materials for sun protection
Marketing at Alukon (Fig. 4). “As a supplier of
systems and rolling shutter boxes. Belonging to
both components and complete systems, Alukon
the Hörmann Group since 2013 and characterised
provides its customers with great flexibility, as
by a layered production and sale structure
they can decide if and what to produce or buy
including both individual components and end
depending on their order volume. We aim at
© Alukon
from 3 to about 400 employees and it gradually
ANTARES S.r.l. 2 1
Figure 2: The entrance of Alukon AG in Konradsreuth.
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
© ipcm ®
INNOVATIONS IN SURFACE TREATMENTS FOR METAL ARCHITECTURE
coatings ensure the highest durability and resistance performance, and therefore they are the best option to colour our aluminium products. Colour has become increasingly important in the last few years. Up to ten years ago, one would use five shades at most: requests for different, customised, metallic, and special effect colours have now increased enormously (Fig. 5).” Alukon has a standard colour catalogue with three different finishes: gloss, matte, and textured. However, it offers its customers – not only architecture firms, but also end users – almost any tint they may require. They perform more than 20 colour change operations per day. “Currently, we use two coating systems: one is large-sized and it treats the biggest batches and the other is small-sized and it performs up to
3 1
25 colour change operations per day. Our new coating line, which will © ipcm ®
Figure 3: The brand new vertical warehouse.
be certified according to the GSB standard, will handle the production volumes of both plants, which will be divested,
reacting to the market’s and our
and it will perform a colour
partners’ requests in the most
change in less than 5 minutes,”
versatile way possible in order to
states Alexander Winkler.
develop tailor-made solutions.” In the last two years, Alukon has launched a large number of new
Figure 4: from left to right, David Seim and Alexander Winkler (Alukon) with Alessia Venturi (ipcm) and Oliver Ott and Gilberto Vercesi (RIPOL).
products and innovations, such as the frame-mounted shutters AK-Flex and the last generation systems ZipTex.
4 1 © Alukon
of its textile sun protection
In 2018, one of the most important changes will be the startup of the new coating line. Advanced and extremely flexible, it is currently being installed and it is expected to come into operation by the end of this year. After its completion, Alukon will continue to rely on its proven partners for painting products, including RIPOL (Santo Stefano Ticino, Milan, Italy). “Alukon has been collaborating for many years with RIPOL, which we consider a really trustworthy partner,” says Alexander Winkler. “They provide us quickly and reliably with high quality products characterised by excellent quality consistency among batches. Moreover, they strive to support us in the development of both standard and customised colours.”
Alukon’s production cycle Powder coating is a strategic phase for Alukon. “Powders are the best finishing solution for our products, which, being intended for outdoor use, must withstand a variety of weather conditions,” says Alexander Winkler. “Only powder
40
N. 50 - MARCH/APRIL 2018 - international PAINT&COATING magazine
Established as a distributor of aluminium shutters, Alukon KG is now one of the leading suppliers in Central Europe in the sectors of shutters, window screens, sun protection systems, and garage doors. It is currently expanding its plant by over 12,000 m2; by 2019, it will be updated to the latest construction and technology standards.”
5 1
Figure 5: The application of thermosetting powders.
© ipcm ®
FOCUS ON TECHNOLOGY
6 1
Figure 6: A part of the colour catalogue available to Alukon’s customers.
Of course you can paint 400 horses. Surface coating expertise on many levels – that‘s where Rippert has been making a name for itself for over five decades. We conceived a surface coating plant for the CLAAS Group for the finishing of chassis. We are delighted to accompany a successful company with our ideas and technologies. We make brands shine. Find out more at www.rippert.de
In 2018, one of the most important changes will be the start-up of the new coating line. Advanced and extremely flexible, it is currently being installed and it is expected to come into operation by the end of this year. After its completion, Alukon will continue to rely on its proven partners for painting products, including RIPOL (Santo Stefano Ticino, Milan, Italy).”
© ipcm ®
INNOVATIONS IN SURFACE TREATMENTS FOR METAL ARCHITECTURE
any shade of grey,” Alexander Winkler
high and above all consistent among batches,
says ironically. “Historically, the most
as are their colours,” says Alexander Winkler.
used colours in our production have
“That is why we have never really needed
always been white and brown: even
RIPOL’s technical assistance service. In any
nowadays, these two tints account for
case, their engineers know our coating line
50% of our volume. However, there
very well and they know how to change their
is a growing trend towards grey,
formulations if any surface defects occur.”
especially in its metallic shades, © ipcm ®
which now accounts for about 40% of our production volume. Customised and non-standard colours, such as the yellow and pink tints used on profiles for schools or kindergartens, account for the remaining 10% (Fig. 6).” For a company like Alukon, aiming at extreme service flexibility and at colour and finish customisation, it is crucial to rely on a trustworthy and efficient partner for the supply of coating products. “Their commercial relationship with
7 1
RIPOL began at the turn of 2010
Figure 7: Traditional and innovative solutions in Alukon’s products.
and 2011,” says Oliver Ott, the Business Development Manager of RIPOL GmbH, the commercial
“With the new coating technology that will
branch of the Italian company, located
be available to us by the end of 2018, we
near Stuttgart. “We started with a few
will be extremely flexible. At the moment,
colours, but we now supply a significant
with our old line, we are not: we are forced
share of the outdoor polyester coatings
to organise our production flow based on
they use. We developed a colour of their
the colours to be applied in order not to
catalogue, Alukon White (similar to RAL
lose productivity. In future, we will be able
9016) with a matte finish, exclusively
to adopt a just-in-time approach, coating
for them. Then, we started providing
according to the orders received. We also
another standard tint, Alukon Brown,
aim at increasing our coating capacity, but
with a semi-matte finish. We are now
our main focus is definitely on flexibility, as
working on another custom colour (Figs.
Growing requests for customised colours
we produce components that are then cut,
7 and 8).” “Matte finishes are definitely
“In response to the growing demand for
processed, and assembled by customers,
another trend in the industry,” states
colour innovation in the architectural
finished products on request, and profiles
David Seim, from the purchasing office of
powder coating market, RIPOL invested in
requiring any intermediate processing
Alukon. “Until a few years ago, the most
a new manufacturing unit to produce new
operation.”
requested finish in Germany was smooth
colours, shades and effects from few boxes
and glossy; then, a trend towards matte
up to 200 kg”, states RIPOL Sales Manager
finishes started in Austria and continued
Gilberto Vercesi. “If we need to create
on other Central European markets, such
a custom match, we will do it in 7 – 10
Although Alukon can use any colour shade,
as the Polish one.”
business days, quicker if we can.
the market trend goes towards grey finishes,
“We are very pleased with our supply
I am sure that our cooperation with Alukon
both metallised and matte. “As we like to
relationship with RIPOL, because the
will be strengthened by our flexibility in
put it, the current colour trend is towards
quality of their products is always very
manufacturing also small batches”.
Colour trends: Alukon’s strategy in partnership with RIPOL
42
N. 50 - MARCH/APRIL 2018 - international PAINT&COATING magazine
8 1
Figure 8: Alukon is a leading supplier in Central Europe also of sunblinds.
Visit us at PaintExpo 2018
Hall 3, booth 3417
Alit Technologies Srl • Via Francesco Perlini, sn • 37047 San Bonifacio (VR) • www.alit-tech.com • info@alit-tech.com
SUCCESS STORIES
INNOVATIONS IN SURFACE TREATMENTS FOR METAL ARCHITECTURE
© Luke Hayes
Asif Khan Reveals Super-Dark Vantablack Pavilion for Winter Olympics 2018
1
Figure 1: The 10-metre-high pavilion for the Winter Olympics 2018, spray-painted by architect Asif Khan with Vantablack VBx2.
A
sif Khan has unveiled a pavilion at
absorbs over 99% of light. Vantablack
all four sides of the pavilion, giving the
the Pyeongchang Winter Olympic
VBx2, is a sprayable version of Vantablack
impression of stars suspended against
Games in South Korea, described as
pigment, which British artist Anish Kapoor
the darkness of space.
the “darkest building on earth” (Fig. 1).
controversially acquired exclusive rights for
Speaking to Dezeen, Khan – who
The British architect spray-painted the
in 2016.
describes himself as a “closet astronaut” –
10-metre-high temporary structure
Rods tipped with tiny white lights protrude
said he “wanted to create the impression
Vantablack VBx2, a substance that
from the “super-black” parabolic curves of
of a window cut into space”.
44
N. 50 - MARCH/APRIL 2018 - international PAINT&COATING magazine
SUCCESS STORIES
Asif Khan, a British architect, spray-painted the 10-metre-high temporary structure Vantablack VBx2, a substance that absorbs over 99% of light. Vantablack VBx2, is a sprayable version of Vantablack pigment, which British artist Anish Kapoor controversially acquired exclusive rights for in 2016.” “It’s a preoccupation of mine, trying to create experiences to better understand where we are now as humans, placing ourselves in the big picture,” said Khan. “I’m interested in that feeling of the sublime when you pull back the curtain of reality. It’s a different way of
Bring more colour to your product
experiencing architecture.” The sprayable Vantablack VBx2, is so black that it is almost impossible for the human eye to perceive the shape of an object it coats. “It changes as you approach it. From far away you see it as a surface of blackness, it just looks like a void,” said Khan. “As you approach you pick out the stars, and as you get closer the stars begin to move in parallax,
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which means they appear as a three-dimensional body. As you walk past it they’re almost globular in their clustering.” The light-absorbing power of Vantablack VBx2 and the optical illusions created by the lights against the curved walls is almost too difficult for humans to comprehend, according to the architect. “There’s a tension between wanting to know what form something is and actually accepting that it could be formless – you’re looking at infinity,” he said. Khan had been in contact with the scientists behind the original Vantablack, since 2013, after reading a paper on the subject while researching how to create a building that could be as black as space.
The sprayable Vantablack VBx2, is so black that it is almost impossible for the human eye to perceive the shape of an object it coats.”
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Clean operating environment and automated colour change Significant powder savings with high level of process control High finish quality with integrated ultrasonic sieve for fresh and recovered powders Unmatched powder application efficiency delivered by Encore® HD spray systems For a new fast colour change system or easy integration with your existing cyclone booth, get in contact with Nordson for more information. ics.eu@nordson.com www.nordson.com/hdlv
SUCCESS STORIES
rights over uses microscopic stems to
Park you don’t have much of a time frame to
absorb light, VBx2 has a sponge-like
get anything wrong,” said Khan.
structure at micro level.
When it opened on 9 February 2018, visitors
To build the PyeongChang Winter
will be able to enter the pavilion through a
Olympics pavilion, the steel substructure
dark corridor that opens into a bright white
was bolted together on site and then
space lined with solid-surface material Corian.
clad to create the curved surfaces.
Channels have been carved into its surface
A scaffold was then erected around
as part of a multi-sensory hydrophobic water
the pavilion and tented, creating
installation also designed by Khan. Walking across a pathway, visitors
© Luke Hayes
The Vantablack used for Khan’s building is structurally different to the original pigment. Whereas the black Kapoor has rights over uses microscopic stems to absorb light, VBx2 has a sponge-like structure at micro level.”
INNOVATIONS IN SURFACE TREATMENTS FOR METAL ARCHITECTURE
interact with sensors causing 25,000 water droplets a minute to whizz along the channels, colliding and splitting before pooling into a lake. The 35-metre by 35-metre
“They were quite taken aback that
building was commissioned
someone would think to try and
by Hyundai Motor as part of
apply their materials in the built
its global art initiative, with the
environment,” he said. “They’re
pavilion’s space theme aligning
a bunch of very skilled scientists
with the car manufacturer’s latest
who are working a lot of the time
technology: a Hydrogen Fuel Cell
in a laboratory. They are working
vehicle.
at nanoscale and the idea of
The “stars” on the outside (Fig. 2)
making something that’s millions
represent the chemical element
of times bigger than that hadn’t
on a cosmic level – gaseous balls
really come into their minds.”
shining due to the thermonuclear
Khan and the scientists first
fusion of hydrogen into helium at
collaborated on a proposal using
their core.
the material for the UK Pavilion
Inside the pavilion, the liquid
at Milan Expo 2015, which was
embodies hydrogen at a more
eventually shortlisted.
human scale, as two atoms of
In the meantime, the
hydrogen bond with one oxygen
manufacturers devised Vantablack
atom to form water.
VBx2, a more versatile material
The building also references
better suited to architectural pigmented coating is suspended in a carrier solution that allows it
its location in South Korea.
2 1
application. The light-absorbing
The curved wall of the building
Figure 2: A detail of the “stars” on the outside of the pavilion.
makes it star-shaped in plan, yet rectangular in elevation, while the shape formed by the intersection
to be sprayed onto larger areas. “This was the real challenge, actually going
conditions suitable for spray painting.
of the curved walls echoes the swooping roofs
from the lab to full scale manufacturing,
During construction the team had to
of traditional temple architecture.
which they pulled off. It’s amazing,” said
contend with the mountain climate and
Khan.
temperatures between -15°C and -25°C.
The Vantablack used for Khan’s building
“It’s a challenging climate to work in,
is structurally different to the original
because of the temperature, because of
For further information:
pigment. Whereas the black Kapoor has
the extreme high winds. On an Olympic
www.dezeen.com
46
N. 50 - MARCH/APRIL 2018 - international PAINT&COATING magazine
Author: © India Block for Dezeen
Innovate today. Inspire tomorrow. IGP. FOR SURE.
IGP Pulvertechnik AG CH-9500 Wil Phone +41 (0)71 929 81 11 www.igp-powder.com info@igp-powder.com A member of the DOLD GROUP
PaintExpo 2018 Visit us at booth 2517 in Hall 2 17. – 20. April 2018, Karlsruhe
www.igp-future.com
© Sevalcon
Opening photo: The Luzhniki Stadium, built in 1956 and recently renovated in view of the upcoming FIFA World Cup, coated with the Olympic Gold colour.
FOCUS ON TECHNOLOGY
INNOVATIONS IN SURFACE TREATMENTS FOR METAL ARCHITECTURE
Impol: the Supplier of High Quality PVDF Pre-Painted Aluminium for the Infrastructure of the 2018 World Cup in Russia Alessia Venturi ipcm®
E
leven cities and twelve stadiums will host the 64 matches of
The Luzhniki Stadium, built in 1956, has hosted a myriad of sporting
the 2018 FIFA World Cup in Russia. About 15 billion Euros were
and non-sporting events, including the 1980 Olympics. This wonderful
invested in setting up the tournament, to build and renovate the
building has 80,000 seats and it will host the opening match on June 14,
infrastructures of the selected locations. These will be Moscow, with two
which will see the home team face Saudi Arabia, and of course the final,
facilities, Saint Petersburg, Kaliningrad, Nizhny Novgorod, Kazan, Samara,
scheduled for July 15.
Saransk, Volgograd, Rostov-on-Don, Sochi, and Ekaterinburg. The two
The complete renovation of this stadium has required an investment of
semi-finals will be played in Saint Petersburg and Moscow, while the final
over EUR 350 million and it has included the creation of an upper band
will be hosted by Moscow’s Luzhniki Stadium.
in pre-painted aluminium, for which PVDF coatings were used to ensure
48
N. 50 - MARCH/APRIL 2018 - international PAINT&COATING magazine
FOCUS ON TECHNOLOGY
The complete renovation of this stadium has required an investment of over EUR 350 million and it has included the creation of an upper band in pre-painted aluminium, for which PVDF coatings were used to ensure that the exterior appearance of the building will remain intact for decades. The Olympic Gold-coloured pre-painted aluminium used for the Luzhniki Stadium was produced by Impol Seval, a company based in Sevojno, Serbia, which is a division of IMPOL group with the head office in Slovenska Bistrica, Slovenia.� that the exterior appearance of the building will
onion dome coated with a wrinkled product
remain intact for decades. The Olympic Gold-
featuring a gold/iridescent pigment; the new
coloured pre-painted aluminium used for the
terminal of the Perm international airport
Luzhniki Stadium (ref. Opening photo) was
(Fig. 2) for which the Dubai Gold colour was
produced by Impol Seval, a company based in
used (Fig. 3); VTB Arena, located in the heart
Sevojno, Serbia, which is a division of IMPOL
of Moscow, for which a sea foam-inspired
group with the head office in Slovenska Bistrica,
white pearl finish was used; and Zaryadye
Slovenia.
Park (Fig. 4), the new green lung of the city of Moscow a few steps from the Red Square, characterised by a metallic finish called Silver
many projects, which Impol Seval has completed
Charge. Thanks to its 35-year experience in the
in Russia in the last few years, with its products
coil coating technology for aluminium and long
branded Sevalcon, using high quality PVDF
term cooperation with SALCHI Metalcoat, high
coatings. Among others, they were used for the
performance coatings with special effects were
Rossosh monastery, with the beautiful golden
developed.
Š Sevalcon
The Luzhniki Stadium (Fig. 1), is just one of the
1
Figure 1: Detail of the Luzhniki Stadium, painted with PVDF products supplied by Salchi Metalcoat.
© Sevalcon
INNOVATIONS IN SURFACE TREATMENTS FOR METAL ARCHITECTURE
2 1
Figure 2: The new and futuristic terminal of the Perm international airport, where Impol and Sevalcon have applied the Dubai Gold finish.
In 2013, Impol started a new coating line that enabled it to dramatically change its product portfolio, positioning itself in a very high-end market segment. From the beginning, Impol focussed on special products for architecture and infrastructure. In these sectors, quality is everything. Thanks to the new advanced coil coating line, they can finally offer structural aluminium for iconic buildings with special aesthetic effects and very high aging resistance performance. At the same time, Impol can ensure quality consistency also with very high volumes, which is the most critical issue when it comes to producing special finishes.”
Impol: focus on quality in coil coating
Europe, especially Germany, Holland, Italy
In 2013, Impol started a new coating line
even the most specific needs, we have now
that enabled it to dramatically change
greatly increased our market share in Russia,
its product portfolio, positioning itself
thus becoming suppliers of many exclusive
in a very high-end market segment.
projects such as the new infrastructure for
“From the beginning, Impol focussed on
the 2018 World Cup.”
special products for architecture and
Impol is highly flexible, equipped with casting
uniform coating thicknesses and perfect
infrastructure. In these sectors, quality is
ovens, hot and cold rolling mills, coil coating
film spreading along the whole coil surface.
everything. Thanks to our new advanced
line and hot-lamination section. Over the
In order to achieve this quality result, the
coil coating line, we can finally offer
years it has used more than 1000 different
Serbian coil coater cooperates closely with its
structural aluminium for iconic buildings
coatings. Its coil coating line operates at a
paint suppliers in terms of both development
with special aesthetic effects and very high
speed of 60 metres/minute and ensures
of the coating and regulation of the line based
and Poland. Thanks to our ability to meet
on the characteristics
time, we can ensure quality consistency
of the product to be
also with very high volumes, which is
© Sevalcon
aging resistance performance. At the same
applied. Therefore
the most critical issue when it comes to
Impol Seval insists
producing special finishes”, states Impol
with its paint suppliers
Seval’s Senior Sales Officer Nemanja Rosić.
on fast and efficient
“There are two key elements to succeed in
technical service and
the field of exclusive architectural projects:
collaboration in matching
high quality customised coatings made
the coatings to the needs
with high-performance raw materials and
and requirements of
a plant able to apply them – these paints
the coil coating line in
usually present some application problems
Sevojno, emphasizing a
from the beginning to the end of metal
high level of satisfaction
coils,” says Ljubomir Jevtić, Impol’s Coil Coating Line Manager. “Until today, we have sold 99% of our pre-painted metal in
50
3 1
Figure 3: The Dubai Gold shade.
N. 50 - MARCH/APRIL 2018 - international PAINT&COATING magazine
with the cooperation with the supplier SALCHI Metalcoat.
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
© Sevalcon
INNOVATIONS IN SURFACE TREATMENTS FOR METAL ARCHITECTURE
Customisation, performance, and special effects: the three pillars of Impol’s success
short time (Fig. 5). The choice to rely on an Italian partner also stems from Italy’s reputation in terms
Impol works in close
of aesthetics and
contact with clients
design.”
and architectural firms.
“As for performance,
“Before approving a
PVDF products
certain coating product,
account for 90% of
we supply many
the coatings used
different samples, all
for our projects in
with customised colours.
Russia. They are the
This is our strength,”
only coatings that can
says Milos Popovic,
ensure exceptional
who manages the
aging resistance,
relationships between Impol and its Russian clients. “Very often, the choice falls on colours and
colour retention,
4 1
and no need for
Figure 4: Zaryadye Park is the largest green area in the city of Moscow, featuring modern high-tech infrastructure.
maintenance over very long periods of time. Our paint
effects that combine several different
speed of its deliveries: our paint development
suppliers must therefore also be expert in
samples. Architect always require specific
partners must be equally timely,” states
the use of PVDF raw materials in special
coatings for their projects: that is why it is
Popovic. “For example, for the cladding
effect products,” says Milos Popovic.
important that the paint supplier selected
of Moscow’s VTB Arena, we developed a
“Furthermore, they must be able to solve
is able to offer customised products.
complete ocean-inspired collection in a very
any colour matching problems that may occur between pre-painted
not have months or years to develop a
aluminium and aluminium
coating that meets the architects’ needs.
© Sevalcon
Moreover, time is of the essence: we do
profiles, which are traditionally powder coated. Providing a
Impol is well known on the market for the
customised product exactly in line with the architects’ ideas is not enough: such coating
Besides the Luzhniki Stadium, which exceeded the expectations of both investors and Football Federation officials, Impol has worked on several international airports in the Russian cities of Rostov, Saransk, Volgograd, and Perm. Russia is in fact making huge investments in its infrastructure, not only for the FIFA World Cup but also as a part of a larger country development project.”
52
must also harmonise with the paint products made by other suppliers for different components of the structure. Finally, a crucial requirement for Impol is the fire resistance certificate: it enables our aluminium to be used in airports, commercial and financial buildings, hospitals, schools, stadiums, and all types of infrastructure that provide 5 1
Figure 5: The ocean-inspired colour range developed by Impol Seval in collaboration with the coating supplier Salchi Metalcoat.
N. 50 - MARCH/APRIL 2018 - international PAINT&COATING magazine
access to the public. I think that Impol is the only pre-painted aluminium producer to have this certificate in Russia.”
FOCUS ON TECHNOLOGY
Russia: great excitement in architecture
Russian capital, which turned 870 years
“It should also be noted that Salchi’s
old, Zaryadye Park is the largest green
coatings are customised not only
Besides the Luzhniki Stadium, which
area created in the city in the last fifty
in terms of colours, effects, and
exceeded the expectations of both
years. Here, modern high-tech structures
performance, but also based on the
investors and Football Federation
can be admired, such as the “suspension
characteristics of our application line,
officials, Impol has worked on several
bridge” on the Moskva River, an
which its engineers know very well,”
international airports in the Russian
underground glacier, and the honeycomb
says Ljubomir Jevtić from Impol. “Each
cities of Rostov, Saransk, Volgograd,
roof of the Philharmonic Hall,” says Milos
coating line has its own influence on
and Perm. Russia is in fact making
Popovic. “A very metallic finish that we
the application process, which can
huge investments in its infrastructure,
called Silver Charge has been chosen to
affect the finishing results. However,
not only for the FIFA World Cup but
enhance the modernity of this structure.
our projects require uniformly
also as a part of a larger country
“We collaborated with Salchi also for
perfect surfaces from the beginning
development project (Fig. 6). “We
this project because it is a coil coating
to the end of coils. That is why we
participated in the realisation of
manufacturer particularly inclined to
have fully automated our coating
one of the most important projects
produce specialty coatings – exactly what
process, which is adjusted from time
implemented in Moscow in the last
we are looking for. On the other hand,
to time depending on the type of
few years, Zaryadye Park, rising on
Impol has a great expertise in the coating
coating product to be applied, and
the ashes of the colossal 7000-room
of aluminium coils: they are able to
we monitor the thickness of both the
Rossiya Hotel, demolished in 2008.
perfectly coat very thick aluminium strips
tape to be painted and of the coating
Inaugurated on September 9, 2017
with an impressive final quality, even with
layers applied with three different
on the occasion of the birthday of the
“difficult” products such as PVDF.”
measurement and control devices.”
Your efficiency, our innovations.
Visit us at the PaintExpo ! 17 - 20 April 2018, hall 3 Booths 3228 · 3230 · 3328 · 3330
www.wagner-group.com/paintexpo
Coating. Bonding. Sealing. Efficiency and highest quality.
Characteristics of the coating system
© Sevalcon
INNOVATIONS IN SURFACE TREATMENTS FOR METAL ARCHITECTURE
From a technical point of view, the Kynar 500®-based PVDF coatings used by Impol Seval guarantee a minimum outdoor service life of 20 years. Impol generally applies two or three-coat systems, depending on customer requests. “In some special cases, metallic/iridescent effects may call for the application of an intermediate layer and a topcoat,” explains Jevtić. “Normally, the former gives the surfaces corrosion and ageing resistance characteristics, while the latter creates the special effect. At other times, the special effect is already present in the
6 1
Figure 6: Moscow’s Crocus City Oceanarium, another impressive and futuristic structure built by Impol Seval
intermediate layer and the topcoat as the preferred building material,
significantly lengthen the maintenance
treatment cycle is the same for all our
especially thanks to its durability,
intervals of structures, reducing their
products.”
design versatility, lightness, and
management and maintenance costs.
aesthetic characteristics. Preserving
They please the eye, preserve cities
the beauty of a building for a long
from the ugliness of decadence,
time goes far beyond aesthetics.
and allow to pass the heritage of
Modern times have seen the rise of
Maintenance-free materials,
contemporary society on to future
metal, and in particular of aluminium,
such as PVDF coatings, enable to
generations.
Aluminium: a protagonist of modern times
Salchi – Arkema: a winning partnership since 1963 Established in 1963, Glidden-Salchi (fig. A) was the first licensee of the Kynar material. In that same year, Pennwalt (Cleveland, Ohio, USA) decided to start a licensing program to ensure high quality for the end users of PVDF coatings formulated with Kynar resin. When, in 1976-77, the industrial Group led by the Brenni family acquired Glidden-Salchi and turned it into Salchi Spa, the license formally passed to the new legal entity. Since then, Salchi and Arkema (the current manufacturer of PVDF Kynar 500®) have been partners in the formulation of surface materials aimed at enhancing the aesthetics, decoration, protection, and durability of building skins. Over the past fifty years, Arkema has conducted several studies on the
54
© Salchi Metalcoat
improves and protects it. The pre-
of their coating products, with positive effects along the entire value chain up to architects, who can be 100% sure of the durability of their creations’ look for fifty years. As a licensee, Salchi has always followed the guidelines provided by these studies and it is therefore able to offer solid guarantees to all Figure A: The inauguration of the Glidden-Salchi plant in 1963. its customers. The fun fact about the PVDF Kynar 500® program is that aging of coatings, testing different combinations of pigments and additives some samples have been exposed in PVDF Kynar 500®-based formulations. in Florida for the last fifty years, and This makes the technology licensees we have absolutely no idea if one day 100% sure about the aging behaviour they will start to deteriorate.
N. 50 - MARCH/APRIL 2018 - international PAINT&COATING magazine
THE FIRST VERTICAL POWDER COATING
COMPACT LINE IN THE WORLD COMPACT
1.000MTQ C.A.
TRADITIONAL COATING SYSTEM
VS
150MTQ
CUBE COATING SYSTEM
FAST COLOUR CHANGE
EFFICIENT THERMAL ENERGY CONSUMPTION
PLANPRODUCTION 5 MINUTES CH A N G E C O L O U R & H I G H F L E X I B I L I T Y
600.000KCAL
TRADITIONAL COATING SYSTEM
VS
350.000KCAL CUBE COATING SYSTEM
cube.sataluminium.com
BRAND-NEW
INNOVATIONS IN SURFACE TREATMENTS FOR METAL ARCHITECTURE
© Adapta Color
Adapta Color Presents Metal Vivendi Collection for Architectural Design
1
Figure 1: Vivendi SDS METAL Collection samples.
I
f something distinguishes Adapta
The new outstanding Metal Vivendi
finishes and other special effects
Color in the powder coatings
Collection is based on the proven Adapta
when they are applied to aluminium.
industry is its positioning in the
Vivendi technology for architecture,
Table 2 shows the mechanical and
market of metallic finishes. The new
which holds the Environmental Products
chemical properties of this product,
metallic colours of the Vivendi METAL
Declaration (EPD) and has been tested
obtained applying on 0.8 mm AA1050
range offer innovative developments
according to ISO 16000-9:2006 getting an
aluminium panels with the right
with excellent resistance to weathering
A+ for indoor emissions.
pre-treatment process and correctly baked, following the individual product
and maximum light fastness, always complying with international quality
Vivendi SDS METAL Collection products
data sheet instructions in order to get
specifications.
(Fig. 1) are based on ultra-durable
a right cross-linking reaction.
Coatings within Adapta’s Vivendi
polyester resins, hardeners without TGIC,
range have given an excellent exterior
pigments and additives (Table 1). They
Vivendi SDS METAL Collection
durability during more than 20 years
are semi-transparent pigmented clear
products meet or exceed the highest
with very good gloss retention and
coats to imitate noble metals (such as
international quality specifications for
colour stability.
copper, rose gold, brass…), anodised
powder coatings and can be used for
56
N. 50 - MARCH/APRIL 2018 - international PAINT&COATING magazine
BRAND-NEW
INNOVATIONS IN SURFACE TREATMENTS FOR METAL ARCHITECTURE
external architectural applications. These are available in smooth satin gloss finish with a gloss range from 30 to 80. They offer 70% gloss retention after 1000 hours of QUV313B test. Vivendi products have been designed mainly to be used on aluminium surfaces as: - expanded and perforated aluminium panels - raised and flattened aluminium meshes - aluminium rain screens and sun protection parts - aluminium cassettes for faรงades. The substrate to be coated must be
Table 1: Powder characteristics and cure-stoving conditions of the product.
cleaned, degreased and pre-treated with the most suitable process (chrome-free or pre-anodizing). Vivendi SDS METAL Collection can bel electrostatically sprayed with all commercial Corona Guns. At the end of 1997, ADAPTA COLOR began to manufacture powder coatings. Since then, the company has been deeply committed to providing high quality solutions for all the requirements of the market, foreseeing the emergence of such needs to the greatest extent possible. With wholly Spanish capital, ADAPTA COLOR today represents the integration of experience and youth in the manufacture of powder coatings in Europe. A team of professionals with a long history of development in the industry and enterprising management have managed to place this company in an outstanding position in the market of powder coatings in a short period of time. For further information: www.adaptacolor.com
Table 2: Mechanical and chemical properties of the new Metal Vivendi products.
international PAINT&COATING magazine - MARCH/APRIL 2018 - N. 50
57
© ipcm ®
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N. 50 - MARCH/APRIL 2018 - international PAINT&COATING magazine
INNOVATIONS IN SURFACE TREATMENTS FOR METAL ARCHITECTURE
FOCUS ON TECHNOLOGY
How Cutting-Edge Technologies and Targeted Interventions Have Made Sepal One of the Most Advanced and Flexible Aluminium Processing Companies in Europe Barbara Pennati ipcm®
F
or a company performing coating
were both supplied by SAT Spa (Verona, Italy),
Qualicoat Seaside standard without any
tasks, a high finishing quality level
specialising in the design of vertical coating and
surface conversion process. Today, as then,
is just as important as a good
surface finishing plants for extruded aluminium
Sepal is driven by a will to renew and search
productivity rate. Production volumes
profiles.
for the best quality possible. That is why it has
should not be sacrificed in order to reach
ipcm visited Sepal’s premises in 2015 to report
recently made further important investments
the best quality possible for a given
the installation of the first plant in Europe, in
that led it to consolidate its presence on
®
© ipcm ®
markets. Another critical parameter to be competitive nowadays is
international markets. Once again, it chose SAT as its technological
flexibility, in terms not only of types
partner.
of component treated but also of
“Before the latest plant
compliance with specifications.
modifications, Sepal always
These can vary a lot among different
performed a flash oxidation pre-
markets, not so much for the
treatment process with the FOX®
requirements as for the processes
technology patented by SAT, that
needed to comply with them.
is, a very rapid anodic oxidation
Sepal Spa (Lograto, Brescia, Italy) is
phase able to improve corrosion
a well-established company in the
resistance. However, a few
sector of aluminium extrusion, which
markets, especially the French one,
has managed to distinguish itself in through the installation of some of the most advanced technologies available on the market. The aim was
have very strict specifications in
1
the field of aluminium profile coating
terms of chrome-free conversion,”
Figure 1: The brushes scratch the profiles’ first layer of aluminium to significantly reduce the possibility that surface defects appear after coating.
achieving higher quality and finishing
explains Andrea Trevisan, the CEO of SAT. “Therefore, we decided to modify their already-existing plant by integrating an acid attack
levels for their products, combined with
terms of both dimensions and production
and chrome-free conversion phase, which
high flexibility to meet the demands
cycle integration, to have industrialised the
enables Sepal to perform both the FOX® and
of different markets as well as high
flash oxidation pre-treatment technology ,
conventional pre-treatments on the same
productivity. Established in 1973, in 2014
which ensures salt spray resistance values of
line.” In the framework of this important
Sepal insourced its finishing operations
about 3000 hours and compliance with the
investment, other crucial changes were made
through the implementation of a modern coating plant with an in-line flash oxidation system and an anodising plant. These
1
1 “The first coating plant in Italy for aluminium profiles with an in-line flash oxidation pre-treatment process” ipcm®_International Paint&Coating Magazine Vol. VI, No. 31 January-February, pages 46-55
for quality purposes, but also to ensure constant productivity and greater versatility of the line.
Opening photo: The in-line brushing system added between the loading of profiles and the start of the pre-treatment cycle.
international PAINT&COATING magazine - MARCH/APRIL 2018 - N. 50
59
© ipcm ®
INNOVATIONS IN SURFACE TREATMENTS FOR METAL ARCHITECTURE
2 1
Figure 2: The coating booths feature 18 guns each.
In-line brushing machines for optimal surface preparation One of the main innovations was the addition of an in-line double brushing machine between the loading of profiles and the start of the pre-treatment cycle (ref. Opening photo). “Another important change to the plant was the integration of a brushing system to scratch all four sides of the profiles and remove any residues and surface defects created by the extrusion process,” says Trevisan. “Normally, with a part of Sepal’s production for which a very high surface quality is required, the brushing operation takes place before loading. However, performing this process offline entails high costs in terms of labour and time, and therefore a loss of productivity. That is why, based on Sepal’s automation-oriented approach and thanks to our patented system, we installed these in-line brushing machines.” This system is the second one installed by SAT and the first one in Italy, which confirms Sepal’s inclination towards technological experimentation. “By scratching the profiles’ first layer of aluminium, the brushes eliminate ‘stubborn’ chips and residues that
Sepal Spa (Lograto, Brescia, Italy) is a well-established company in the sector of aluminium extrusion, which has managed to distinguish itself in the field of aluminium profile coating through the installation of some of the most advanced technologies available on the market. The aim was achieving higher quality and finishing levels for their products, combined with high flexibility to meet the demands of different markets as well as high productivity.”
FOCUS ON TECHNOLOGY
chemical pre-treatment alone can hardly remove. It is an expensive process, but it significantly reduces the possibility that surface defects appear after coating, resulting in waste or expensive rework (Fig. 1),” says Trevisan. “The in-line integration of the brushing process also gives an advantage in terms of productivity: once the profiles are loaded, the whole finishing process is performed fully automatically. The same operation carried out offline, moreover, would require the use of one or more machines depending on the volumes to be treated.” “What makes our in-line brushing machines unique and innovative is their patented system to stop the profiles only in the brushing area, thus ensuring a safer, simpler and more consistent process. At the same time, the stop of the workpieces does not affect the speed of the line, because this patented system allows to compensate for the time required with an increase in the movement speed from one station to another,” explains Andrea Trevisan. “This is the second brushing system we have installed after the one of Cortizo, a Spanish manufacturer of aluminium profiles.”
The revamping of the coating booths The third plant modification involved the coating booths and it was aimed at increasing their productivity and quality levels. “Sepal’s plant includes two powder coating booths: the one dating back to 2014 is equipped with Venturi injectors, whereas the one added in 2015 features Gema dense phase pumps, a dispensing technology that ensures significant paint saving and better adhesion,” states © ipcm ®
Trevisan. “In order to further improve their performance, we increased the number of guns from 12 to 18 in the second booth, so that they both have the same number of guns (Fig. 2), and we retrofitted the first booth’s multiple controls to simplify its operation. Moreover, the oldest booth was replaced with a new V-shaped one, patented by SAT (Fig. 3). Originally, the line had been conceived to rotate the profiles; now, with these two
3 1
Figure 3: One of the two V-shaped booths, patented by SAT.
© ipcm ®
INNOVATIONS IN SURFACE TREATMENTS FOR METAL ARCHITECTURE
4 1
Figure 4: Sepal can manage both the booth and the guns with one control panel.
due to excessive
Performance and aesthetics 4.0
exposure.
“In 2015, Sepal was the first factory in
However,
Italy to employ the FOX® pre-treatment
it ensures
on all its products; their line could work
extremely
at a speed of 1-1.2 m per minute. With
durable and
the implementation of a chrome-free
resistant
pre-treatment process, the line can
products and
now work at a higher speed, up to
it has allowed
1.8 m per minute. Combined with the
Sepal to improve
two coating booths featuring 18 guns
the productivity
each, the modified unloading system
of its line, as
that automatically wraps the profiles
well as meeting
in packages, and the hook stripping
the quality
system that has allowed to insource
requirements
this operation, this has given Sepal
of international
extreme versatility and production
markets,” states
speed,” states Andrea Trevisan.
Trevisan.
“Finally, the reproducibility of process phases through the automation and
new generation booths, this is no longer
In-line hook stripping process
necessary,” says Trevisan. “Finally, we installed
Performing all the coating phases in-line
has contributed to ensure very high
a software for the vision system, able to
is a significant advantage: it enables to
production and quality standards.”
interact with the Gema powder management
reduce handling and labour and it increases
“The example of Sepal proves that
unit and in particular with the control system
economic efficiency. That is why SAT also
remarkable advantages in terms of
OptiControl CM22. This enables Sepal to
equipped Sepal’s plant with a hook stripper
both aesthetics and finishing quality
manage both the booth and the guns with one
supplied by Alit (San Bonifacio, Verona),
can be obtained through targeted
control panel (Fig. 4).”
which eliminates the need to remove the
interventions and small investments
hooks from the conveyor and send them to
on the already existing plants,
A 25-micron oxidation tank
interconnection of the production flow
modified quickly and without stopping
consists of a tank for the paint stripping
production by taking advantage of
treatment, which has given Sepal greater
product positioned between the unloading
summer breaks and holidays,” says
versatility, we also improved their anodic
and loading stations. On their way from
Andrea Trevisan.
oxidation system,” says Trevisan. “This
one station
plant is completely automatic and able to
to another,
handle profiles up to 8 metres. The initial
the hooks are
project provided for the installation of three
immersed in the
16,000-amperes tanks to obtain thicknesses
stripping tank
between 10 and 16 microns with a standard
while still hanging
oxidation process. However, we also created
on the chain.
the space for another tank, which we
After about 3
equipped with a 20,000-ampere rectifier in
minutes, they
December 2017, when the revamping project
are cleaned
started. This provides 25-micron oxide layers,
from any paint
as requested in particular in the United
accumulation
Kingdom.”
that can affect
“This type of oxidation is very difficult to obtain
electrostatic
because it requires the right balance between
generation during
the time spent in the tank and the acidity
application.
degree, so that the surface is not damaged
62
N. 50 - MARCH/APRIL 2018 - international PAINT&COATING magazine
© ipcm ®
a stripping contractor (Fig. 5). The system
“Besides implementing a chrome-free pre-
5 1
Figure 5: Alit’s hook stripper.
Paint Engineering
Premium quality Formulation, design and manufacture adapted to technical requirements, and highly complex facilities.
Anticorrosive systems
Coil Coating Superdurable Superdurable coatings for sublimation effect Metallic bonding
www.titanpowdercoatings.com
BRAND-NEW
INNOVATIONS IN SURFACE TREATMENTS FOR METAL ARCHITECTURE
C
ondoroil Launches Condorcoat EC 930, a New
© Condoroil
Condoroil Launches Condorcoat EC 930, a New Nanotechnology Conversion Product Nanotechnology Conversion
Product Condorcoat EC 930 is the new frontier of pre-treatment: a nano ceramic process, more commonly known as “nanotechnology process”, for the surface conversion of iron, galvanised metal and aluminium (Fig. 1). The nanotechnology product Condorcoat EC 930 creates a very compact inorganic layer, although much thinner than that achieved with iron phosphating. The protection obtained is of higher quality and with lower operating costs. Condorcoat EC 930 is free from phosphates, heavy metals such as zinc, manganese, nickel, etc., COD, and VOC; it is therefore highly eco-
1
Figure 1: Condorcoat EC 930 is the new nanotechnology product developed by Condoroil.
friendly. The economic-applicative advantages
with surfactants ensuring the
to perform application tests in its
of nanotechnology are manifold,
perfect removal of processing oils
technological laboratories, where
since it is possible to operate at
and greases, commonly found on
the effectiveness of the proposed
room temperature thus reducing the
iron and galvanised parts.
solutions can be assessed by
conversion bath management costs.
Condorcoat EC 930 is preferably
exposing the treated samples in
Sludge production is reduced, calling
used in demineralised water
accelerated corrosion chambers
for smaller doses of Condorcoat EC
solutions, with both spraying
before the in-line application.
930 and thus increasing the duration
and immersion techniques, from
Specialised engineers are also
of the bath itself. This generates
room temperature up to 50 °C, in
available to support the customers in
further savings, thanks to the
AISI 304 or 316 L stainless steel
the application phase.
reduced consumption of water due
systems. The workpiece treatment
to the lower replacement frequency
is followed by a rinse with
For further information:
of the bath.
demineralised water.
www.condoroil.it
Condorcoat EC 930 can also be
The pre-treatment process with
used in a single degreasing/surface
Condorcoat EC 930 is compatible
conversion stage (nanotechnology
with all coating processes.
degreasing), because it is enriched
Condoroil offers the possibility
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N. 50 - MARCH/APRIL 2018 - international PAINT&COATING magazine
SPECIAL
BRAND-NEW
© Verind
M
APSA, the Spanish producer of aluminium
The painting line, being
wheels based in Orkoyen, near Pamplona, and
told as the fastest for
affiliate to Mondragon Group, has awarded
aluminium wheels in Europe, running at 8 m/min, will
to Dürr the realization of the entire new painting line for
be a real challenge for Dürr technicians, both for rims
aluminium wheels on a turnkey basis.
handling and conveyor synchronization as for paint
MAPSA will exploit the advantages of the extended
application and multiple rims baking and cooling.
product portfolio of Dürr Group for aluminium wheels
The new line will allow MAPSA to prosecute its
that includes layouting, complete process line, conveyors,
plan of capacity expansion with a high quality and
handling robots, complete automatic liquid paint
productivity plant, fully automated, from robotic
application system with electrostatic EcoBell 2 (Fig. 1), demi and waste water plant, VOC abatement systems – that in case of regenerative thermal oxidisers are specially tailored to handle wheel paints exhaust – and a dedicated software for the management of the entire system.
1
Figure 1: MAPSA’s new painting line will feature a complete automatic liquid paint application system with electrostatic EcoBell 2.
© MAPSA
Dürr Will Realise the New Aluminium Wheels Painting Line for MAPSA
loading to final inspection, provided with innovative solutions including the state of the art liquid paint application systems. For further information: www.olpidurr.it
EcoGun AUTO
Automatic spray gun for wood working industry Compact and light automatic spray gun for air-assisted, air-less and airspray application. Can be used for paint application in the machining and wood working industry. All EcoGun automatic spray guns offer a wide range of spraynozzels and additional equipment.
www.verind.it
SPECIAL
BRAND-NEW
T
he second test plant, primarily focusing on the coating of temperature-sensitive substrates
© IGP Pulvertechnik AG
IGP Pulvertechnik AG: Test Plant for Temperature-Sensitive Substrates Enters Operation such as MDF and plastics, became operational in February 2018 in addition to the existing metal coating technical centre located at the headquarters in Switzerland. The new test centre enables IGP to simulate the coating of temperature-sensitive substrates under real production conditions and to experiment with application methods (Fig. 1). This will create the foundation for shorter product launch times as well as robust volume production processes at the customer premises. Furthermore, the plant also functions as a research and training centre. In doing so, IGP is consolidating its position as a premium provider of powder coatings and ensures its ability to provide a suitable solution for all customer requirements. “With the new technical centre, we are further expanding the strategically important field of powder coating for temperature-sensitive substrates. In doing so, we are creating a further condition for consolidating our leading role in terms of innovations and design in addition to competitiveness,” explained Savvas Legidis, Head of Technology. “The ultra-modern technical centre is an important component of this. One particularly noteworthy special feature of the new technical centre is the variable speed control in the furnace, which permits a simulation of various furnace lengths (Fig. 2).”
66
1
Figure 1: The new test centre enables IGP to simulate the coating of temperature-sensitive substrates and to experiment with application methods.
N. 50 - MARCH/APRIL 2018 - international PAINT&COATING magazine
SPECIAL
© IGP Pulvertechnik AG
BRAND-NEW
Special features of the technical centre: – Furnace with 56 individually controllable radiator elements constantly in a halo arrangement – Pre-heating furnace with 8 individually controllable radiator elements constantly in a halo arrangement – Fully electric furnaces with medium-wave infrared radiators – Conveying system with 3 power lines for pre-heating furnace, coating and stoving oven – Plastic coating cabin with 6 guns respectively on each side in a short-stroke arrangement – Gun arrangement can be variably adjusted (short-stroke/long-stroke) – One counter-electrode on each coating side – Stoving oven with variable radiator distance, individually adjustable on each side. IGP Pulvertechnik AG will be at PaintExpo 2018, booth 2517, Hall 2. For further information: www.igp-powder.com
2 1
Figure 2: The technical centre features a variable speed control in the furnace, which permits a simulation of various furnace lengths.
SPECIAL
BRAND-NEW
T
© Le Fonti Innovation Awards
ST Powder Coatings Received the “Le Fonti Innovation Awards®” Nomination he company was among the finalists in the special category Excellence of the Year / Innovation & Leadership.
The nomination came after various prizes and certifications obtained by the company both nationally and internationally, including the recent admission to the Elite project of the
The eighth edition of the “Le Fonti Innovation
London Stock Exchange Group. A pleasant
Awards ” (Fig. 1), a prestigious international
surprise, therefore, but also a strong confirm
®
award dedicated to entrepreneurial excellence, took place on March 9 in th
Milan, at the famous headquarters of the Italian Stock Exchange placed in Palazzo The event was organized by the Milanese editorial group Le Fonti
for ST Powder Coatings and for its constant effort in terms of innovation, quality and customer service. The selection was developed by the Centro Studi Le Fonti in
© ernestomedapress.com
Mezzanotte (Fig. 2).
Figure 1: ST Powder Coatings was nominated at “Le Fonti Innovation Awards”, an international award dedicated to entrepreneurial excellence.
concert with the editors of the magazines World Excellence, Le
with the patronage
Fonti Legal and
of the European
the newspaper
Commission and, in
Finanza & Diritto.
previous editions,
The choice was
had winners such
also made on the
as Basf, Bosch,
basis of a survey
Sanofi, Dainese,
carried out by over
Fujitsu, Epson,
40,000 qualified
Porsche, Bmw,
contacts from the
Panasonic, Ibm and
world of industry
Vodafone.
and professionals.
Business results,
Le Fonti Awards’
industry leadership,
gala, which was
strategic development, internationalization, quality of service, sustainability,
preceded by a
2 1
World Financial
Figure 2: The event took place at the headquarters of the Italian Stock Exchange placed in Palazzo Mezzanotte.
Summit, has been live broadcasted and widely distributed on
innovation and training are the criteria by which the
by the editorial staff and readers of the
the main national media like Il Sole 24 Ore,
competitors are rewarded.
magazine World Excellence, is motivated
La Repubblica - Affari e Finanza, Il Corriere
ST Powder Coatings has been selected
by the fact that the company constitutes
della Sera, La Stampa, L’Impresa and Harvard
as finalist along with 14 other companies
“a growing Italian excellence, a leader and
Business Review.
rated “excellent” in the special category
a milestone in the chemical sector of the
of Excellence of the Year / Innovation &
production of powder coatings for innovation
For further information:
Leadership. The nomination, promoted
and quality.”
www.stpowdercoatings.com
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N. 50 - MARCH/APRIL 2018 - international PAINT&COATING magazine
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
Š CMA Robotics
Opening photo: For 25 years, CMA Robotics has been passionately dedicated to the production of high-tech coating robots with a distinctive green colour.
HIGHLIGHT OF THE MONTH
INNOVATIONS IN SURFACE TREATMENTS FOR METAL ARCHITECTURE
CMA Robotics Celebrates 25 Years of History at the Forefront of Technology in the Automatic Coating Sector Alessia Venturi ipcmÂŽ
F
rom a small warehouse for rent in the
These two sentences summarise the
electronic controls and automatic machines,
early 1990s to a well-established company
extraordinary and emblematic story of CMA
they decided to apply the expertise gained in
present in 60 countries across the world.
Robotics, made possible by the talent, passion,
the electronic field to the robotics world. On
From a passion-driven local start up to one of
and vision of its three founding members: Paolo
Friday, March 2, Sergio and Marco celebrated
the top ten companies in the world with the
Piano, Sergio Della Mea, and Marco Zanor.
the 25 years of activity of CMA Robotics
highest technological level in the automatic
In 1993, when they were just thirty years old
and the inauguration of its new, futuristic
coating sector (ref. Opening photo).
and worked together in a company producing
headquarters in Pavia di Udine (Fig. 2) with a
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N. 50 - MARCH/APRIL 2018 - international PAINT&COATING magazine
© ipcm ®
HIGHLIGHT OF THE MONTH
1
Figure 1: The event organised on March 2 to celebrate the 25 years of activity of the Friulian company.
big party (Fig. 1) also dedicated to the memory of Paolo,
automatic execution. Thanks to a self-learning
who died prematurely in 1997.
programming system, the control computer saves
CMA currently designs, builds and installs the widest
the operator’s movements and repeats them at the
range of coating robots and systems now available on
desired speed. The coating operator plays a different
the market. It provides complete solutions, from design
role: he is no longer in contact with chemicals, but
to the integration in complex plants: besides supplying
he manages the machine and controls its quality and
individual robots and machines, CMA Robotics handles
operational efficiency.
the integration of such systems in their intended lines
With the self-generation of programs, CMA Robotics
in collaboration with the customers.
has then taken a further step forward: thanks to
Its first of coating robot prototype dates back to 1994.
artificial vision systems, the robot recognises the
advanced technology and it was designed for painting chairs: the aim
© CMA Robotics
It featured a particularly
was to meet the growing needs for automation of local companies. In 1997, a renowned Brazilian company chose CMA for the construction of 14 customised plastic-coating robots. It was a turning point for the Friulian company, as well as its chance to take full advantage of the enormous potential of the product it had created. Coating robots combine human intelligence and
2 1
Figure 2: The entrance of the new futuristic headquarters in Pavia di Udine, Italy.
© CMA Robotics
INNOVATIONS IN SURFACE TREATMENTS FOR METAL ARCHITECTURE
“The health of operators and the environment is at the core of our idea of automation: the application of coatings through robots reduces paint consumption up to 40% and it enables the operators to be no longer in direct contact with chemicals and emissions.” CMA Robotics also focusses on customer service, offering turnkey solutions complete with hardware, software, control, and assistance and, above all, ensuring high quality levels and speed of execution.
The insourcing phase CMA’s expansion began in 2003 with the establishment of a German branch, CMA Roboter. In 2005, the company underwent a complete makeover, modernising its image
3 1
and logo and giving its robots a green colour for greater recognisability on the market – since then, no other company
Figure 3: The cutting of the ribbon for the inauguration of the new headquarters.
© ipcm ®
established through a strategic joint venture with Efort, the largest Chinese robot manufacturer. With this, CMA improved its commercial power and design scope. In 2018, now known all over the world, the company has finally inaugurated its new prestigious, advanced headquarters
4 1
(Fig. 3).
Figure 4: Sergio Della Mea (left) and Marco Zanor (right), two of the three founding members of CMA Robotics, with Alessia Venturi from ipcm®.
shape, size and characteristics of the parts to be treated and it generates the best coating program in real time. Robots are therefore able to acquire skills and apply them to processes. “Our robotics is humanfriendly: machines evolve the work functions of man, improve their conditions, and perfect their final results,” says Sergio Della Mea. “CMA’s robots can self-program by recognising the characteristics of the product to be treated, thus enabling manufacturers to save time, money, and resources. Figure 5: On the stage of the event, employees, customers, and representatives of authorities, business associations, and local financial institutions.
72
2015, CMA China was
N. 50 - MARCH/APRIL 2018 - international PAINT&COATING magazine
“We work in 60 countries worldwide, but we
© CMA Robotics
Coating robots combine human intelligence and automatic execution. Thanks to a self-learning programming system, the control computer saves the operator’s movements and repeats them at the desired speed.”
in the robotics industry has used it for its products. In
5 1
HIGHLIGHT OF THE MONTH
are still a small business compared
CMA’s expansion began in 2003 with the establishment of a German branch, CMA Roboter. In 2005, the company underwent a complete makeover, modernising its image and logo and giving its robots a green colour for greater recognisability on the market – since then, no other company in the robotics industry has used it for its products. In 2015, CMA China was established through a strategic joint venture with Efort, the largest Chinese robot manufacturer. ”
Della Mea and Marco Zanor (Fig. 4)
right size to ensure flexibility, quality,
thanked and welcomed on the stage
high performance, and continuous
their first collaborators, some of the first
innovation,” states Marco Zanor on the
customers who trusted the company, and
sidelines of the event. “We now have
the representatives of authorities, business
an international team to implement
associations, and local financial institutions,
numerous experimentation and
as well as Paolo Piano’s daughter in
innovation projects. We also collaborate
memory of her father (Fig. 5). The evening
with several universities at the national
culminated in a fascinating display of the
level, especially the Udine and Trieste
capabilities of some robots that, instructed
ones, but also at the international
by CMA’s engineers, “danced” on the notes
level, including the National Robotics
of two pieces of music, as well as in a dinner
Engineering Center of Pittsburgh and the
with Friulian specialities and wines.
Wuhu Hit Robot Technology Research Institute. This enables us to be futureoriented and focus on the development of systems in which the robots will be able to share their experiences with other robots.”
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The inventor and global leader in electrostatic painting technology.
Specialists in advanced powder coating equipment and systems.
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World Class Manufacturers of: Process Controls | Curing & Conveying | Electrostatics Fluid Handling | Powder Coating | Atomisation Carlisle Fluid Technologies UK Ltd Ringwood Road, Bournemouth, Dorset, England BH11 9LH Tél: +44 (0)1202 596257 Tél: +33 (0)7 84 37 97 03 Email: marketing-fr@CarlisleFT.eu
During this touching celebration, Sergio
with multinational giants: this is the
SPECIAL
BRAND-NEW
T
Unconventional © Shutterstock
Superdurable Powder Coatings for Architectural Applications he trend towards architectural powder coatings
is becoming unavoidable regarding the high demands on coating solutions in the modern construction landscape. Architectural products are known for having some of the most challenging coating performance requirements in the industry. Coatings for building products need the right properties to withstand rain, humidity, salt air and UV exposure from sunlight while
1
maintaining their original appearance during years of serving. Over time, the long-term performance
Figure 1: Ecopolifix’ powder coatings have proven to provide long-term appearance and excellent weather and corrosion resistance.
of suitably pretreated and powder-coated aluminum has
laboratories, these solutions are
are specifically designed to meet
established a solid track record in
optimized in close cooperation with
these requirements. Thus, they are
terms of performance. Ecopolifix
the customer and tested to perform
the ideal coating solution for outdoor
powders are specially formulated
perfectly in practice.
architectural applications. Ecopolifix
for the architectural needs.
To ensure the quality of the products
offers over 480 Qualicoat-approved,
Known as Superdurables, Ecopolifix’
for architecture, the company
customized and environmentally
powder coatings have proven to
provides Qualicoat-certified powder
friendly products in stock. Additionally,
provide long-term appearance and
coatings, that hold the specification for
Ecopolifix Qualicoat Class 2 product
excellent weather and corrosion
architectural requirements. Ecopolifix,
solutions can be designed in all RAL
resistance (Fig. 1).
will present its Qualicoat-certified,
colours on customer’s demand.
Powder coating systems of Ecopolifix
high-performance class 1 and 2
open up completely new perspectives
powder coatings for aluminum profiles
For further information:
for functional coatings of the future.
at PaintExpo 2018 in Karlsruhe, Hall
www.ecopolifix.it
The development engineers create
2, booth 2128. The Superdurable
system solutions with properties
polyester-based powder coatings with
tailored specifically to customer
their excellent weather resistance,
demands. In Ecopolifix’ in-house R&D
flexibility and adhesion properties,
74
N. 50 - MARCH/APRIL 2018 - international PAINT&COATING magazine
Visit us at: April 2018 KARLSRUHE - hall 1 | Stand 1330
© ipcm ®
Opening photo: The Valladolid’s plant of Extrusiones Metálicas covers a 55,000 m area. 2
FOCUS ON TECHNOLOGY
INNOVATIONS IN SURFACE TREATMENTS FOR METAL ARCHITECTURE
Extrusiones Metálicas: Loyalising a Powder Coating Supplier to Consistently Meet the Quality Requirements of Very Different Markets Alessia Venturi ipcm®
E
xtrusiones Metálicas was established thirty-seven years ago
one thousand employees. It sells products on the US, Latin American,
in Mexico and it has always been dedicated to becoming an
Caribbean, and European markets, and it participates as a supplier in the
excellence in the world of aluminium. It now owns four production
largest Mexican architectural projects.
plants in Mexico (Texcoco, Guanajuato, Vallejo, and Veracruz) and one
The acquisition of the Valladolid plant, one of the most advanced in
in Europe, in Valladolid (Spain) (ref. Opening photo), and it has over
Europe, is part of a company expansion plan on the industrial and
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N. 50 - MARCH/APRIL 2018 - international PAINT&COATING magazine
© ipcm ®
FOCUS ON TECHNOLOGY
automotive markets, as well as the
and employing different
metal architecture one. The facility
technologies and skills.
covers a 55,000 m2 area and it is
A solution to ensure
equipped with 7, 8, and 10-inches
quality consistency is
extrusion presses (Fig. 1),
choosing partners able
machining centres, an automatic
to supply all the factories
warehouse for profiles and one
of the Group with the
for dies, a vertical and a horizontal
same products, adjusted
coating plant, a sublimation
according to the technical
machine for wood-effect
needs of each plant and
decorations, and thermal bridge
to the requirements of all
assembly, packaging, and delivery
markets, with very different
departments.
environmental regulations
Extrusiones Metálicas is
and quality standards from
synonymous with operational
each other.
excellence, commitment to service,
For Extrusiones Metálicas,
high quality, and attention to detail
one of these partners is
in every process. That is why all
Industrias TITAN S.A.U.,
production phases are completely
one of the most well-
integrated in its factories, from
established and innovative
foundry to delivery. In order to
Spanish companies in
do so, in addition to its internal
the field of industrial and
warehouses, it has a large network
decorative coatings. It
of distributors throughout the
supplies both the Spanish
whole Mexican Republic.
and the Mexican plants of
“We want to be much more than
the Group with powder
suppliers: we want to be a partner
coatings for aluminium.
for our customers. Therefore,
“Extrusiones Metálicas is
we have a technical department support our clients in terms of design, material specifications,
Qualicoat, Qualideco and
1
with architectural experts who
AAMA (for the American
Figure 1: The plant is equipped with 7, 8 and 10 inches extrusion presses.
powders complying with
explains Antonio Sanz, the
both these standards,” says Fernando
production manager of Extrusiones thirty-five years of activity, our Group has become a leader in the field of extrusion, anodising, coating, and decoration of aluminium profiles. This result has been achieved also thanks to our deep relationships with our operators, customers, and suppliers, which have created one strong value chain.” Establishing a relationship of trust and continuity with suppliers is a strategic factor for a company that has plants located in distant geographical areas
they require high and very high-quality polyester
development, and consultancy,”
Metálicas Europea, in Valladolid. “In over
market) certified. Therefore,
Extrusiones Metálicas was established thirtyseven years ago in Mexico and it has always been dedicated to becoming an excellence in the world of aluminium. It now owns four production plants in Mexico (Texcoco, Guanajuato, Vallejo, and Veracruz) and one in Europe, in Valladolid (Spain), and it has over one thousand employees.”
Blas, Titan’s supervisor for the Mexican Group. “Moreover, let us not forget that TGIC powders are still used in the North and South American markets, while they have been banned here in Europe. Their Valladolid plant, however, also produces architectural profiles intended for those markets. Our R&D department, therefore, strives to meet the colour requests of their Mexican customers, which send samples formulated with TGIC, by creating TGICfree products with the same tint and effect that can be used in Europe.”
international PAINT&COATING magazine - MARCH/APRIL 2018 - N. 50
77
© ipcm ®
INNOVATIONS IN SURFACE TREATMENTS FOR METAL ARCHITECTURE
2 1
Figure 2: The coating plant can treat profiles with a length up to 7.4 metres.
A highly automated production process
profiles up to 7 metres reach the loading
tunnel, which performs 4 active stages:
area directly from the automatic vertical
degreasing, acid stage, alkaline stage, and
Extrusiones Metálicas Europea
warehouse, an imposing 28-level structure
chrome-free conversion. We work with the
implements a highly automated
with 1792 slots and a capacity of about
Qualicoat Seaside certification for all our products: it requires a
production process that
minimum attack of 2
provides for minimal manipulation of the profiles along the various phases, from extrusion to packaging. “In our Valladolid plant, all movements of material from one department to another
One of the partners of Extrusiones Metálicas is Industrias TITAN S.A.U., one of the most wellestablished and innovative Spanish companies in the field of industrial and decorative coatings. It supplies both the Spanish and the Mexican plants of the Group with powder coatings for aluminium.”
gr/m2, but our process average is higher, about 3,5 gr/m2. “Then, the material enters the drying oven and it reaches
are automated through
the coating station,
bridge cranes,” states Julio
equipped with
Nogal, the coating manager. “Also the
500 kg per container (Fig. 3); only the
two automatic vertical booths with a
feeding of the coating plant, which can
profiles exceeding this length are taken to
conventional Venturi application system,
treat profiles with a length up to 7.4
the coating plant manually. After loading,
supplied by Gema (Fig. 4). Each booth
metres, is mainly automatic (Fig. 2). The
the profiles enter the pre-treatment
features 22 guns (Fig. 5). The colour
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N. 50 - MARCH/APRIL 2018 - international PAINT&COATING magazine
One partner for your automated paint applications Preprogrammed centralized controls Easy integration Modular build User friendly interface (HMI)
DISCOVER OUR SOLUTIONS
graco.com/ďŹ nishing
© ipcm ®
INNOVATIONS IN SURFACE TREATMENTS FOR METAL ARCHITECTURE
change time is about 5 minutes. One booth is devoted to light colours, the other to the dark ones. Before curing, the profiles go through an IR oven for the gelation of the film, in order to avoid colour contamination. The average productivity is 12 tonnes per shift with, on average, 8 colour change operations per day.” “Titan is our main supplier of powder coatings,” says Julio Nogal, “accounting for more than 60% only of the paints used in the Valladolid plant. However, it also supplies all the Mexican branches of our Group.” “We provide Extrusiones Metálicas with all the types of products they use: sublimation bases as well as textured, matte, metallic, satin, and glossy coatings, all complying with the Qualicoat or Qualideco quality levels for the wood effect (Fig. 6),” states Fernando Blas from Titan. “Most products are in Class 1 for the European branch, whereas in Mexico we mainly supply Class 2 coatings. Currently, we have not received any request for Class 3 products, yet.”
Loyalising a supplier to ensure quality consistency “We have loyalised Industrias Titan as our main powder supplies especially because they have very good products. We have never encountered any quality problem and they have always met our expectations,” states Antonio Sanz. “Moreover, Titan’s products have a very high yield, thus increasing our coating productivity. We have established a true partnership, a mutual collaboration aimed at the maintenance of a high quality level at competitive costs. Together, we also carry out
3 1
projects for the development of
Figure 3: The automatic vertical warehouse, with 28 levels and 1792 slots.
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N. 50 - MARCH/APRIL 2018 - international PAINT&COATING magazine
new and customised products.”
FOCUS ON TECHNOLOGY
The feeding of the coating plant, which can treat profiles with a length up to 7.4 metres, is mainly automatic. The profiles up to 7 metres reach the loading area directly from the automatic vertical warehouse, an imposing 28-level structure with 1792 slots and a capacity of about 500 kg per container.”
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.
© ipcm ®
Non avrai più dubbi sulla produzione del tuo materiale Produzione: Costruiremo il tuo trasportatore secondo metodi standardizzati sviluppati nel tempo per farti avere un impianto performante.
Non dovrai più preoccuparti del montaggio del convogliatore Installazione: Con quest’opzione, avrai il tuo convogliatore chiavi in mano montato da un team di tecnici montatori esperti.
Non avrai più blocchi di produzione 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.
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”
4 1
Figure 4: One of the two automatic vertical booths with a conventional Venturi application system, supplied by Gema.
REPORT IIN N RE REGALO! REGALO EGALO! LO
© ipcm ®
INNOVATIONS IN SURFACE TREATMENTS FOR METAL ARCHITECTURE
The coating station is equipped with two automatic vertical booths with a conventional Venturi application system, supplied by Gema. Each booth features 22 guns. The colour change time is about 5 minutes. One booth is devoted to light colours, the other to the dark ones.”
“We have developed the colours included in Extrusiones Metálicas’ European catalogue as well as all wood-effect (Fig. 7) sublimation bases for profiles mainly intended for the Mexican market,” says Fernando Blas. “Titan has chosen to establish an exclusive partnership with a sublimation film producer, the Miroglio Group. This enables us to give full guarantees on the sublimation process, with no attempt to waive liability by the paint or film supplier in case of any quality problems.”
A complete service for a global market Extrusiones Metálicas Europea’s main target market is the European one. “Besides the domestic market, we have an export share of around 40% to France, Belgium, the Netherlands, and the United Kingdom. The rest of our production is intended for customers in the United States and Latin America through our Mexican Group. Here in Valladolid, thanks to our cutting-edge plant equipment, we can extrude profiles that cannot be produced in the Mexican factories. Moreover,
82
5 1
Figure 5: Each booth features 22 guns.
N. 50 - MARCH/APRIL 2018 - international PAINT&COATING magazine
FOCUS ON TECHNOLOGY
© ipcm ®
Central Europe
6 1
Figure 6: Some profiles coated with wood-effect sublimation bases.
Industrias TITAN S.A.U. provides Extrusiones Metálicas with all the types of products they use: sublimation bases as well as textured, matte, metallic, satin, and glossy coatings, all complying with the Qualicoat or Qualideco quality levels for the wood effect.” i n f o @ w a t e r e n e r g y. i t w w w.w a t e r e n e r g y. i t
visit us at hall 2 - booth 2369
wece@wece.eu w w w.w e c e . e u
INNOVATIONS IN SURFACE TREATMENTS FOR METAL ARCHITECTURE
© ipcm ®
Figure 7: The wood-effect range available by Extrusiones Metálicas was developed by Titan.
our Group is constantly engaged in reducing the carbon footprint of its activities and it is equipped with a water treatment plant (Fig. 8). Moreover, the use of recycled aluminium for our productions makes us one of the most sustainable companies in the extrusion industry, with LEED and “Industria Limpia de Mexico”
7 1
certifications.”
the high automation of our plant enables us to offer customised packaging and shipping services based on our customers’ needs and location,” says Antonio
Extrusiones Metálicas Europea’s main target market is the European one. Besides the domestic market, they have an export share of around 40% to France, Belgium, the Netherlands, and the United Kingdom. The rest of the production is intended for customers in the United States and Latin America through the Mexican Group.” © ipcm ®
Sanz. “For instance, we can make a type A package, i.e. a stretch-wrapped Euro-pallet, a type B one, which is boxed and palletised, and a type C one, with profiles arranged in wooden boxes. In many cases, we prepare the profiles in advance, dividing them according to sales orders. “Our mission is to offer a service that goes beyond the mere production of a finished profile. Another important part of this mission are respect for the environment and commitment to our planet. Every factory of
84
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Figure 8: The water treatment plant.
N. 50 - MARCH/APRIL 2018 - international PAINT&COATING magazine
SPECIAL
BRAND-NEW
T
he third generation of Interpon
shades even matter (8-12 gloss)! And
Stock Range is now available in
there are many other exciting finishes
Europe and it offers a wider range
for every kind of projects.
of product technologies, shades and
Those interested in discovering the
finishes.
whole range of 1500 products can
AkzoNobel’s experts reviewed it every year
contact Customer Service.
to embrace markets’ needs with a more
The products are every day available
dedicated offer of products and services
in AkzoNobel’s storehouses all over
based on sector peculiarities.
Europe, ready to be shipped to the
Powder Coatings Interpon Stock Range
clients (Fig. 2)!
now includes also Interpon EC (Anti-Grafiti)
Detailed product information and newly
in 10 new RAL colours (Fig. 1) – suitable for
added collections can be found on
public transportation, street furniture etc.
AkzoNobel’s digital tools. To download
Some ranges have been enlarged to
AkzoNobel’s app on i-Pad, visit the
include new shades aligned with recent
following link: https://itunes.apple.com/
color trends. Interpon D2525 Structura,
us/app/akzonobel-powdercoatings/
Class 2 fine texture finishes, includes 15
id1063656164?mt=8
new RAL. Superdurable Matt range (25+/-5 For further information:
now. Précis Deep Matt range has 6 new
www.interpon.it
© Interpon European Stock Range
gloss) offers quite the whole RAL range
Figure 1: Powder Coatings Interpon Stock Range includes Interpon EC (Anti-Grafiti) in 10 new RAL colours.
86
N. 50 - MARCH/APRIL 2018 - international PAINT&COATING magazine
© Interpon European Stock Range
Interpon European Stock Range Gets Bigger!
Figure 2: Interpon Stock Range counts 1500 products, directly available at AkzoNobel’s storehouses all over Europe.
SPECIAL
BRAND-NEW
T
he entrepreneurial
© Orbita
Since 1962 Manufacturers of Premium Quality Overhead Conveyor Chains path of Nazzareno Roda, the President
of TSPGROUP, belonging to Trafilerie San Paolo, is the emblem of that of an entire generation. In the mid-1960s, Nazzareno Roda crossed destinies with Trafilerie San Paolo, a company established in 1966 by three partners and specialising in drawing stainless steel tubes. Nazzareno Roda made their business take off, importing the cold plastic deformation technique to Italy. This important innovation gradually turned Trafilerie San Paolo’s customers from
1
turners (with 60% waste and non-constant quality levels) to moulders.
Figure 1: Orbita, established in 1962, is specialized in the manufacturing of overhead conveyor chains.
In addition to the parent company Trafilerie San Paolo, the
of conveyor systems and our chains
got the upper hand. It now produces
Group includes two other drawing
are basically the ‘core’ of the whole
tens of thousands of meters of chain per
mills, Gerosa and Meal, each with a
mechanism,” say Andrea and Massimo
year.”
different specialisation; Raptor, for the
Roda. “By observing these plants, my
Today, the company’s activity is carried
development of application software;
father realised that the chains used
out in a modern plant of about 2,000
Tramev; EME, with its tools intended
were extremely heavy, thus adding a
square meters. Its highly qualified staff
for the main drawing machines; and
further burden to those structures.
uses sophisticated automatic machines,
Orbita. The latter is located in Cesana
Thanks to his experience with the
as well as assembly robots able to
Brianza (Lecco, Italy) and it is the pride
highest quality steels, he invented a
complete the production process of an
of the Roda family (Fig. 1).
much lighter chain combined with
entire component autonomously and
“The company was established in 1962
a new full-complement bearing also
in absolute safety. Technical skills and
to manufacture overhead conveyor
invented by him, which featured no ring
innovation are still the forte and the
chains: this is a small niche in which
nuts to withstand high temperatures.
distinctive feature of the entire Group.
we are the European leader with
It was not easy to fight against the
our products of excellence. We work
‘battleships’ of the great British and US
For further information:
for the world’s major manufacturers
manufacturers, but in the end Orbita
www.orbita.it
international PAINT&COATING magazine - MARCH/APRIL 2018 - N. 50
87
La ďŹ era leader mondiale per le tecnologie di verniciatura industriale World‘s Leading Trade Fair for Industrial Coating Technology 17 - 20 April 2018 Exhibition Centre Karlsruhe, Germany
www.paintexpo.com In collaborazione con: In cooperation with:
Agenzia per Italia, Spagna e Portogallo: Agency for Italy, Spain and Portugal: EOS Mktg&Communication Srl Tel +39 0362 503215 info@eosmarketing.it
INNOVATIONS IN SURFACE TREATMENTS FOR METAL WORKING
90
FOCUS ON TECHNOLOGY Arneg Italia’s New Coating Line: an Industry 4.0-Oriented Management System in Compliance with the Most Advanced Environmental Protection Requirements
102
FOCUS ON TECHNOLOGY When the Proper Design of a Two-Rail Conveyor Improves the Versatility and Productivity of a Coating Company: The Success Story of Franchini Snc
110
INNOVATIONS: PRESENT&FUTURE Ready for “Industry 4.0” and The Smart Factory with Nordson Dense Phase Technology
116
FOCUS ON TECHNOLOGY CNH Industrial: A new Smart Factory in Pune, India. Industry 4.0-Oriented, High Technology Innovation in Coating
126
SUCCESS STORIES Looking Inside the Microcosm of Car Painting - With The Viledon® filterCair Module “Basic + Dirt In Paint”, Freudenberg Brings the Cause of the Tiniest Paint Defects Into the Light of Day
130
FOCUS ON TECHNOLOGY Shot Blasting 4.0 for a Flexible and Highly Efficient Pre-Treatment Process Prior to Coating
138 140
BRAND NEW FOCUS ON TECHNOLOGY Collaboration Between Specialists for the Versatile, Integrated, and 4.0-Oriented Coating of Light Carpentry Components: Tecnolaser’s Success Story FOCUS ON TECHNOLOGY Metalcolor: a New Coating Plant with a Low Environmental Impact for Greater Production Versatility
Wisky © Fotolia
148
© Arneg Italia
Opening photo: Arneg Group produces refrigerated cabinets, refrigeration systems, furniture & heavy duty, check-out counters, cold rooms and doors.
FOCUS ON TECHNOLOGY
INNOVATIONS IN SURFACE TREATMENTS FOR METAL WORKING
Arneg Italia’s New Coating Line: an Industry 4.0-Oriented Management System in Compliance with the Most Advanced Environmental Protection Requirements Monica Fumagalli ipcm®
A
rneg is a world leader in the design, production and
“We produce refrigerated furniture and refrigeration systems that
installation of complete equipment for the retail sector.
are our core business, but also shelves for display cabinets in the
Established half a century ago in Marsango (Padua, Italy) by
food and non-food sectors, sales counters, cold rooms, and doors
Luigi Finco and Roberto Marzaro, it is now an international Group
(ref. Opening photo).”
consisting of 36 companies throughout the world. “The Arneg
This is a constantly growing sector, now faced with one of the
Group’s products are all intended for the small and large retail
most critical current issues: the environmental impact not only of
industry, mainly but not only in the food sector,” says Federico
its companies’ production activities, but also of the refrigeration
Pandolfo, the Industrial Engineering Manager of Arneg (Fig. 1).
systems installed at supermarket chains and other commercial
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N. 50 - MARCH/APRIL 2018 - international PAINT&COATING magazine
FOCUS ON TECHNOLOGY
for both specialised
businesses. “We have always stood out for our policy
Arneg’s goal is to enhance and continuously improve production processes: the recent project of the new paintshop, whose installation was the result of the synergy between different suppliers, was born in the framework of this development plan. The powder coating plant was built by Imel, the overhead conveyor by Futura Convogliatori Aerei, the three coating booths by Gema, and the water treatment plant by KMU Loft”
sensitive to the major issues of environmental protection, energy saving, and respect for people,” states Pandolfo. “This is reflected in our effort to provide our customers not only with equipment, but also with assistance in terms
and non-specialised stores to conventional and customised sales counters. “At the international level, we have 20 production plants and 16 representative companies. This gives us a global vision of
their stores, in an integrated
our customers’ needs,
production system
enabling us to meet
developed to ensure that all
© ipcm ®
of energy management of
all their requirements
manufacturing processes
through a daily exchange
and supply relationships
of ideas that is crucial
with third parties comply
to develop innovative solutions for the market.
with the current regulations on quality, safety, energy
The high collaboration
saving, and eco-friendliness.
and coordination
Our goal is to enhance
capacity of our different
and continuously improve
production sites also
production processes: the
confirms the validity of
recent project of our new
our Group’s management
paintshop, whose installation
system.”
was the result of the synergy
Arneg’s procurement logistics
between different suppliers, was born in the framework of this development plan. The powder coating plant was built by Imel (Codroipo,
1
Figure 1: From left to right Katia Cattelan, Federico Pandolfo with Luca Zaramella.
Udine, Italy), the overhead
Arneg Italia produces raw and coated sheets that are used
conveyor by Futura
The Group is present in Italy with four
Convogliatori Aerei (Robecco Pavese, Pavia,
subsidiaries, each specialising in the
of its refrigeration systems’ bodies. It
Italy), the three coating booths by Gema,
manufacture of specific products:
buys already machined but uncoated
and the water treatment plant by KMU Loft.
- Arneg, the leading company, designs,
sheets from both its subsidiaries and
for the construction
Arneg acted as the prime contractor and
manufactures, and installs complete and
other suppliers. In this second case,
coordinated the whole project.”
advanced equipment for the retail sector;
for the finishing of their semi-finished
An international Group with an Italian heart One of the Group’s strengths is its ability to offer complete equipment solutions to furnish every department of a supermarket. “Our company structure translates into
- Oscartielle is among the main European
products, such suppliers can use the
producers of refrigerated counters with
coating plant installed by Arneg, which
built-in units and custom plug-in counters;
in this way also provides a contracting
- Incold specialises in the production of
coating service. Different procurement
commercial and industrial cold rooms and
and treatment methods are used in
of a complete range of doors;
Arneg’s plant: some raw sheets are
- Intrac operates in the furnishing sector
both machined and coated in-house,
flexibility and customisation capacity
for the small, medium and large retail
whereas sometimes semi-finished
levels that have no equal on the market,”
industries with a wide and diversified
products are bought and then coated in
states Katia Cattelan, the Marketing &
range of products, from commercial
the company’s paintshop.
Communication Specialist of Arneg.
shelving for any product category and
The production activity mainly focusses on
international PAINT&COATING magazine - MARCH/APRIL 2018 - N. 50
91
© ipcm ®
INNOVATIONS IN SURFACE TREATMENTS FOR METAL WORKING
2 1
Figure 2: The manual loading area devoted to sheet metal.
Arneg Italia produces raw and coated sheets that are used for the construction of its refrigeration systems’ bodies. It buys already machined but uncoated sheets from both its subsidiaries and other suppliers. In this second case, for the finishing of their semi-finished products, such suppliers can use the coating plant installed by Arneg, which in this way also provides a contracting coating service.” the refrigerated counters’ insulated bodies, made of sheets and high-density polyurethane supporting structures. A base, lower supports, refrigerating elements, lighting and the electrical system are then added during assembly to create
© ipcm ®
complete refrigeration systems, which are finally packaged and
3 1
Figure 3: A detail of a load bar that can carry up to 300 kg.
FOCUS ON TECHNOLOGY
stored. “Our corporate strategy fully embodies the just-in-time philosophy,” says Pandolfo. “We build our equipment on order: we start the raw or semi-finished material procurement process and any required machining operation only after receiving an order. Since we do not produce any standard product, but only tailor-made systems, there are no stocks in our warehouse and our material delivery flow is lean and flexible.”
Quality finishes for high aesthetics and functionality levels “The materials used for the construction of Arneg’s systems,” says Pandolfo, “range from aluminium to iron and from galvanised and black sheet to plastics. The coating results on the refrigerator bodies’ external elements must ensure a high aesthetic quality level and they must be repeatable for all the substrates treated because, as well as defining the quality of our products, they must consistently reproduce the colours of each
© ipcm ®
supermarket brand. As for the internal components, we apply
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Figure 4: A detail of the conveyor supplied by Futura Convogliatori Aerei.
a protective coating against corrosion and rust – which are caused by wear and the chemical products used by stores for their cleaning operations – that must also achieve the hygiene level needed for direct contact with food.” In the Marsango plant, every component is sent to the paintshop regardless of its origin (the firm’s machining department or a supplier’s plant). “We have diversified both our machining operations and our suppliers,” says Katia Cattelan. “If an unexpected event occurs in the supply chain, we can rely on another partner or directly produce in-house the parts required. The production flow continuity is thus ensured.”
© ipcm ®
INNOVATIONS IN SURFACE TREATMENTS FOR METAL WORKING
design team and to integrate their equipment with the others’.” The line concept was based on the innovative technologies of the Industry 4.0, aimed at effective human-machine interaction, optimal integration of all internal and external management systems (especially in the framework of supplier relationships), and energy waste reduction for a more sustainable environmental impact. The system is entirely PLC-managed and it features 2 manual loading operations (Fig. 2). The 4 m long load bars can carry up to 300 kg (Fig. 3). Once loaded on the conveyor frames (Fig. 4), the parts are taken to the storage buffer of the 60 m
5 1
long 6-stage multi metal cleaning tunnel (Figs. 5 and 6). Drying after
Figure 5: A bird’s eye view of the 60 m long pre-treatment tunnel.
time, with a downtime of
The new coating line developed by Imel
on Imel for this project
came into operation in April 2017, after
because we already knew
about a year of project development
the efficiency of its systems.
coordinated by Arneg’s technical staff and
This previous experience
based on the experience gained with the
played a fundamental role
firm’s previous plant. “Our previous line
in the selection of the plant
was built in 1986: after thirty years, it could
engineering company, as
still ensure a good performance level, but
well as their ability to interact
it included obsolete machines. Composed
with the other suppliers that
of two plants, it was replaced in a short
formed the new paintshop
only three weeks. We relied
The line concept was based on the innovative technologies of the Industry 4.0, aimed at effective human-machine interaction, optimal integration of all internal and external management systems (especially in the framework of supplier relationships), and energy waste reduction for a more sustainable environmental impact. The system is entirely PLC-managed and it features 2 manual loading operations. The 4 m long load bars can carry up to 300 kg. Once loaded on the conveyor frames, the parts are taken to the storage buffer of the 60 m long 6-stage multi metal cleaning tunnel.”
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© ipcm ®
A new coating plant for high production flexibility
pre-treatment occurs in a bell oven with
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Figure 6: Components entering the cleaning tunnel.
© ipcm ®
INNOVATIONS IN SURFACE TREATMENTS FOR METAL WORKING
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we perform is non-aggressive, but, on
an outgoing gas heat recovery
the other hand, it represents a guarantee
station, which heats the renewal
of greater surface protection against
air of the oven itself. A second
corrosion (Fig. 7).”
buffer accommodates the
The components are sorted from the
workpieces after drying, which
post-drying buffer to three different
concludes the first treatment
storage buffers connected to the three
phase. This buffer allows to
coating booths (two automatic and
empty the cleaning tunnel at
a manual one where powder is not
the end of the day, in order
recovered) operating simultaneously
to ensure that all material
(Figs. 8 and 9). The correct destination
is perfectly dry, avoid the
of each batch to be painted is set at the
formation of rust, and improve
beginning of processing through the
the application and functional
software program, depending on the
quality level of the subsequent
number of parts loaded onto the bars
coating phase.
and their shape. The manual spray booth
“The materials we treat do not
(Fig. 10) is most suitable for small-sized
present any heavily polluted
batches requiring a specific colour, for
surfaces: galvanised sheets,
parts with particular undercuts or cavities,
accounting for 99% of the
and in the case of a colour change
material used both for the
requested by the client at the last minute.
external and internal parts of
“The system was designed to ensure
our refrigerated counters, do not
maximum loading flexibility, without
have any oil residues or welds.
constraints deriving from the need to
Therefore, the cleaning process
pool workpieces requiring the same tint
© ipcm ®
Figure 7: The inside of the cleaning tunnel.
an air vein burner connected to
Figure 8: Parts taken to the application area.
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FOCUS ON TECHNOLOGY
© ipcm ®
Figure 9: The coating application area.
© ipcm ®
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but belonging to different batches. Again, this choice was aimed at creating a high-level just-in-time production. Since we produce on order, we can happen to load a part to be coated with red, followed by a part requiring the yellow colour and by a second one requiring red. In this case, for example, it is more convenient to send the load bar to be treated with yellow to the manual booth, in order not to decrease the line productivity by performing a colour change on an automatic booth. In any moment of the day, however, one of the booths is always non-operative.” “Thanks to the power&free conveyor layout designed by Futura, we can easily manage the line speeds of the different surface treatment stages (from the 5 m/min of the pre-treatment tunnel to the 3 m/min of the application booths). This ensures a constant average speed of 4.5 m/min. The buffers compensate for both the colour change times and the different loading speeds of parts, with highly variable shapes and dimensions,” states Pandolfo. After coating, a “traffic light” system brings together the workpieces coming from all booths and sends them to the polymerisation oven.
The system was designed to ensure maximum loading flexibility, without constraints deriving from the need to pool workpieces requiring the same tint but belonging to different batches. This choice was aimed at creating a high-level just-in-time production.”
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Figure 10: The coating application carried out in the manual booth.
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© ipcm ®
INNOVATIONS IN SURFACE TREATMENTS FOR METAL WORKING
Application consistency and quick colour change operations thanks to the dense phase technology
Arneg performs 40 to 60 colour change operations per day: having 3 booths alternating during the two work shifts so that the application operations are never interrupted was decisive for the production flow. Moreover, the powder transport and spraying technology with dense phase pumps instead of conventional Venturi injectors guarantees the quality consistency typical of Arneg’s products.”
The line flexibility characteristics requested by Arneg to Imel were further reflected in the powder application system chosen, which implements the Optispray dense phase technology developed by Gema. “We perform 40 to 60 colour change operations per day: having 3 booths alternating during the two work shifts so that the application operations are never interrupted was decisive for our production flow (Fig. 11). Moreover, the powder transport and spraying technology with dense phase pumps (Fig. 12) instead of conventional Venturi injectors guarantees the quality consistency typical of Arneg’s products. The supermarket brand colours must be identical even if applied on different elements and regardless of their material. We must ensure that the coating results can be reproduced over time,” says Federico Pandolfo.
11 1
Figure 11: The coating application carried out in an automatic booth
After application, the conveyor sends the parts coated by the three booths to the
© ipcm ®
polymerisation oven – also a bell oven but with no air vein in order not to pollute the drying air with the burner’s exhaust gases. Curing occurs at a controlled and constant temperature. Although load bars with parts coated in different tints enter the oven one after the other, there is no risk of colour contamination during drying thanks to the zone controlled ventilation system. The first zone was designed for powder gelling: it is not ventilated and has a temperature of 120150 °C. It is followed by a segment with hot air at 180 °C. The workpieces then reach the cooling buffer (Fig. 13) and finally
12 1
the two unloading areas (Fig. 14)
Figure 12: A detail of the dense phase application pumps supplied by Gema Europe.
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where the coating cycle ends.
© ipcm ®
FOCUS ON TECHNOLOGY
GANCI | HOOKS
TELAI | RACKS
13 1
Figure 13: A detail of the conveyor taking the coated workpieces to the unloading station.
From production to installation: Arneg’s green soul
Federico Pandolfo. “Special attention was paid
During the design phase of the new paintshop,
air vein drying oven, operating at 120-130 kWt
the team coordinated by Arneg never lost
and recovering heat through inverter motors,
sight of one of the main requirements of the
and to the thermal energy consumed by the
company: the commitment to reducing energy
polymerisation oven, which operates at
consumption that has always characterised it.
220-250 kWt and which does not implement
“The new plant was designed to optimise
the air vein technology not to pollute the paint
electricity and heat consumption,” states
film, although it still allows to recover the
to the ventilation of the post-pre-treatment
The new plant was designed to optimise electricity and heat consumption. Special attention was paid to the ventilation of the post-pre-treatment air vein drying oven, operating at 120-130 kWt and recovering heat through inverter motors, and to the thermal energy consumed by the polymerisation oven, which operates at 220-250 kWt and which does not implement the air vein technology not to pollute the paint film, although it still allows to recover the renewal air thanks to its bell structure.”
MASCHERATURE | MASKING
Visit us! 17. - 20.04.2018 Hall 2, Booth 2320
www.emptmeyer.it
© ipcm ®
INNOVATIONS IN SURFACE TREATMENTS FOR METAL WORKING
renewal air thanks to
consultant for
its bell structure.
the energy
“Moreover, the pre-
consumption
treatment tunnel
management of
is equipped with
our customers’
inverter-managed
commercial
cleaning pumps
activities.”
that switch off automatically if there
Conclusions
is no part on the line.
“We are really
This system also
pleased with
enables the operators
the team that
to adjust the cleaning
was created
product spraying
during the
capacity depending
design phase
on the workpieces’
of our new
dimensions. On
plant, which
average, the cleaning
maximum installed
a year,” states Pandolfo. “It
Figure 14: The collection buffer of the unloading area.
power of 70 kW. The whole cleaning department is
has not always been easy
© ipcm ®
kW compared with its
lasted about
14 1
tunnel consumes 20
to coordinate all our suppliers’
powered by a biomass boiler also
activities, but in the end, thanks to
connected to other plant areas,
their know-how, it was possible to
which leads to a significant saving
resolve every critical issue – such
in gas consumption.” Waste
as, for example, the software
water is treated in two tanks
setting based on the security
equipped with an evaporator
requirements of applicable laws.
supplied by KMU Loft, which
Of course, each supplier could
separates the eluate from water
guarantee that all the safety
and recirculates the latter. This
parameters of its equipment were
closed-loop system with zero
met, but, thanks to the technical
liquid discharge minimises mains
skills and professionalism of
water consumption.
their staffs, we have managed to
“These results are extremely
create a digital system capable
good and have even exceeded
of signalling any anomalies or
the expectations of our suppliers.
dangers on the entire line. IT
Our attention to our production
systems have proved crucial also
activities’ environmental impact
in terms of safety and health,
is not limited to our in-house
management of production
processes, but it is also reflected
processes and suppliers, and
on the performance of our
efficiency of all energy saving
refrigeration systems. Thanks to
resources: each of these elements
the studies conducted by our
is essential, in order to be a true
R&D centre, we reduced the
“Smart Factory”.
consumption of a refrigerated counter by 50% and we can act as a reliable partner and
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Figure 15: The water treatment plant installed by KMU Loft.
N. 50 - MARCH/APRIL 2018 - international PAINT&COATING magazine
Our new coating department is the most obvious and significant example of this.”
OptiStarÂŽ 4.0 Gun Control The benchmark for the efficient gun control OptiStar 4.0 gun control ensures an optimized application with an exceptional coating result. The new generation of OptiStar presents the proven DVC- and PCCTechnologies and the new Electrostatic App, delivering an intelligent control to provide a seamless link to Smart Factory Automation. With the new Electrostatic App, essential application data and parameters can be retrieved at any time, with crucial coating information and statistics available via your mobile device. This opens up new possibilities for process control.
www.gemapowdercoating.com
GEMA EUROPE SRL Via Carlo Goldoni 29 | 20090 Trezzano Sul Naviglio (MI) | ITALY T. +39 02 48 400 486 | F. +39 02 48 400 874
© Franchini Snc
Opening photo: Franchini has been working in the sector of surface treatments for light and heavy carpentry structures for over thirty years.
FOCUS ON TECHNOLOGY
INNOVATIONS IN SURFACE TREATMENTS FOR METAL WORKING
When the Proper Design of a Two-Rail Conveyor Improves the Versatility and Productivity of a Coating Company: The Success Story of Franchini Snc Francesco Stucchi ipcm®
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FOCUS ON TECHNOLOGY
I
n 1970, a small individual company
for the building sector. However, since
carpentry components (Fig. 2),”
specialising in car bodyworks was
this activity provided little chance of
states Federico Franchini. “It is a very
established in Villimpenta (Mantua, Italy)
development in the winter months, in
demanding industry, in which we have
by Giuliano Guerrino Franchini. Franchini
2002 we expanded our business with
to face the most diverse requirements
Snc is now a well-known company in the
new headquarters of about 10,000 m2, of
because the products will be installed
sector of contracting sandblasting and
which 3,000 are covered, and we started
all over the world. For example, our
coating of small, medium and large-sized
focusing on the contracting sandblasting
corrosion protection processes
metal carpentry components. During these
and coating of light and heavy carpentry
must meet very strict specifications
almost fifty years, the firm has grown in
structures (ref. Opening photo).” In
complying almost exclusively with ISO
terms of both business and size: currently,
2007, a decisive increase in orders led
12944 C4 and C5 classes.”
it has an about 21,000 m production site,
the Franchini family to plan a further
“Over the years, however, we have
24 employees, and customers from the
expansion of their headquarters. In 2009,
understood that the key to our
most diverse industrial sectors (Fig. 1).
they inaugurated a new facility in an area
success is diversifying our services
“In the 1990’s, with the entry into the
of 11,000 m2, of which about 6,000 are
as much as possible, in order to
company of me and my brother Cristian
covered, devoted to the treatment of small
meet any kind of need. We have to
and due to the increasing requests from
and medium parts.
be able to treat both small and big
2
parts even for the same customers,
the building industry, our bodywork activity “We serve various sectors (furniture, exhibit
without limiting ourselves but rather
abandoned,” says Federico Franchini,
spaces, pneumatic cylinders, mechanical
offering a complete service,” says
one of the founder’s sons. “The current
carpentry), but our core business are
Cristian Franchini. “While gradually
company was established as a coater
amusement rides, with their large-sized
abandoning the building sector,
© Franchini Snc
was gradually diminished and finally
1
Figure 1: The Franchini headquarters in Villimpenta (MN) are located on an area of 21,000 m2.
international PAINT&COATING magazine - MARCH/APRIL 2018 - N. 50
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© Franchini Snc
INNOVATIONS IN SURFACE TREATMENTS FOR METAL WORKING
we have therefore focussed on our production site expansion and on the plant development of our treatment line for small and medium carpentry parts through the implementation of a completely versatile system.”
Treatment lines Franchini’s activity is divided into two large categories: heavy carpentry, with workpieces up to 18 metres, and light carpentry, with parts up to 3.5 metres in length and weighing up to 400 kg. “In order to treat large-sized components,” says Cristian Franchini, “we have a dedicated line consisting of a 18x5x5 m manual free jet sandblasting tunnel using garnet and three static coating plants, of which two with a size of 20x10 m (Fig. 3) and a modular one. The parts are handled through overhead cranes with a maximum capacity of 10 tonnes.” Garnet is a natural mineral abrasive, therefore free from any harmful substances, which ensures maximum film adhesion on aluminium, steel, stainless steel, and special steels. These large workpieces are never subjected to any chemical pre-treatment. The subsequent coating phase is performed with a continuous monitoring of environmental conditions and always indoor, so as to ensure continuity of the production flow regardless of the weather conditions. All three static coating booths are heated and ventilated; one of them,
2 1
buffered and closed, can also act as
Figure 2: A liquid coated heavy carpentry workpiece.
an oven booth for the drying of parts, which otherwise are air-dried. “Coating is performed exclusively with liquid products,” explains Federico Franchini. “50% with a
In 1970, a small individual company specialising in car bodyworks was established in Villimpenta (Mantua, Italy) by Giuliano Guerrino Franchini. Franchini Snc is now a well-known company in the sector of contracting sandblasting and coating of small, medium and large-sized metal carpentry components. During these almost fifty years, the firm has grown in terms of both business and size: currently, it has an about 21,000 m2 production site, 24 employees, and customers from the most diverse industrial sectors.”
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one-coat cycle and 50% with the application of a surface tolerant primer and a twocomponent epoxy, polyurethane, or acrylic topcoat.” The second treatment line is devoted to the finishing of light carpentry workpieces, with maximum dimensions of 3,5x1x2 m. It is an actual 80-metre long in-line plant equipped with a two-rail overhead conveyor (Fig. 4).
© ipcm ®
FOCUS ON TECHNOLOGY
Franchini’s activity is divided into two large categories: heavy carpentry, with workpieces up to 18 metres, and light carpentry, with parts up to 3.5 metres in length and weighing up to 400 kg. In order to treat large-sized components, Franchini has a dedicated line consisting of a 18x5x5 m manual free jet sandblasting tunnel using garnet and three static coating plants, of which two with a size of 20x10 m and a modular one.”
3 1
Figure 3: One of the three static coating systems for large-sized parts.
PAINT SHOP 4.0 DIGITAL ∙ SMART ∙ EFFICIENT
www.eisenmann.com
Visit us at
PaintExp o Apr
il 17 to 2 0, 2018 in Karlsru he hall 1, b ooth 122 0
INNOVATIONS IN SURFACE TREATMENTS FOR METAL WORKING
© ipcm ®
Figure 4: A bird’s eye view of the plant devoted to light carpentry components.
© ipcm ®
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Figure 5: The continuous shotblasting machine: the first phase of the coating process.
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FOCUS ON TECHNOLOGY
The overhead conveyor: the core of the in-line coating plant
of this project lies therefore in the presence
The coating process
and management capacity of several
The first phase is pre-treatment. The line is
storage buffers.” From the technical point
equipped with a continuous shotblasting
“This system was built in 2008, but we
of view, there was a need to manage the
machine (Fig. 5) and a 4-stage cleaning
started using it at full capacity in 2010.
plant used only if the parts are not perfectly
It was the result of a close collaboration
prepared after shotblasting. “The requests for
with Tras-Mec (Casalromano, Mantua),
shotblasting from our customers account for
which designed the two-rail overhead conveyor as the core of the whole plant,” says Cristian Franchini. “We decided to rely on Tras-Mec based on the excellent references we had always received about them. This plant was entirely designed by our father Giuliano, Tras-Mec owner Silvio Zanelli, passed away in 2014, and TrasMec’s engineers; we now consider it the
This system was built in 2008, but they started using it at full capacity in 2010. It was the result of a close collaboration with Tras-Mec (Casalromano, Mantua), which designed the two-rail overhead conveyor as the core of the whole plant.”
99% of the total; chemical pre-treatment is a plus that we can provide if necessary in order to be fully versatile,” says Cristian Franchini. “A SA 3 preparation degree is generally required.” At the exit of the shotblasting system, there is a first buffer where the workpieces accumulate before the following stations: - 5 stations for accessory work (grouting, sealing, protection, masking);
flagship line of our company.”
- basecoat and liquid primer application booth;
“The conveyor plays a crucial role in this plant because the large and heavy
parts accumulating at the entrance of the
- flash-off booth;
iron parts it treats cannot be unloaded
shotblasting machine and at the exit of the
- topcoat application booth;
after each phase,” explains Claudia
ovens, since the cooling time of large-sized
- flash-off booth;
Zanelli from Tras-Mec. “The peculiarity
workpieces is considerable.
- drying and flash-off ovens (Fig. 6).
© ipcm ®
INNOVATIONS IN SURFACE TREATMENTS FOR METAL WORKING
The last storage buffer
The conveyor is also equipped with a
is devoted to finished
motor-powered bar rotating system with a
parts, which are then
manual control panel, in order to place the
sent to one of the two
workpieces in the most suitable position to
warehouses and finally
optimally coat them on every side.” Finally,
unloaded.
the plant features an efficient software package providing for PLC control as well as
“The overhead system we have designed for 45 mm double speed
Complete versatility: the key to success
biplanar chain conveyor
“We work on order and with a long-term
with a total length of 515
order portfolio. The versatility of our
metres, of which 189 are
systems enables us to meet the most
devoted to shotblasting
diverse needs, always ensuring workflow
and 326 to coating,” says
efficiency and continuity,” states Federico
Claudia Zanelli. “The load
Franchini. “We look to the future with
bars have a maximum
even more ambition. Just consider
capacity of 400 kg, for a
that, when we designed this plant in
total allowable load of
2009, despite the economic crisis we
27,000 kg (Fig. 7).
had already planned extra spaces to
The loading and
implement robotic coating systems in
unloading operations are
future.” Indeed, Franchini’s vision has
performed on a straight
resulted in excellent achievements, which
stretch in which the
over the last four years have translated
bars are stopped with
into a successful turnover and high
special locking stations.
customer loyalty.
Franchini is a two-rail,
6 1
© ipcm ®
Figure 6: The storage buffer near the flash-off booth.
remote assistance.
The loading and unloading operations are performed on a straight stretch in which the bars are stopped with special locking stations. The conveyor is also equipped with a motor-powered bar rotating system with a manual control panel, in order to place the workpieces in the most suitable position to optimally coat them on every side. Finally, the plant features an efficient software package providing for PLC control as well as remote assistance.”
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Figure 7: The 515 metre long two-rail overhead conveyor designed by Tras-mec.
N. 50 - MARCH/APRIL 2018 - international PAINT&COATING magazine
WASHING
COATING
IMPREGNATION
Passion is our engine. For over 60 years, we have come a long way. Our mission has always been reaching new horizons in industrial washing, coating and impregnation. It was a call of innovation that has led us to an outstanding achievement: to become the appreciated partner of the most important companies in the automotive market. For us, it is the recognition of our ability to offer solutions and to respond in the shortest time to constantly accelerating customers’demands. For our clients, making choice of our plants has guaranteed reaching their best performance over all type of surfaces, for all their products. All around the world.
TECNOFIRMA S.p.A. - Viale Elvezia, 35 - 20900 Monza (MB) Italy - Phone +39 039 236 01 - Fax +39 039 324 283 - www.tecnofirma.com - tecnofirma@tecnofirma.com - Company Certified ISO 9001 since 1992
© Nordson
Opening photo: Advanced nozzle technology enables Encore HD guns to achieve first transfer efficiency and consistent film build.
INNOVATIONS: PRESENT&FUTURE
Ready for “Industry 4.0” and The Smart Factory with Nordson Dense Phase Technology Corinna Hellwig Nordson Industrial Coatings Systems
ics.eu@nordson.com
“I
ndustry 4.0” develops solutions that use proven mass
coating operations. With its HDLV pumps, Nordson’s highly efficient
production methods to manufacture customized products
dense phase technology is available from manual application to fully
– in extreme cases with a batch size of 1. In that context,
automated, robot-controlled coating systems: a perfect example of
personal color selection is playing an increasingly important role
pioneering coating technology that combines maximum productivity
in many markets – and also posing new challenges for powder
and flexibility with optimum profitability.
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N. 50 - MARCH/APRIL 2018 - international PAINT&COATING magazine
INNOVATIONS: PRESENT&FUTURE
In the 1910s, when a journalist timidly
“Industry 4.0” is characterized by sensory-perceptive and intelligent machines (“artificial intelligence”) arranged together and with others in a continuous exchange of data (“Internet of Things”). Their objective is to achieve “individually customized mass production” (“mass customization”), i.e. to apply the beneficial effects of mass production (economies of scale, learning curve advantages) toward the manufacture of extremely individual products.”
asked why the Model T only came in one color, Henry Ford replied with the now famous phrase: “Every customer can have his car painted any color they want
Customization in its ultimate form: Batch size = 1 The more product individuality a manufacturer accords its customers, the greater the resulting
as long as it’s black.”
complexity costs.
The journalist purportedly let it go at that,
configurations), and there is a Maserati
And those costs were precisely what Henry
and for the millions of people who bought
Quattroporte with over 4 million variants
Ford so successfully fought against.
the first large-scale production automobile
– to say nothing of the variation that can
That’s the way things were – till now.
manufactured in mass quantities, the
be achieved through combinations. “All
The smart factory or “Industry 4.0” – the great
importance accorded individual color
together, the number of different ways we
transformation that has already taken hold
comparison with the high practical benefit
of production and
© Nordson
selection also paled in
work processes and is attracting the
provided at a low
attention of about
price: When the last
half of all German
“Tin Lizzie” rolled off
companies – has
the production line in
become a top priority,
1926, black remained
above all in the
the only color option.
manufacturing sector.
Since the days of
It aims to maximize
“Industry 2.0” – just
production flexibility
like after what
by seamlessly
eventually came to be
networking people,
known as the age of
machines, systems
mass production that
and services. “Industry
Henry Ford helped
4.0” is characterized
launch – the demands
by sensory-perceptive
of customers have
and intelligent
changed dramatically. Today it goes without saying that they configure even the most complex
machines (“artificial 1
intelligence”)
Figure 1: Powder coating application with PowderPilot HD advanced control system and integrated network interface for production data acquisition, system status monitoring and remote diagnosis.
technical devices to
arranged together and with others in a continuous exchange of data (“Internet
match their strictly
of Things”). Their
personal preferences. Cars are still a good
can combine components is 10 raised to
objective is to achieve “individually customized
example: At the height of the current wave of
the 20th power,” according to the Head of
mass production” (“mass customization”), i.e. to
automation driven by platforms and modules
Complexity Management at Audi, Klaus
apply the beneficial effects of mass production
(Industry 3.0), the VW Group offers 156
Alders, who was quoted at the time.
(economies of scale, learning curve advantages)
different steering wheels, an Opel Astra can
And the Variant Manager at BMW, Franz
toward the manufacture of extremely individual
be ordered in 360 different combinations
Decker, even estimates the number of
products. Ideally, even the customer is
of engines and optional equipment (while
options available to him as “10 raised to
integrated into this network, selecting their
a 3-Series BMW is available in 453 different
the 32nd power.”
configuration online to control the machinery
international PAINT&COATING magazine - MARCH/APRIL 2018 - N. 50
111
© Nordson
2 1
Figure 2: Nordson HDLV pumps are virtually maintenance-free, which means they also enhance quality, flexibility and production benefits over the long term.
that then produces their desired product right before their eyes. This enables the manufacturer to produce a previously unimaginable range of products without having to maintain uneconomically large component inventories. And ultimately, why not “Batch size 1” – i.e. a product produced only once for a single customer?
More economical coating as a step toward mass customization With many articles of everyday life, a personally selected color expresses the individual taste of the owner. In the case of supplied parts and technical
112
components, painting is indicative
Since demands for the customizability of products are rising right along with more intense competition and cost pressures, the costeffectiveness and flexibility of coating systems are playing an increasingly decisive role. The solution lies in the streamlining of processes (“lean manufacturing”) and the minimization of downtimes, while effective material usage also helps reduce production costs and raise profit margins.”
N. 50 - MARCH/APRIL 2018 - international PAINT&COATING magazine
of origin (manufacturer’s color) and underscores the intended quality appeal (ref. Opening photo). Since demands for the customizability of products are rising right along with more intense competition and cost pressures, the cost-effectiveness and flexibility of coating systems are playing an increasingly decisive role. The solution lies in the streamlining of processes (“lean manufacturing”) and the minimization of downtimes, while effective material usage also helps reduce production costs and raise profit margins.
INNOVATIONS: PRESENT&FUTURE
This also places high demands on an equipment system, because the investment in a state-of-the-art powder coating system is amortized by - fast coating processes and high output - uniformly high coating quality and film thickness without rework - a high degree of automation requiring minimal intervention by operating personnel - economical operation that consumes a minimum of resources - careful application of materials - the ability to change colors rapidly – even more than once during a shift - fast and thorough cleaning of the equipment - easy maintenance, and - extremely durable components. In order to take full advantage of flexibility and economic potentials, it is important not only to optimize individual components, but also to fully integrate and harmonize entire powder coating systems. That means powder materials, lines, pumps, guns, extraction technology and booths (Fig. 1).
Nordson dense phase technology: Integrated, efficient, flexible The key to Nordson’s high-efficiency powder coating is dense phase technology with its characteristic HDLV (High Density Low Velocity) pumps (Fig. 2), which has dramatically improved both processes and results. Enabling powder material savings of up to 45%, this technology operates at much lower air pressure, gives users accurate control over the quantity of powder coating supplied and allows them to work with even greater precision. Instead of a conventional Venturi pump, it uses a
The key to Nordson’s high-efficiency powder coating is dense phase technology with its characteristic HDLV (High Density Low Velocity) pumps, which has dramatically improved both processes and results. Enabling powder material savings of up to 45%, this technology operates at much lower air pressure, gives users accurate control over the quantity of powder coating supplied and allows them to work with even greater precision.”
air-operated pinch valves open
© Nordson
two-chamber pump in which four
so no mechanical adjustments are required.
and close in pairs. As soon as an
The technology is ideally suited
inlet value opens, the discharge
for fully automated production
valve closes, powder is drawn in
and helps achieve even the most
and stored. In the next work cycle,
ambitious lean manufacturing
the powder is forced out of the
objectives.
first chamber while the second
ensuring high application efficiency
Intelligent control, essentially independent of operator qualifications
with low powder consumption –
Equipped with many sensors, a
and maintains that performance
modern powder coating application
for extended periods under an
system determines all relevant
extremely wide range of settings,
control parameters for material
even when processing thin film
supply, application and booth, and
powders.
continuously provides production
Nordson’s HDLV pumps are virtually
and system status data to a central
maintenance-free, which means
control system. Integrated network
they also boost quality, flexibility and
interfaces make it possible to
production benefits over the long
monitor the powder application and
term. The only components subject
greatly facilitate remote diagnosis.
to wear are the pinch valves, which
An industrial touchscreen enables
are designed for a service life up
control of all coating process
to 4,000 hours. They regularly last
parameter, such as supply and
well beyond that figure, however,
atomizer air settings, electrostatics,
thereby minimizing expensive
and gun stroke and triggering, as
maintenance and downtime.
well as color change sequences.
chamber is being filled. This results in constant, linear powder delivery,
When used in combination with powder guns (Fig. 3), HDLV pumps offer even greater benefits. These include reduced color
Preset and widely adaptable
3 1
the specially developed Nordson
programs make it easy to optimize
Figure 3: The soft spray at low velocity improves transfer efficiency in the initial coating operation.
contamination, more uniform
also especially fast and the selfcleaning feature keeps them troublefree. Hoses with a diameter of just 6 millimeters supply the guns and produce soft spray pattern. This adheres better, thereby raising application efficiency, facilitating the coating of complex geometries, minimizing the amount of work required, increasing the production rate and reducing powder consumption. The powder application rate is easily regulated by means of the control system,
114
range of products and powder materials. Last but not least, such a highly automated system lowers
coating thickness and better coating of Faraday cages. Color changes are
performance for an extremely wide
the qualifications required of the equipment
Nordson’s HDLV pumps are virtually maintenancefree, which means they also boost quality, flexibility and production benefits over the long term. The only components subject to wear are the pinch valves, which are designed for a service life up to 4,000 hours. They regularly last well beyond that figure, however, thereby minimizing expensive maintenance and downtime.”
N. 50 - MARCH/APRIL 2018 - international PAINT&COATING magazine
operators. Whether manual, automatic or fully robotcontrolled, Nordson’s perfectly harmonized dense phase components provide powder coaters with the right technology to coat even the smallest batch sizes flexibly and economically and to take full advantage of the opportunities that “Industry 4.0” offers. At this year’s PaintExpo, from April 17-20, 2018, (Messe Karlsruhe, Hall 2, Booth 2440) Nordson will show the appropriate coating solutions with a variety of dense phase applications and end user products.
s.r.l.
CHAINS FOR CONVEYORS
Visit Us at
PaintExpo 2018 Hall 1 Booth 1332
Leader in Europe since 1962
M A D E
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© CNH Industrial
Opening photo: CNH Industrial is a global leader in the design, production and selling of agricultural and construction equipment, trucks, commercial vehicles, buses and specialty vehicles, in addition to a broad portfolio of powertrain applications.
FOCUS ON TECHNOLOGY
INNOVATIONS IN SURFACE TREATMENTS FOR METAL WORKING
CNH Industrial: A new Smart Factory in Pune, India. Industry 4.0-Oriented, High Technology Innovation in Coating Alessia Venturi ipcm®
“C
NHi’s objective is to make its machines recognisable on the
Group, to summarise his company’s attitude towards finishing (Fig. 1).
market not just for their brand but also and above all for the
CNH Industrial is a global leader in the capital goods sector, operating on
quality of their finishes,” says Massimiliano Rosoldi, the APAC
international markets with commercial and financial activities of design,
Region ME and Operation Process and Methods manager of the CNH
116
N. 50 - MARCH/APRIL 2018 - international PAINT&COATING magazine
production and distribution. It is present in 180 countries, with nearly
FOCUS ON TECHNOLOGY
63,000 employees in 64 manufacturing facilities
headquarters – and the Italian company Verind
product waste; monitoring of the
and 49 research and development centres.
Spa, belonging to the international DĂźrr Group,
Key Performance Indicators (KPI) of
CNH Industrial designs, builds and markets
for the coating process. Verind was already a
application systems; monitoring of
“work machines� and has 12 brands of vehicles
partner of the CNHi Group for the supply of
the KPI of operators with a numerical
for the agriculture and industry sectors: tractors
painting systems and equipment, including
assessment of the line personnel’s
(ref. Opening photo), combined harvesters,
some special solutions for the direct-to-metal
abilities; and collection of the systems’
lorries, buses, propulsion and transmission
(DTM) technology1.
operating, consuming and performance Š ipcm Ž
systems for trucks and road and off-road commercial vehicles,
data. “We asked our industrial
engines for marine applications,
partners for solutions
and so on.
that could minimise
CNH Industrial is also present
the problems arising
in India with the brands Case
from manual coating,
IH, a leader in the field of
which is necessarily
sugarcane harvesters, and
required in our industry,�
New Holland, with its new
says Massimiliano
harvesters assembled in the
Rosoldi. “Unfortunately,
production and R&D centre
it is always assumed
of Pune. CNHi’s plant in Pune
that colour change
is a complete manufacturing
inefficiencies are normal,
facility performing laser cutting,
that a system can only
subgroup welding, coating and assembly operations on such agricultural machines. In 2017, the plant has been
be either manual or
1
automatic, and that the
Figure 1: Massimiliano Rosoldi (centre) with Alessandro Soba on the left and Ivan De Angelis from Verind on the right.
involved in a highly innovative plant engineering investment.
issues arising from any functional aspects or from the poor capacity of an operator are
unsolvable. Our project has proved
an Industry 4.0-oriented factory has been
Innovative and digital solutions for common issues
created through the implementation of
The aim of the investment in Pune was to
all our needs with the development
advanced digital systems specially developed
find a technologically advanced and possibly
of special solutions that have resulted
to meet CNHi’s ambitious goals. The industrial
digital solution to a few thorny problems of
in the creation of Pune Painting, an
partners chosen for this project were the
the whole coating industry, such as: colour
Industry 4.0-oriented factory.� It is worth
German company DĂźrr Systems AG for the
change management in terms of time and
adding that all CNHi’s requests included
The coating stage has been improved and
plant engineering aspects – the project has been entirely developed by Dßrr India’s
1
that this attitude is wrong and has met
technical proposals and solutions that
Ref. IPCM no. 42 November-December, Vol. VII, year 2016, pages 96-104.
were then developed by the designers.
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international PAINT&COATING magazine - MARCH/APRIL 2018 - N. 50
117
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© Verinid
INNOVATIONS IN SURFACE TREATMENTS FOR METAL WORKING
The future of the industry and a new coating concept
and finishing results, whereas the
“Verind translated
data and any deviations from the
the engineering
pre-set standards are monitored and
and plant ideas
made available on a specific interface
of Massimiliano
of the Line Master to enable corrective
Rosoldi and his
actions.
team into an 2 1
Figure 2: EcoDose 2K is an evolved electronic system for the stoichiometric dosing and mixing of 2K/3K coatings.
management of the 2K coating products and the process digitisation are entrusted to a special integrated automation feature. The production
- Developing an electronic device,
industrial project,”
EcoDose 2K, suitable for handling
states Ivan De
different series of two-component
Angelis, Verind’s
epoxy and polyurethane coatings.
Site Manager. “Pune Painting
- Continuous monitoring of the application parameters and KPIs.
is a paintshop
118
“The coating process is complex due to
to this project, is now semi-automated in
its high number of variables, especially
terms of automation management and
with manual application operations,”
performance. System engineering, know-how
says Alessandro Soba, the APT Industry
and innovation were the winning factors
Sales Manager of Verind. “A joint
that enabled Verind to meet CNHi Group’s
and coordinated work enabled the
challenging industrialisation demands.”
development of innovative and industrially
The main objectives were as follows:
sustainable market-oriented solutions:
- Creating a coating line with several manual
- Eco-friendliness and safety of the work
operators, but managed according to a
environment;
new concept with integrated control and
- Lower production costs;
automation features that make it unique
- High surface quality;
on the market. The booth operators’ team
- Industry 4.0 and digitisation of the
is required to get the best application © Verinid
CNH Industrial is a global leader in the capital goods sector, operating on international markets with commercial and financial activities of design, production and distribution. It is present in 180 countries, with nearly 63,000 employees in 64 manufacturing facilities and 49 research and development centres. CNH Industrial designs, builds and markets “work machines” and has 12 brands of vehicles for the agriculture and industry sectors: tractors, combine harvesters, lorries, buses, propulsion and transmission systems for trucks and road and off-road commercial vehicles, engines for marine applications, and so on.”
designed for manual operations that, thanks
3 1
Figure 3: A partial view of the large coating plant.
N. 50 - MARCH/APRIL 2018 - international PAINT&COATING magazine
coating process.”
Zaniolo CdA - 1.18
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INNOVATIONS IN SURFACE TREATMENTS FOR METAL WORKING
• Advanced management of the pot life
“Innovation enables us to remain technologically competitive. We strive to ensure that all our new products/solutions contribute to lower the costs per unit produced while increasing efficiency,” states Soba. “That is why we built a flexible and modular system combining an electrostatic application device with an automatic 2K coating dosing and mixing system based on the Coriolis technology. EcoDose 2K (Fig. 2) is an advanced electronic system for the stoichiometric dosing and mixing of 2K/3K solvent-based, water-based, and HS coatings, also suitable for DTM processes.” “The main technical benefits of the Coriolis technology are as follows: • Function control with an industrial PLC and an operator panel; • 1:1 to 30:1 stoichiometric catalysis ratio;
The coating stage has been improved and an Industry 4.0-oriented factory has been created through the implementation of advanced digital systems specially developed to meet CNHi’s ambitious goals. The industrial partners chosen for this project were the German company Dürr Systems AG for the plant engineering aspects – the project has been entirely developed by Dürr India’s headquarters – and the Italian company Verind Spa, belonging to the international Dürr Group, for the coating process.”
• Possibility to store over 1024 treatment
parameter; • “Push out” function in the automatic colour change operation to optimise consumption; • Closed loop flow control; • Local and remote function control; • Connection to a Line Master for the automatic colour change management based on the conveyor’s FIFO information; • Advanced management of the consumption measurement for each application station; • Consumption statistics based on models/ colours used in the whole production flow; • Predictive maintenance service on all components.”
Solutions for 100% efficient colour changes and for the control of all KPIs The solutions provided by Verind have had a major impact on the plant’s colour change management and have enabled © Verinid
programs; • Dosing tolerance less than 1%; • Direct Injection
the monitoring of numerous operational parameters. To this day, in conventional
Technology (DIT)
manual coating
dosing with two
booths with two
channels (A and B);
or more stations,
• Separate cleaning
the colour change
circuits for the A and
process has always
B components;
be performed as
• Measurement of
follows: the operator
the coating and
stops the line at the
cleaning product
end of a job requiring
consumption;
the application of
• Modular automatic
a given colour, he
colour change system for paints and catalysts; • Display of the actual flow and partial
carries out the colour change operations, he
4 1
restarts the line and he begins coating
Figure 4: The inside of the pre-treatment tunnel.
the following batch.
consumption rates
In plants devoted to
for each program; • Display of alarms with extensive diagnostics and of VOC levels; • Data transmission to a supervisory
off-road vehicles, this • Measurement of the density and
can happen four or five times a day for each
temperature values for the A and B
manual workstation.
channels and their alarm thresholds;
Massimiliano Rosoldi says: “When talking
system for the analysis and printing of
• High reliability and stability;
about colour change with Verind, we asked
current and/or past events;
• No stress on coatings;
ourselves, why work in this way if it is possible
120
N. 50 - MARCH/APRIL 2018 - international PAINT&COATING magazine
FOCUS ON TECHNOLOGY
to implement an application tracking
before the arrival of a new batch.
in progress and to use the residual paint in
system on our conveyor? We realised that
â&#x20AC;&#x153;The second issue related to colour change
the gun supply circuit (through a separate
this would have enabled us to generate
processes is the product waste that results
circuit) without requiring further product.
only one empty place on the conveyor,
from the emptying, washing and re-loading
Of course, we previously compared the
automatically positioning in front of the
of the dosing device. Since we use two-
workload to the amount of paint remaining
different coating stations.â&#x20AC;? Such empty
component coatings, moreover, these
in the pipes, and we determined that this
space represents only â&#x20AC;&#x153;oneâ&#x20AC;? loss of
operations are required on two circuits,
was more than sufficient to saturate the
productivity due to the colour change
that of the painting product and that of
last component of any job. Just to be sure,
operation, instead of the many losses of a
the catalyst. The product wasted during a
however, we excluded from this feature
conventional system.
colour change operation, however, is still in
the last workstation, so that it can perform
â&#x20AC;&#x153;In Pune, we implemented a â&#x20AC;&#x153;semi-
good conditions and can be safely reused.
any operation that might not have been
automaticâ&#x20AC;? system by connecting our
Thanks to the tracking function integrated
completed by the previous ones.â&#x20AC;?
conveyor with the application system
into the conveyor, we have found a way
â&#x20AC;&#x153;Pune Painting currently uses a
â&#x20AC;&#x201C; which is common when working with
to use the product left in the circuit
management system that we call â&#x20AC;&#x153;pushing
robots, but innovative in a manual process,â&#x20AC;?
before the start of a new coating job to
outâ&#x20AC;?. It allows to spray the residual coating
says Rosoldi. â&#x20AC;&#x153;We managed to do this
paint the last component of the previous
in the circuit to treat the last component
together with Verind. Our system now
one: in our case, it equals to about 2
of a batch, thus reducing the colour
generates only one empty place on the
minutes and a half spraying. CNHi can
change times, since the pipeline is already
conveyor; the operator no longer has to
now efficiently manage the end of tasks:
empty, as well as the paint waste and the
stop the line because he has enough space
the tracking system enables the plant to
environmental impact of the process,â&#x20AC;?
to perform the colour change operation
recognise the last component of the job
states Rosoldi.
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INNOVATIONS IN SURFACE TREATMENTS FOR METAL WORKING
The conveyor’s application tracking
an impressive amount of operating data is
to generate the outputs needed to plan
feature also opens up to countless KPI
available. In addition to standard parameters,
preventive maintenance processes,
monitoring functions. “It makes the
such as running time, total downtime and the
assess the plant’s performance, control
system very flexible and enables us to
data normally generated by simple “clock”
its environmental sustainability, identify
monitor the operators’ performance
counters, values like water, gas and electricity
areas requiring predictive maintenance
EcoDose 2K machines control the amount of paint used on
operations, and handle all
© Verinid
with numeric parameters. The
process variables that are now monitored offline and manually.
all operating stations from the beginning to the end of the
compares the theoretical coating
The main features of the coating plant
consumption (expected based
The new coating plant
on the component’s design
was designed by Dürr and
application phase and they generate a KPI that immediately
and surface area) with the real between the two consumption
installed by its local branch.
5 1
consumption level. The gap
Although it looks like a standard system, it is highly
Figure 5: Workpieces exiting the drying oven.
values is a performance indicator
technological and has a
that allows us to understand
much more sophisticated
if the operator is skilled, if we
structure than normally
are using the correct time and process parameters, and the paint consumption habit of each operator,” says Rosoldi. “We were then excited to generate other indicators, such as the VOC quantity. The Coriolis flowmeters allow us to monitor the total
required by the agriculture
The coating booth is 24 metres long, of which 20 are usable and can be equipped with five application station. As well as equipping the manual coating stations with EcoDose 2K systems, Verind also set up some non-in-line coating units, installed on skids with pumps and paint and catalyst circuits. They are used for the application of special colours.”
First of all, the 6-stage pre-treatment cycle is highly innovative since, for the first time, it includes a neutral pickling process as the first stage instead © Verinid
amount of paint delivered every
sector (Fig. 3).
hour compared to the known volumes of air in the booth and
of the conventional acid degreasing one (Fig. 4). “In Pune, we laser cut
therefore to calculate the amount
our sheets generating
of VOCs released in the booth
oxidation on their
itself and in the ovens. This will
edges; moreover, the
enable us to generate a further
subgroups supplied by
set of indicators automatically in
our contractors often
future.”
have oxidation and rust traces on their surfaces,”
A future Industry 4.0 The main characteristic of an Industry 4.0-oriented department
says Massimiliano Rosoldi.
6 1
“Chemetall developed a
Figure 6: The coating booth.
neutral pickling product, therefore free of
is the availability of system
hydrochloric acid, able to
inputs. However, an authentic Factory 4.0 needs, above all, a software
consumption of each point of use, coating
significantly reduce surface oxidation.
package analysing the data collected
consumption, VOC emission, alarm times, and
It has a pH of 7, it is not labelled as
and providing operational indications.
operating times are available in digital form.
hazardous, and it can completely
CNHi’s Pune Painting paintshop is
These Big Data, however, can only be exploited
remove oxidation and light rust from
Industry 4.0-oriented precisely because
at best if they are collected in a database able
metal sheets and components with a
122
N. 50 - MARCH/APRIL 2018 - international PAINT&COATING magazine
© Verinid
FOCUS ON TECHNOLOGY
spray application process with those of a cataphoretic basecoat for the yellow and red machines and of a one-layer coating for the grey ones (Fig. 9). “The coating system is still one of this project’s variables,” states Massimiliano Rosoldi. “We currently use a standard system including a primer and a “bake-on-bake” enamel (Fig. 10), but the project of this painting system was born with the aim of using cataphoresis. That is why we did not add any booth exclusively devoted to primer: it would
7 1
have soon remained unused. On the other hand, we opted for one semi-
Figure 7: The curing oven on the left and the coating booth on the right.
automatic coating booth with six stations for the two-coat application of both the primer and the enamel. maximum concentration of 10% and in
a code stored in the EcoDose 2K system:
This is possible thanks to a carefully
1 minute and 20 seconds, with better
when a special colour is needed, the skid
designed use of in-line buffers. The
results than the conventional process.
code is inserted and the system proceeds
buffers at the exit of both the pre-
We performed numerous laboratory
automatically.”
treatment area and the coating
tests before using it on our line. I can
The oven’s design is typical of the automotive
booth are long enough to free the
now state that such a pre-treatment
sector, with smooth walls, inspectable man-
two processes. Therefore, through
process, combined with the use of a
height pedestrian walkways, and a top and
the continuous conveyor’s software
surface tolerant epoxy primer ensuring
bottom area entirely cleanable from the
program, we manage to work on a
good adhesion even on imperfect
inside through access doors (Fig. 7).
mission basis. The pre-treatment and
substrates, certainly helps us control our
The system is ready for the possible
the primer and enamel application
quality levels.”
installation of a second drying oven to tackle
missions are stand-alone: they are
The pre-treatment cycle also includes a
any future increase in productivity, as well as
released at a specific time and based on
second degreasing stage, two rinses, an
of a cataphoresis tank (Fig. 8). In fact, CNHi
a precise sequence.” The system is very
Oxsilan nano-ceramic conversion stage,
Pune intends to replace its expensive primer
flexible and can manage one-layer,
water (Fig.5). The coating booth is 24 metres long, of which 20 are usable and can be
© Verinid
and a final rinse with demineralised
equipped with five application stations (Fig. 6). As well as equipping the manual coating stations with EcoDose 2K systems, Verind also set up some non-in-line coating units, installed on skids with pumps and paint and catalyst circuits. They are used for the application of special colours. “After entering the booth, these wheeled skids connect to the coating station and to the EcoDose 2K equipment feeding two opposing electrostatic coating guns,” says Ivan De Angelis. “Each skid has
8 1
Figure 8: The raised area of the plant.
international PAINT&COATING magazine - MARCH/APRIL 2018 - N. 50
123
© Verinid
INNOVATIONS IN SURFACE TREATMENTS FOR METAL WORKING
9 1
Figure 9: The coating management unit.
two-layer and, for higher quality standards, even three-layer (cataphoretic basecoat + primer + enamel) systems. Another advantage in the integrated communication between the conveyor and the process is that, thanks to the inverters installed on all motors and pumps and following the phase sequence (pre-treatment, primer
Besides the introduction of management software for the Big Data coming from the coating plant and the application equipment, which will turn CNHi Pune into an all-round Factory 4.0, another goal of CNHi is the implementation of a grey-coloured one-layer system.”
application and enamel application), it is
Goals of productivity increase Besides the introduction of management software for the Big Data coming from the coating plant and the application equipment, which will turn CNHi Pune into an all-round Factory 4.0, another goal of CNHi is the implementation of a grey-coloured one-layer system. “For yellow and red, © Verinid
possible to adjust the consumption of gas and electricity according to three modes of operation:
we will continue to apply a primer + topcoat system, where the primer will be replaced
Warming, Stand-by, and Running.
by a cataphoretic coating,
If, for example, the pre-treatment
whereas the grey components
station is in a waiting phase
will be coated with a one-layer
between one mission and another,
product. In this way, when
the software program automatically
the cataphoresis plant will be
starts the Stand-by mode; the
operating, the coating booth will
inverters drive the pumps at lower
apply only one coating layer for
frequencies (15-20 Hz) or those
both yellow and grey. This will
that are not needed are turned off, with great benefits in terms of sustainability.
124
10 1
Figure 10: A yellow workpiece exiting the curing oven.
N. 50 - MARCH/APRIL 2018 - international PAINT&COATING magazine
increase the modular capacity of the plant with significantly reduced costs.”
SPECIAL
SUCCESS STORIES
Looking Inside the Microcosm of Car Painting - With The Viledon® filterCair Module “Basic + Dirt In Paint”, Freudenberg Brings the Cause of the Tiniest Paint Defects Into the Light of Day
F
or cars packed with innovative technologies such as BMW, nothing should dull the driving pleasure
and futuristic design (Fig. 1). Not even the smallest surface defects in plastic components, which are barely visible to the human eye. But what is the source of these ever recurring faults in the coating of plastic parts? A wetting defect?
Under the name Viledon® filterCair, Freudenberg Filtration Technologies combines its flexible, individually tailored complete service package, aimed at the qualitative and economic optimization of coating processes.”
The experts at Freudenberg Filtration able to assist in solving and clarifying this question. Under the name Viledon® filterCair (Fig. 2), the company combines its flexible, individually tailored
Back to the specific case at BMW. As the BMW Group already relies on Viledon® filters for the purity of its painting processes at its plant in Lower Bavaria, the two Viledon® Site Engineers, Pascal Brodhun and Stephan Wassermann, were already familiar with the local situation. A status analysis of the paint zone is usually the first step in seeking to identify the cause, since the causes can be as diverse
© Freudenberg Filtration Technologies
Technologies should be
First step: status analysis of the painting zone
as the paint defects themselves. Potential sources include fiber or dirt inclusions, paint overspray, pollen, wetting defects caused by
complete service package,
application technology,
aimed at the qualitative
contaminated
and economic optimization
compressed air, silicone-
of coating processes.
containing lubricants
For many years, Viledon®
and oils, dirt carried in
filterCair has symbolized
by employees as well as
the holistic understanding of the filtration experts at Freudenberg: offering customers not just filters, but consistently high air
on their clothes or tools.
1
“Due to the large number
Figure 1: For cars packed with innovative technologies such as BMW, nothing should dull the driving pleasure and futuristic design.
of possible sources of contamination, it is necessary to look at the process holistically and
quality; acting not only
has also been providing this expertise on a
as product suppliers but as consultants
demand-driven basis outside fixed service
to examine it onsite. No two cases are alike”,
and problem-solvers too. Since 2017,
contracts, including for the BMW Group’s
explained Christian Westenburger, Contract
Freudenberg Filtration Technologies
plant.
Manager Viledon® filterCair.
126
N. 50 - MARCH/APRIL 2018 - international PAINT&COATING magazine
SPECIAL
© Freudenberg Filtration Technologies
SUCCESS STORIES
Since 2017, Freudenberg Filtration Technologies has also been providing their expertise on a demand-driven basis outside fixed service contracts, including for the BMW Group’s plant in Lower Bavaria.” Figure 2: Viledon® filterCair modules: customized service packages to meet your precise needs.
2 1
A thorough filter analysis and evaluation, meaningful particle,
“Our aim is to systematically rule out possible sources of error step
temperature, humidity and volume flow measurements and determining
by step”, commented Michael Steuer, Regional Manager Viledon®
the sinking speed in the paint line - these are the key components of the
filterCair, describing the procedure. “One element of this is the process
Viledon® filterCair module “Basic”. However, they did not reveal anything
or root cause analysis on site. At the same time, we began detailed
unusual at the BMW Group plant. The painting process was flawless: the
paint damage analysis for BMW in our laboratories”, he explained.
work processes were stable, all systems were set up correctly and the air
This second approach with the Viledon® filterCair module “Basic + Dirt
balance in the spray booth was perfectly in order.
in Paint” was the successful one in this specific case.
Welcome to the
Visioneering
Group
Best surface quality by heating up the car body from the inside Best process times with up to 30 % shorter heat-up Best curing technology for EVs EcoInCure: Innovative car body curing from the inside www.durr-paint.com
SPECIAL
© Freudenberg Filtration Technologies
SUCCESS STORIES
Any color that exhibits the circular to oval inclusions below the defect represents a chemical element that makes up this particle. In this specific case, that meant silicon and oxygen in particular, but also phosphorus, aluminum and a little potassium.”
Second step: problem-specific analysis under high performance microscopes
electron microscopic (SEM/EDX) analysis
Freudenberg then examined the granulate
into play. In this case, the faulty spot is
from which the car catchers were sprayed.
precisely cross-sectioned and inspected in
“From samples, we produced wafer-thin
During this process, Freudenberg experts
cross-section to find out which elements
films with a melting temperature of 280°C”,
immerse themselves in the microcosm of
are causing the flaw (Fig. 4). What may look
explained Frank Hofmann, Contract
the plastic paint. To begin with, they use
to the layman like a variety of differently
Manager Viledon® filterCair. This granulate
incident light microscopy. “This showed us
colored images set the Freudenberg
analysis showed that the quartz particles
an inhomogeneous surface. In some places,
experts immediately on the right track.
found were a constituent of the raw
there was no basecoat at all (Fig. 3). At the
Any color that exhibits the circular to oval
material. In places where they were too
same time, however, since the entire defect
inclusions below the defect represents
coarsely grained, painting errors emerged.
was covered with clear lacquer, we were able
a chemical element that makes up this
Problem solved. This fulfilled the most
to exclude a wetting defect caused by silicone
particle. In this specific case, that meant
important goal: a satisfied customer.
or similar”, explained Michael Steuer.
silicon and oxygen in particular, but
The problem thus had to lie deeper, in the
also phosphorus, aluminum and a little
For further information:
true sense of the word. This brought an
potassium.
www. freudenberg-filter.com
4 1
A thorough filter analysis and evaluation, meaningful particle, temperature, humidity and volume flow measurements and determining the sinking speed in the paint line - these are the key components of the Viledon® filterCair module “Basic”.”
128
Figure 4: Observation of the faulty spot in cross section by means of scanning electron microscopic SEM/EDX analysis.
N. 50 - MARCH/APRIL 2018 - international PAINT&COATING magazine
© Freudenberg Filtration Technologies
Figure 3: Incident light microscopy of the defect in the paint.
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AERTECH S.A.S. CHEMTEC NORTH AMERICA LLC CHEMTEC LATIN AMERICA LLC
© Tosca
130
N. 50 - MARCH/APRIL 2018 - international PAINT&COATING magazine
INNOVATIONS IN SURFACE TREATMENTS FOR METAL WORKING
FOCUS ON TECHNOLOGY
Shot Blasting 4.0 for a Flexible and Highly Efficient Pre-Treatment Process Prior to Coating Francesco Stucchi ipcm®
O
perating based on the Industry 4.0
into the firm; our next goal is to become a
on its clients’ parts, when requested or
principles, with highly automated
company 4.0.” Co.An.Auto is no longer a simple
authorised, is shot blasting. This is followed
and interconnected production
coating contractor, but it is a true enterprise.
by cataphoresis coating with a chemical pre-
processes and rationalised and optimised
By operating in the most diverse industries
treatment phase and/or powder coating for
costs, is now crucial for companies in the
(motorcycles, cars, tractors and earth-moving
combined systems; if only a powder coating
industrial sector. A firm based in the Italian
machines, toys, lighting), it has increasingly
process is required, this is carried out with an
Brianza area has turned its generational
Oxsilan “green technology” nanotechnology
change into a starting point towards
pre-treatment.”
innovation 4.0: Co.An.Auto Componenti S.r.L.,
“Based on our company philosophy, we have
established in Arcore (MB, Italy) in 1997.
always refused to include any acid pickling
“When it was established twenty years ago, Co.An.Auto Componenti S.r.L. was a cataphoresis coating contractor,” explains Bruno Maggioni, one of the owners and founding partners, “but we immediately started widening our horizons. Our service range now includes shot blasting as well as cataphoresis, powder and combined-system coating for both steel and aluminium parts. The latter is currently our most requested treatment besides processes requiring masking. Initially, we dealt almost exclusively
When it was established twenty years ago, Co.An. Auto Componenti S.r.L. was a cataphoresis coating contractor but they immediately started widening their horizons. The service range now includes shot blasting as well as cataphoresis, powder and combined-system coating for both steel and aluminium parts. The latter is currently the most requested treatment besides processes requiring masking. ”
stage in our chemical pre-treatment,” states Maggioni. “First of all, it is a little controllable chemical process and it decreases the corrosion resistance performance of substrates. Secondly, it has a negative environmental impact, which is totally unacceptable for us. The only alternative to acid pickling that is equally effective for preparing surfaces is shot blasting: if performed properly according to the metal treated, it offers an incomparable level of surface cleanliness and paint adhesion. That is why we opted for a largesized, highly automated advanced shot blasting
with auto parts, hence our name; now, we
system, enabling us to be competitive also in
can treat workpieces from the most varied
terms of costs.”
industrial sectors.” “In the last seven years, we have started a
focused on surface preparation processes
The new shot blasting plant
generational change,” says Maggioni, “with my
through shot blasting, besides coating (with a
“Our turning point towards innovation 4.0 was
son Alberto, a management engineer who
cataphoresis and a powder plant).
precisely the purchase of this new shot blasting
is now our technical-commercial manager
machine (ref. Opening photo) in December
founding member, Matteo Teruzzi, currently
The importance of shot blasting for Co.An.Auto
our production manager and an advocate of
Whether a cataphoresis or powder coating
over fifty years’ experience in the industry, a
process industrialisation. Our entrepreneurial
or a combined system is required, the
team composed of young and proactive people
vocation was strengthened with their entry
first process performed by Co.An.Auto
with which we have worked in perfect harmony
as well as a partner, and the son of another
2017,” states Maggioni. “As a supplier, we chose Tosca Srl (Canegrate, MI, Italy), a company with
Opening photo: The tailor - made shot blasting system supplied to Co.An.Auto by Tosca Srl.
international PAINT&COATING magazine - MARCH/APRIL 2018 - N. 50
131
© ipcm ®
INNOVATIONS IN SURFACE TREATMENTS FOR METAL WORKING
Figure 1: A detail of the ring-shaped onerail conveyor, which enables to load and unload parts on different hooks outside the chamber while another one is being subjected to shot blasting.
The plant installed at the premises of Co.An.Auto is a cluster shot blasting system equipped with a one-rail conveyor and several hooks; its ring layout enables to load and unload parts on different hooks outside the chamber while another one is being subjected to shot blasting (Fig. 1). During this phase, the hooks are rotated and simultaneously perform a “coming
1
and going” movement, in order to ensure that the media launched by the turbines in terms of electronics – to facilitate their
hit the parts’ surfaces with different
know-how for our needs.”
digital integration with already automated
angles and therefore optimally.
“The peculiarity of our company,” states
customer lines, which is very important in
The plant is equipped with four 7.5
Tosca srl’s team, “is that over the years
the framework of the Industry 4.0 – as well
kW turbines managed by separate
our customers have led us to develop a
as easy to maintain and definitely durable.
inverters, which allow to select the
definite kind of machines. We build shot
Our “standard” are tailor made shot blasting
abrasive throw speed depending on the
blasting machines that are very solid in
systems and not “basic models”: this is what
type of workpiece to be treated (Fig. 2).
terms of mechanics and very well equipped
differentiates us from our competitors.”
These are matched to servo controls
© ipcm ®
right from the design phase, and the ideal
Whether a cataphoresis or powder coating or a combined system is required, the first process performed by Co.An.Auto on its clients’ parts, when requested or authorised, is shot blasting. This is followed by cataphoresis coating with a chemical pre-treatment phase and/ or powder coating for combined systems; if only a powder coating process is required, this is carried out with an Oxsilan “green technology” nanotechnology pre-treatment. ”
132
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Figure 2: Electric circuits equipped with an inverter to allow the selection of the abrasive throw speed.
N. 50 - MARCH/APRIL 2018 - international PAINT&COATING magazine
© ipcm ®
INNOVATIONS IN SURFACE TREATMENTS FOR METAL WORKING
Figure 3: The recovery and reconditioning system.
that regulate the quantity of abrasive based on the rotation speed of the turbines, thus optimising their operation. The abrasives used are small conditioned steel cut wire; by being able to set out their throw speed, users can define in advance the surface roughness value they want to obtain for each hook. A recovery and reconditioning system ensures the total elimination of waste, burrs and powders (Fig. 3). Since aluminium parts are also shot blasted, in order to comply with the regulations concerning the risk of detonation due to the concentration of aluminium powders, which explode at lower concentrations than the iron ones, Tosca srl opted to install an Atexcompliant filter, not ‘self-certified’, but supplied by one of the world’s leading companies in the sector. A PLC programmable via the operator panel allows to control all system functions and create customised sequences with different pace, turbine rotation speed, and media flow values (Fig. 4). Tosca created a series of HUB connections so that all solenoid valves and sensors can be managed via PROFINET through the PLC and remotely with a modem and an Internet connection (Fig. 5). When properly developed, in future this system will enable to monitor the systems’
3 1
© ipcm ®
status even from a smartphone.
The plant installed at the premises of Co.An.Auto is a cluster shot blasting system equipped with a one-rail conveyor and several hooks; its ring layout enables to load and unload parts on different hooks outside the chamber while another one is being subjected to shot blasting. During this phase, the hooks are rotated and simultaneously perform a “coming and going” movement, in order to ensure that the media launched by the turbines hit the parts’ surfaces with different angles and therefore optimally. ”
134
4 1
Figure 4: The touch screen operator panel for setting all the shot blasting machine’s functions.
N. 50 - MARCH/APRIL 2018 - international PAINT&COATING magazine
© ipcm ®
FOCUS ON TECHNOLOGY
5 1
Figure 5: HUB connections of all the solenoid valves and sensors of the system.
A PLC programmable via the operator panel allows to control all system functions and create customised sequences with different pace, turbine rotation speed, and media flow values. Tosca created a series of HUB connections so that all solenoid valves and sensors can be managed via PROFINET through the PLC and remotely with a modem and an Internet connection. When properly developed, in future this system will enable to monitor the systems’ status even from a smartphone. ”
© ipcm ®
INNOVATIONS IN SURFACE TREATMENTS FOR METAL WORKING
“Tosca’s shot blasting machines can adapt their characteristics and working parameters to the products treated and the finishes required. Before starting a cycle, the operator selects the proper sequence through a touch screen panel,” states Tosca’s team. “However, this stage will soon be completely automated and managed remotely through pre-set barcodes for each type of product, again in compliance with the Industry 4.0 principles.” As for the plant’s construction, the shot blasting chamber is made with steel and manganese steel sheets featuring reinforcement profiles and an anti-wear lining as follows: - interchangeable 10 mm thick manganese steel plates at the centre - interchangeable 6 mm thick manganese steel plates at both sides - special anti-abrasive rubber sheets on the interior walls of the automatic doors (Fig. 6). Another characteristic of all the machines produced by Tosca, besides extreme durability, it is their ease of maintenance. For instance, the interchangeable plates are fixed outside the plant, so that it is always possible to replace them quickly and easily, thus reducing costs and downtimes.
Industry 4.0: goal achieved “Relying on Tosca was the right choice,” states Maggioni. “Their shot blasting machines are highly technological and effective. All our requirements have been met quickly and concretely. The Tosca team has always been available and above all flexible, paying attention to the smallest details and enabling us to get the most out of their expertise.” In terms
6 1
of both process and finishes obtained, the
Figure 6: The shot blasting machine is equipped with two automatic doors operated by pneumatic cylinders.
results are definitely satisfactory. “Since we installed the system two months ago,” says Maggioni, “we are still at the ‘break-in’ stage, but we are already working on implementing a management interface between the Tosca
Another characteristic of all the machines produced by Tosca, besides extreme durability, it is their ease of maintenance. For instance, the interchangeable plates are fixed outside the plant, so that it is always possible to replace them quickly and easily, thus reducing costs and downtimes.”
136
N. 50 - MARCH/APRIL 2018 - international PAINT&COATING magazine
machine and Co.An.Auto’s already existing software. This will enable us to manage the over 5,000 part numbers we deal with, each with different shot blasting needs, much more efficiently.”
SPECIAL
BRAND-NEW
Sames Kremlin Announces the Launch of Our Brand New Manual Fpro Airspray Spray Gun Pressure Range
S
ames Kremlin announces the
FPro - effortless and perfect spraying:
launch of the FPro Airspray
- a painter must feel comfortable and at ease with his spray gun to be efficient and
spray gun bringing professional
finishing for all (Fig. 1).
productive. With the new generation of
«For all» means easy to
super light hoses, lightweight gun body and
use for all. The FPro
ergonomic handling, the FPro spray gun
spray gun is perfectly
applies the coating with ease and less effort
balanced; therefore,
(Fig. 2).
delivering the perfect finish In 1925 Sames Kremlin industrialized the first
«For all» means the largest range
airspray gun in Europe and reinvents the way
of pressure guns and accessories for
to atomize paint with patented innovations
all applications in all the high finishing
with the New FPro airspray spray gun. Sames
markets.
Kremlin understands the customers’ needs
FPro is the new standard in airspray:
2 1
Thanks to innovative patent pending technologies inside the gun, the painter has complete control with the paint
Figure 1: The new FPro Airspray gun.
lin Krem mes © Sa
for any type of painter.
due to decades of knowledge and customer application experience. For further information: www.sames-kremlin.com
application. The paint speed controller and spin effect deliver a perfect © Sames Kremlin
atomization with very high transfer efficiency (up to 78% in HVLP). FPro delivers performance at your fingertips: - the FPro delivers a rich experience at your fingertip with a perfectly balanced gun body and a high level of sensation on the trigger for perfect applications.
Figure 2: FPro Airspray guarantees a perfect and easy application thanks to its lightweight and ergonomic handling.
138
2 1
N. 50 - MARCH/APRIL 2018 - international PAINT&COATING magazine
BRAND-NEW
INNOVATIONS IN SURFACE TREATMENTS FOR METAL WORKING
Feltani Reti: High Quality Coating Hooks Since 1975 AISI304 stainless steel wire can be produced
Snc, based in Campodarsego (Pd),
upon request.
was established in 1975 by the
The characteristics of each product are collected
©Feltani Reti
T
he Italian company Feltani Reti
Feltani family, which has dedicated itself to metal wire processing for almost forty
in a technical file containing information on each type of hook, in accordance with the UNI EN
years now. Initially, it was a handicraft
standards:
manufacturer of bed and sofa bed nets,
- indications of use;
but over the years and with the advent of
- identification of the coil used for each batch,
automation it has constantly expanded
complete with the certification of the steel mill
its plant equipment, thus improving its
(Fig. 3);
product range and focussing on the production of coating hooks, which is still its core business (Fig. 1).
- maximum hook capacity; Figure 1: Coating hooks manufactured by Feltani Reti.
from mechanical
Written on the initiative of Isabella Feltani, our marketing and communication manager, this
©Feltani Reti
The switch
- load test results.
manual is a plus for users in terms of both safety and process optimisation.
control to
Its forty-year experience, advanced technology
advanced
and extreme processing precision have led
numerical
Figure 2: Technologically advanced numerical control machines ensure maximum production flexibility.
control machines (Fig. 2) has enabled Feltani Reti to produce hooks in the
2 1
Feltani Reti to collaborate with the leading companies of the coating, furniture, and automotive sectors, as well as becoming well known on the market for its professionalism, flexibility, quality, and delivery speed. For further information: www.feltanireti.it
most varied ©Feltani Reti
sizes, types and materials (normal metal, galvanised, or stainless steel wire), ensuring high flexibility in meeting customer requests with the right mix of technique and creativity. Indeed, this company’s strength is its ability to produce hooks based on its customers’ designs, in addition to having a large stock availability with very fast delivery times. Feltani’s production is divided into two large categories, standard bend and round bend coating hooks. They are available with various diameters: - hooks in FE360 with a diameter from 2.00 mm to 15.00 mm - hooks in SM phosphated steel with a diameter from 1.50 mm to 8.00 mm.
Figure 3: Metal wire coils labelled and identified by the producing steel mill.
3 1
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© ipcm ®
Opening photo: Tecnolaser is a company specialised in the processing of sheet metal for machine tools, textile machines, earth moving machines, and accessories for the industry
FOCUS ON TECHNOLOGY
INNOVATIONS IN SURFACE TREATMENTS FOR METAL WORKING
Collaboration Between Specialists for the Versatile, Integrated, and 4.0-Oriented Coating of Light Carpentry Components: Tecnolaser’s Success Story Barbara Pennati ipcm®
T
ecnolaser, based in Curtarolo (PD, Italy) and specialising in the
The advent of automatic machines, which have facilitated some mechanical
processing of sheet metal, was established in 1986 as a production
processes and reduced production times, then led Tecnolaser to expand
department of Officine Facco & C. Spa, a manufacturer of plant
its production capacity and acquire new customers. That is why it moved
engineering solutions for the poultry farming and breeding industry.
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to a new larger site, suitable for hosting its new work cycles (Fig. 1).
© Tecnolaser
FOCUS ON TECHNOLOGY
“The intensification of our activities and the increase in our turnover forced
The first coating plant Thanks to the implementation of
us to change our logistics. In the late
a pre-treatment nanotechnology,
Nineties, we decided to move our
Tecnolaser could make a
company headquarters and build a first
qualitative leap in terms of finishing
plant devoted to machining, assembly,
performance. However, the ever-
and welding. Coating was entrusted to
increasing workload and the small
contractors,” explains Gian Maria Tonin,
size of its coating system limited the
Tecnolaser’s quality system manager
versatility and quality of its service.
(Fig. 2). “However, we experienced
“We performed over 70 colour
various quality problems with the
change operations per month but,
finishing of our products, not so much
since we had a one-rail conveyor, the
due to the coating process itself as
plant downtime negatively affected
1
related to transport. Light carpentry components, made of carbon steel, coil
our production rate and forced
Figure 1: Tecnolaser’s plant in Curtarolo (PD, Italy).
galvanised or electro galvanised steel, and structural steel (Fig. 3), are easily
us to double the shifts,” says Gian Maria Tonin. “Moreover, although the strength that distinguishes
damaged if not carefully handled, and we often found damaged workpieces that resulted in an increase in waste and production times (ref. Opening photo).” “Besides these quality issues, we also needed to support our customers during the whole sheet metal treatment process, from our co-design service in the components’ development to the supply of end products,” says Tonin. “We installed our first powder coating plant in 2009, which enabled us to meet our clients’ needs in terms of quality and delivery times.” “When one of our important customers
Tecnolaser, based in Curtarolo (PD, Italy) and specialising in the processing of sheet metal, was established in 1986 as a production department of Officine Facco & C. Spa, a manufacturer of plant engineering solutions for the poultry farming and breeding industry. The advent of automatic machines, which have facilitated some mechanical processes and reduced production times, then led Tecnolaser to expand its production capacity and acquire new customers. That is why it moved to a new larger site, suitable for hosting its new work cycles.”
us on the market is our ability to handle medium-low volume production batches, our reduced space, the impossibility to integrate a second spray paint booth, and the increase in the number of orders led us to make a second important investment. We built a new adjacent building of about 4500 m2, where we installed a new coating plant that could finally meet all our needs, ensuring also we had the possibility and the space for any future implementations.”
The new coating plant
Padua, a part of its processes
“In order to design the
© ipcm ®
closed its production plant near was entrusted to Tecnolaser.
new system, we set up a
However, the finishing quality
roundtable with Dollmar,
requirements, i.e. 500-hour salt
as the sole supplier of
spray resistance, where higher
pre-treatment products;
than those met by our coating
Costabeber, as the plant
plant,” states Gian Maria Tonin.
engineering company; Gema
“While searching for the best
Europe, for the installation
suited passivation system, we
of the new coating booth;
came into contact with Dollmar
and Futura Convogliatori
(Caleppio di Settala, Italy). The
Aerei, for the installation of
tests performed with them led us to integrate a multi-metal pretreatment process with the final nebulisation of a nanotechnology passivation product,” he says.
the conveyor and of the 4.0 2 1
management software,” states
Figure 2: From left to right, Tecnolaser plant manager Filippo Tonello, Tecnolaser quality system manager Gian Maria Tonin, and Alessia Venturi from ipcm.
Tonin. The new coating line, in operation since December 2017, includes a multi-metal
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© ipcm ®
© ipcm ®
INNOVATIONS IN SURFACE TREATMENTS FOR METAL WORKING
3 1
4 1
Figure 3: Tecnolaser treats parts in carbon steel, coil galvanised or electro galvanised steel, and structural steel.
Figure 4: The pre-treatment tunnel
no rinse pre-treatment process performed as
“Aware that one of the main process variables is
their process versatility and quality level,”
follows: acid phosphodegreasing with products
the substrate quality of sheets, which cannot be
explains Gherardo Minotti, Dollmar’s
from the Dollphos range; 3 rinses with mains
controlled, we relied on Tecnolaser’s previous
Products Division Business Development
water; 1 semi-osmotic rinse; a pure flash of
experience to solve the old plant’s critical issues
specialist. “The current tunnel (Fig. 4) is
osmotic water; a nanotechnology passivation
and fully meet their needs. That is why we
62 metres long, of which 9 are devoted
through nebulisation; and a hot air drying stage.
implemented technologies that could improve
to the first phosphodegreasing stage. Its
Thanks to the implementation of a pre-treatment nanotechnology, Tecnolaser could make a qualitative leap in terms of finishing performance. However, the ever-increasing workload and the small size of its coating system limited the versatility and quality of its service.”
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© ipcm ®
© ipcm ®
dimensions are based on the longest workpieces treated by Tecnolaser, which are 5 metres long. The cleaning tanks are equipped with pH and conductivity control probes, integrated into the level control system and featuring a dedicated interface to constantly monitor the process and avoid any lowering of cycle performance.” “The Soft Level system, besides optimising water consumption, can 5A 1
5B 1
Figures 5A and 5B: The new Gema MagicCylinder coating booth with a quick colour change system.
N. 50 - MARCH/APRIL 2018 - international PAINT&COATING magazine
communicate with Soft Rain Advanced. This system enables to apply an osmotic water flash,
© ipcm ®
INNOVATIONS IN SURFACE TREATMENTS FOR METAL WORKING
Tecnolaser’s customers generally choose the
other the light ones, in order to avoid any
coatings. They can be epoxy, polyester or
contamination. They both have pre and
epoxy-polyester products. Their application is
post-retouching stations, used only if the
carried out in two booths. “For cost efficiency
workpieces’ shape requires it (Fig. 8).
reasons, we decided to keep the first plant’s
“Thanks to the new plant layout, including
booth and add a new MagicCylinder booth
a Futura power and free overhead
(Figs. 5a and 5b) with the new OptiCenter
conveyor (Figs. 9a and 9b), we can now
system (Fig. 6) featuring OptiSpray dense
also perform two-coat processes. In
phase application pumps (Fig. 7),” says
this case, we lower the polymerisation
Tecnolaser plant manager Filippo Tonello.
oven temperature in order to avoid
“One booth applies the dark colours and the
complete gelling of the primer and we © ipcm ®
return the parts to the booth selected for the application of the second layer through a priority route.” “We carry
6 1
out around 5
Figure 6: The new Gema OptiCenter.
colour change operations per day. Thanks
therefore free of the pollutants present in the tank due to dragging, which ensures optimal product preparation
to the storage
7 1
buffers (Fig. 10) strategically
Figure 7: Gema OptiSpray dense phase pumps.
before the nanotechnology passivation © ipcm ®
stage. This is carried out with Dollcoat SA 115, already used in the first plant. The Dollcoat SA product range is based on synthetic oligomers containing organically functionalised silanes, able to enhance the properties of the silanes themselves and ensuring excellent paint adhesion and corrosion protection. The nebulisation action ensures that a fresh product is always applied on parts for maximum treatment quality, avoiding any contamination due to dragging or to the presence of reaction by-products,” states Minotti. “At the moment, we have opted for an acid phosphodegreasing stage because it ensures excellent results on both carbon and galvanised steel, the two most treated types of metal by Tecnolaser. However, the plant is ready to switch to an alkaline degreasing process in future.”
144
In order to design the new system, Tecnolaser set up a roundtable with Dollmar, as the sole supplier of pretreatment products; Costabeber, as the plant engineering company; Gema Europe, for the installation of the new coating booth; and Futura Convogliatori Aerei, for the installation of the conveyor and of the 4.0 management software.”
N. 50 - MARCH/APRIL 2018 - international PAINT&COATING magazine
8 1
Figure 8: Both booths are equipped with pre and post-retouching stations.
© ipcm ®
FOCUS ON TECHNOLOGY
© ipcm ®
9A 1
9B 1
Figures 9A and 9B: Futura Convogliatori’s power & free conveyor.
positioned along the two-rail conveyor (in front of the pretreatment tunnel, after the drying oven, and in the two unloading areas, as well as some 3-bar mini buffers at the booths’ entrance and exit), plant downtimes have decreased and our production and delivery processes are no longer slowed down,” states Filippo Tonello.
A software package 4.0 for the integrated management of the plant The new coating plant is totally managed by a software developed by Futura Convogliatori Aerei and integrated with Tecnolaser’s factory management system (Fig. 11). “The whole production flow is organised in “colour chains”, identified by a unique code that is applied to all load bars with parts requiring the same coating process. During processing, the system collects plant data – times of entry and exit from the various stages, pH parameters, oven temperatures, unloading times, and so on. The data are then stored and, once a “colour chain” is ended, they are automatically integrated into the internal database to update the production data related to coating,” explains Gian Maria Tonin. “The automation of the whole
G RT
© ipcm ®
INNOVATIONS IN SURFACE TREATMENTS FOR METAL WORKING
states Tonin. “Our active collaboration with Dollmar, Futura, Costabeber, and Gema, as well as the technical suggestions received, have allowed us not only to improve the quality level of our production, but also to solve the handling and delivery problems that we encountered with the old plant layout. The new line offers us optimal flexibility thanks to the strategic positioning of storage buffers and the creation of priority routes for materials to be delivered urgently, made possible by the two-rail conveyor, but also thanks to the two spray paint booths that enabled us to perform a two-coat cycle and make improvements in terms of overspray and consumption. For
10 1
Figure 10: Several butters of the power & free conveyor by Futura.
the future, we are considering the integration of a third coating booth, working simultaneously to the two
process and its integration with our internal
Conclusions
system enables us to carry out activities such
“Since we are required increasingly
the plant to another transport line that
as updating production orders with no human
different types of coatings and effects,
takes the workpieces directly to the
intervention. Moreover, since the system and
it has been crucial to equip ourselves
subsequent assembly phases, thus
the software communicate with each other,
with a plant enabling us to efficiently
achieving a complete and 4.0-oriented
we can trace the different colour batches and
meet the needs of the market in terms
automation of production,” says
intervene promptly in case of any problems.”
of both quality and delivery times,”
Gian Maria Tonin.
146
© Tecnolaser
Thanks to the storage buffers strategically positioned along the two-rail conveyor (in front of the pre-treatment tunnel, after the drying oven, and in the two unloading areas, as well as some 3-bar mini buffers at the booths’ entrance and exit), plant downtimes have decreased and the production and delivery processes are no longer slowed down.”
already in use, and the connection of
11 1
Figure 11: The new coating system is managed by integrated software 4.0.
N. 50 - MARCH/APRIL 2018 - international PAINT&COATING magazine
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© SAVIM Europe
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INNOVATIONS IN SURFACE TREATMENTS FOR METAL WORKING
FOCUS ON TECHNOLOGY
Metalcolor: a New Coating Plant with a Low Environmental Impact for Greater Production Versatility Barbara Pennati ipcm®
I
n each issue of ipcm®, we bring examples
this purpose, Metalcolor collaborated
whereas for the pre-treatment phase we
of companies that, regardless of their
with SAVIM Europe, a company that
adopted Chemtec’s one-stage process
size, employee number, turnover, and
designs and produces both manual and
Toran 3®: an innovative technology with a
production capacity, have recognised the
automatic complete coating systems.
low environmental impact that uses organic
importance of making targeted investments
In 2016, faced with an increasing
polymers.”
to establish themselves in their target
demand and aiming at opening up to
sectors and stand out in an increasingly
new sectors, Metalcolor turned again to
fast and competitive market through very
SAVIM Europe to install a second coating
The new painting line for light carpentry components
high quality standards. An ever-changing
system. “In order to expand our service
“The layout of the first plant installed by
market, however, entails an evolution of the
range without slowing down our heavy
SAVIM includes two thermosetting powder © SAVIM Europe
demand itself. This, in turn, means that companies must cope with the most diverse needs, thus always
application booths, one automatic and one manual, an oven booth to apply liquid coatings
taking new challenges
on parts up to 14 m,
and looking for the right
and a static oven for
investment and the most
polymerising powder
suitable technological
coatings. The pre-
partner.
treatment is performed
This is the case of
with an automatic
Metalcolor (Caprazzino di
shotblasting system or, in
Sassocorvaro, PU, Italy),
the presence of complex
belonging to the Epta
shapes, with a manual
Group and specialising in the treatment and coating of metal. In 2015, it implemented an important
sandblasting operation,”
1
says Davide Dini.
Figure 1: The new coating system designed by SAVIM Europe.
site expansion project (also
“Treating light carpentry workpieces in such a large system, however,
reported by ipcm®1) by moving to a 3500 m2
carpentry production rate, we installed
was uneconomical and not very productive.
facility equipped with cutting-edge systems,
a new automatic powder coating line
A new automatic line was therefore started in
with the aim of specialising in particular
devoted exclusively to the processing of
November 2016 (Fig. 1), equipped with a one-
in the treatment of large-sized parts. For
small components such as sheets and
stage pre-treatment tunnel, a drying oven, a
carters (ref. Opening photo),” explains
Wagner SuperCenter booth featuring a quick
Metalcolor production manager Davide
colour change system and 10 guns (Fig. 2),
Dini. “We relied again on SAVIM Europe,
and a bell curing oven (Fig. 3).”
1 “A coating line designed specifically for the heavy carpentry sector and to ensure maximum energy savings” ipcm®_International Paint&Coating Magazine Vol. VI, No. 35 September-October, pages 104-108
Opening photo: in order to expand its service range, Metalcolor (Caprazzino di Sassocorvaro, PU, Italy) installed a new automatic powder coating line devoted to light carpentry parts.
international PAINT&COATING magazine - MARCH/APRIL 2018 - N. 50
149
© SAVIM Europe
INNOVATIONS IN SURFACE TREATMENTS FOR METAL WORKING
2 1
Figure 2: The Wagner SuperCenter automatic coating booth with a quick colour change system.
“On average, we perform two colour change
managed to design a functional but compact
operations a day, working in two shifts. In
system: a simple solution, but able to meet our
order to make our production flow more
needs and required standards,” states Dini.
Toran 3®: a one-stage pre-treatment process based on organic fluids
flexible, besides the automatic booth we
“Moreover, Metalcolor pays great attention
The pre-treatment tunnel of the new plant
added a small manual unit built by us. This is
to environmental sustainability and it has
is about 10 m long and equipped with a
devoted to the coating of batches
containment tank with a capacity of
requiring different colours than
about 2,000 litres. It uses Chemtec’s
the one applied on the automatic
Toran 3® technology, a VOC free
line,” says Dini. “The polymerisation oven is about 3 m long and, like the drying oven, it is equipped with a modulating air vein burner that, compared with a conventional burner, ensures lower pollutant emissions and higher energy saving
The pre-treatment tunnel of the new plant is about 10 m long and equipped with a containment tank with a capacity of about 2,000 litres. It uses Chemtec’s Toran 3® technology, a VOC free process based on organic fluids and developed to clean, degrease, and protect metal surfaces.”
thanks to its high combustion
process based on organic fluids and developed to clean, degrease, and protect metal surfaces (Fig. 4). “Metalcolor treats several different materials for different industrial sectors. Our customers are mainly manufacturers of machines for marble, glass, and wood processing,
efficiency.”
always been committed to reduce pollutants.
whose components are usually treated by our
The new plant features a 124 m long one-rail
This is also reflected in the choice of both
plant devoted to heavy carpentry parts. Carters,
overhead conveyor and it was designed
the coatings used, which are free of solvents,
doors, and sheets in general, on the other hand,
to fit the available space. “One of the main
chromium and lead, and the plant installed,
are processed in the new dedicated system.
issues of this project was the relatively small
with a low environmental impact and ensuring
The materials used are also different: carbon
space available in our factory. SAVIM Europe
considerable energy saving.”
steel, cold galvanised steel, iron, and aluminium.
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© SAVIM Europe
FOCUS ON TECHNOLOGY
3 1
© SAVIM Europe
Figure 3: The hot air bell oven for the polymerisation of coatings.
4 1
Figure 4: The containment tank for Chemtec’s Toran 3® process.
5 1
6 1
Figures 5 and 6: A SEM image of a steel Q-Panel degreased without Toran 3® (left) and treated with Toran 3® (right).
© Chemtec
© Chemtec
© Chemtec
INNOVATIONS IN SURFACE TREATMENTS FOR METAL WORKING
7 1
Figure 7: A metal sheet with Toran 3®+ 2% of laminating oil: the oil is incorporated into the polymer in “nanobubbles”.
That is why we needed a versatile multi-metal
The organic polymer that covers the
Conclusions
pre-treatment process able to handle different
components absorbs oils and organic
“Metalcolor was established in 2005 and
types of workpieces while maintaining a high
contaminants up to about 1.5 g of oil
initially it was equipped with a small coating
quality standard,” says Davide Dini. “We had the
per square metre treated (Fig. 7). The
plant. Our immediate strong growth led
opportunity to verify the effectiveness of Toran
process, therefore, traps oils and grease
us to install a larger system designed by
3® first-hand in a few plants in France and we
in the three-dimensional structure of the
SAVIM Europe, which enabled us to cope
decided to adopt it, too.”
polymer created on the metal. It does not
with the growing demand from our area,”
The process operates at room temperature in
generate any waste, but it rather converts
says Davide Dini. “Then, in order to be even
one stage including treatment, dripping, and
contaminants into an active part of the
more competitive and grow in terms of
drying at a maximum temperature of
production, we realised that we
140 °C. Toran 3® consists of polymers
had to invest again in coating.
and special additives dissolved in a particular mixture of organic fluids. When the product dries, cross-linking of polymers occurs; they coat the surfaces with a very thin continuous three-dimensional conversion film, which is about 1 micron thick and able to increase adhesion of the coating (epoxy, polyester, or mixed), provide oxidation protection, and improve
The organic polymer that covers the components absorbs oils and organic contaminants up to about 1.5 g of oil per square metre treated. The process, therefore, traps oils and grease in the three-dimensional structure of the polymer created on the metal. It does not generate any waste, but it rather converts contaminants into an active part of the treatment.”
That is why we relied on the expertise of SAVIM, which once again met our needs with a compact, functional, advanced, and eco-friendly system, the latter characteristic being very important for us.” “The integration of our previously implemented mechanical pretreatment with the Toran 3®
corrosion resistance (Figs. 5 and 6).
organic fluid-based one provided
“We performed some tests with
by Chemtec allowed us to solve
Chemtec’s cleaning process and, with one
treatment. “We were particularly impressed
the problems we encountered in the
powder coat, we managed to achieve a salt
by the presence of a microprimer that, as
cleaning of some parts. We immediately
spray resistance value of 500 hours,” says
well as degreasing the material, incorporates
obtained excellent results that enabled us to
Davide Dini. “Before installing the new system,
dirt and contaminants. This translates into a
successfully meet even the most particular
we only implemented a mechanical pre-
lower environmental impact because there
customer requests and specifications,”
treatment that, however, could not ensure
is no emission or creation of solid waste to
says Davide Dini. “The whole plant
perfect paint adhesion on some types of
be disposed of. This is perfectly in line with
can be managed by one control panel.
parts. With this new pre-treatment process,
our corporate philosophy of respect for the
This facilitates the timely resolution of any
we have managed to get excellent results
environment, including the working one,
problems and the maintenance operations.
in terms of both adhesion and corrosion
which in this way is cleaner and safer,” states
Two years after the installation, we cannot
resistance.”
Dini.
but be very pleased,” he states.
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© Verne Technology
INNOVATIONS IN SURFACE TREATMENTS FOR METAL WORKING
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INNOVATIONS: PRESENT&FUTURE
Dense Phase, Low Pressure (DPLP) Powder Application: Reduced Consumption and High Performance with the New Transport System NEA 415 Carlo Perillo Verne Technology, Milan, Italy
c.perillo@vernetechnology.it
N
NEA 415 hardware for the DPLP powder transport management
for Venturi or other systems. In future,
Verne Technology (ref. Opening photo).
Verne Technology designed a touch
systems managed by one portable
It represents an evolution of the NEA 430
screen control unit that, together with the
touch screen device, operating in Wi-Fi
system, launched on the market last year
NEA 415 software specifically designed
mode and, therefore, requiring no
and already described on this magazine*.
for the coating industry’s needs, forms a
cables.
This innovative DPLP transport system
complete digital control system for the
integrates perfectly with the existing
management of the powder delivery
EA 415 is the new dense phase, low pressure (DPLP) powder transport system developed by
this will be evolved into customisable modules with up to 32 NEA 415
The evolution of NEA 415
plants and application devices in the
Initially, NEA 430 was designed to
industrial coating sector. It ensures optimal management of all powder treatment stages, from recovery to feeding. The main features of the NEA 415 system are as follows: - 4-stroke operating cycle; - transport up to 600 pulsations/min; - powder collection up to 3 m; - powder transport from 10 to 35 m; - constant adjustment of the powder transport capacity from 0 to 400 g/min;
meet the needs for DPLP powder transport in the chemical and
NEA 415 is the new dense phase, low pressure (DPLP) powder transport system developed by Verne Technology. It represents an evolution of the NEA 430 system, launched on the market last year.”
pharmaceutical sectors: based on a pneumatic-mechanical operating principle, it operates without electricity. Its development, however, enabled Verne Technology’s staff to apply it also to the surface treatment industry, thanks to its cyclone’s powder recovery, its dust collector filter’s emptying, and its
- constant adjustment of the powder
powder management unit’s feeding
transport pressure from 0 to 5 bar;
characteristics. The NEA 415 system
- constant regulation of the feeding flow;
and recovery process (Fig. 1). The
was designed based on the results of
- no additional auxiliary air in the feeding unit;
hardware can be supplied separately to
NEA 430: it is completely electronic
- integrated powder flow inversion system;
provide electrostatic application system
and able to ensure consistent feeding
- product change in less than 30 sec.
manufacturers and plant engineers with
thanks to its 4-stroke operation,
the possibility to install NEA 415 and
powder transport up to 600
manage it with an already existing PLC or
pulsations/min, and constant control
circuit board, integrated or modified in
of the powder collection/ transport
the rack control module, be they designed
processes.
* C. Perillo, “NEA 430: an innovative pneumatic system for the low pressure, high density precision feeding of powders”, ipcm® International Paint&Coating Magazine no. 45 (May-June 2017), pages 68-71.
Opening photo: The new generation powder transport pump NEA 415.
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Powder collection and transport
The dense phase powder coating systems
Verne Technology’s software enables to
currently on the market normally operate
set and control the amount of powder
with 2-stage cycles. However, this concept
to be collected, its condensation, its
often causes critical issues due to feeding
transport within the tube, and the
discontinuity: the powder reaches the
type of application flow (Fig. 2). The
dispensing nozzle with an inconsistent
NEA 415 system uses tubes with an
flow. That is why these systems are often
internal diameter of 6 mm and it is
integrated with a “diffusor” near the gun to
able to collect powder up to 3 m and
pump continuous compressed air. Although
transport it for a length of 10 to 35
this partially helps stabilise the feeding flow,
m. Conventional Venturi systems, on
such solution inevitably causes the loss of most of the benefits of a real DPLP transport system. A 4-stroke system, on the other hand,
The NEA 415 system was designed based on the results of NEA 430: it is completely electronic and able to ensure consistent feeding thanks to its 4-stroke operation, powder transport up to 600 pulsations/ min, and constant control of the powder collection/ transport processes.”
© Verne Technology
The effectiveness of the 4-stroke cycle
and application processes of automatic application devices, where the high flow rate and
ensures the feeding consistency
air pressure used considerably
needed for uniform and homogeneous
increase the feeding flow
application. The 4 chambers of the
speed, with a consequent
pump body significantly reduce the
overspray risk.
powder collection and transport time
NEA 415 only exploits the low
(pulsation) compared with conventional
pressure pulsations within
2-stroke systems with the same
the transport tubes without
transport capacity/min, given the larger
the need for any auxiliary air
volume of the chamber to be filled.
supply. It can consistently
Moreover, thanks to the number of
feed minimum quantities
pulsations it can achieve (up to 600/
of powders thanks to the
min, almost twice as much as the dense
management of its parameters
phase devices now available), the NEA
with a decimal precision.
415 system stabilises the powder flow
At a distance of 20 m, the new
without the transport tube length
NEA 415 can feed up to
changing its performance. In fact,
400 gr/min, whereas a
transport tubes with variable lengths
conventional Venturi system
from 10 to 35 meters can be used.
delivers an inconsistent amount of powder. The advantages of DPLP application can therefore be
1
Verne Technology designed a touch screen control unit that, together with the NEA 415 software specifically designed for the coating industry’s needs, forms a complete digital control system for the management of the powder delivery and recovery process.”
156
summarised as follows:
Figure 1: The touch screen control unit designed by Verne Technology for the management of the powder delivery and recovery process.
- lower powder consumption; - shorter application time; - better quality results and more uniform coating
the other hand, require a continuous compressed air supply and, therefore,
application.
they use transport tubes with an
Flow management
internal diameter of at least 10 mm.
Besides managing the amounts of
Moreover, their limitations in terms
powder to be collected and applied,
of powder capacity and transport
the device enables to calibrate also
distance influence the management
the transport flow pressure, from 0 to
N. 50 - MARCH/APRIL 2018 - international PAINT&COATING magazine
INNOVATIONS: PRESENT&FUTURE
powder remains in
5 bar, with the same decimal precision. Verne Technology performed some tests by removing the gun’s delivery body, since the nozzle’s indentations could create friction during spraying (Fig. 3). The results showed that it is possible to reach an output of 400 gr/min
the delivery tube.
NEA 415 only exploits the low pressure pulsations within the transport tubes without the need for any auxiliary air supply. It can consistently feed minimum quantities of powders thanks to the management of its parameters with a decimal precision. At a distance of 20 m, the new NEA 415 can feed up to 400 gr/ min, whereas a conventional Venturi system delivers an inconsistent amount of powder.”
The most common solution is an empty feeding operation performed until the gun is completely clean. Verne, however, conceived a powder flow inversion system controlled with one key and able to return the powder
at a 20 m distance © Verne Technology
with a pressure of only 0.4 bar. With the integration of the dispenser, the
to its management unit or container, thus enabling to recover most of
pressure reaches the
it. This is a further
value of 1.1 bar.
contribution to
NEA 415 allows
reducing coating
therefore to maintain
costs for applicators.
the same transport
and reach a capacity
Quick colour change operations thanks to the cleaning process with a cyclonic valve
of 400 g/min, in order
The cyclonic valve,
to meet application
already integrated
needs that normally
into the NEA 430
call for a capacity 250
system, is based
g/min at most.
on a fluid-dynamic
pressure by modifying, when required, only the quantity of product to be fed. Indeed, it can deliver very small quantities of product
operating
The integrated powder flow inversion system For the recovery of powders, Verne Technology’s engineers have integrated a
principle. In the NEA 415 device, it was made even more efficient
2 1
with the reduction
Figure 2: A detail of the transport pump unit.
of the passage holes from 12 mm (NEA 430)
transport application widespread in the pharmaceutical and food
to 6 mm (NEA 415). This considerably increases
sectors. All current systems have a collection
the speed of the compressed air jet, allowing to
point A and an exit point B. If the powder
completely clean a NEA 415 system in less than
supply must be interrupted at the end of a
30 seconds, both in the pump body and in the
shift, it can occur that a certain amount of
transport tubes.
Š Verne Technology
3 1
Figure 3: The spray gun.
In conclusion, both the NEA 430 and NEA 415 systems can be integrated into new or existing application plants for the efficient management of the transport and delivery of powder coatings. They ensure the high flow transport of virgin coatings to and from the powder management unit,
Verne Technology operates in the field
Both the NEA 430 and NEA 415 systems can be integrated into new or existing application plants for the efficient management of the transport and delivery of powder coatings.â&#x20AC;?
of high density, low pressure transport of powders, granules and polymers. It designs and manufactures high-tech transport systems ensuring remarkably higher performance levels compared with the other similar products currently available on the market. The company
the cyclone powder recovery unit, and
is the exclusive owner of international
the dust collector emptying device,
patent applications (PCT) currently not
as well as the smooth feeding and
yet public and therefore not accessible to
application of powder through the
third parties.
coating guns. As mentioned, they both use the dense phase, low pressure (DPLP) technology.
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SPECIAL
BRAND-NEW
A
new mass finishing system completely
thus, the overall efficiency, fuel consumption
eliminates manual operations.
and noise emissions.
For the efficient surface finishing of
To date the surface finishing of blisks was done manually with grinding disks and
and land-based turbines, Walther Trowal
other manually operated tools. Due to
has redesigned its “CM” vibratory system.
the “human factor” the quality of the final
It ensures that the work pieces receive a
finish could greatly vary between work
uniform, homogeneous high quality finish with
pieces. Frequently, it could even happen
absolutely repeatable results.
that certain surface areas were not
The surface finish of blisks (“Blade Integrated
finished at all.
Disks”) in airplane and other turbines affects to
For the consistent and high quality
a large extent the airflow characteristics and,
finishing of circular high value components
© Walther Trowal
high value work pieces like blisks for airplane
© Walther Trowal
Surface Finishing of Components for the Aerospace Industry: Walther Trowal Cuts Processing Times for Finishing of Blisks From Several Days to A Few Hours
2 1
Figure 2: In the “CM” rotary vibrator work pieces with a diameter of up to 980 mm can be processed. During the finishing process itself the work bowl is covered with a noise absorbing lid.
Walther Trowal redesigned the rotary vibrator “CM” in close cooperation with leading turbine manufacturers to make it more suitable for treating all kinds of turbine components (Fig. 1). The “CM” system allows deburring and general surface improvement of components with diameters of up to 980 mm (Fig. 2). Single work pieces are mounted to the
1
inner dome of the processing bowl.
Figure 1: The work bowl of the “CM” rotary vibrator. The shown work piece is a dummy.
160
N. 50 - MARCH/APRIL 2018 - international PAINT&COATING magazine
The height of the inner dome itself has
SPECIAL
© Walther Trowal
BRAND-NEW
3 1
Figure 3: With a diameter of just 1,450 mm the compact rotary vibrator easily fits into any manufacturing environment.
been drastically shortened (Fig. 3). After grinding media has been filled into the bowl, a vibratory motor causes the complete work bowl to vibrate. This causes a constant “rubbing” of the media against the fixed work piece. Since the “rubbing” action is highly homogeneous, a uniform, even finish on all surface areas of the disk and blades is achieved. After completion of the process the surface roughness readings amount to Ra = 0.2 to 0.4 μm. Starting with an initial surface roughness of Ra = 4 to 5 μm, the desired finishing results are achieved within about five to six hours. Compared to this innovative method the manual finishing of blisks can take several days. Christoph Cruse, sales manager at Walther Trowal, is commenting on the special conditions prevailing in the aerospace industry: “Especially for the production of turbine components any manual manufacturing operations must be viewed with great skepticism, because the quality of the work will vary greatly. With our new finishing machine, we have completely eliminated the vagaries of the human factor. And, we can reduce the finishing times for blisks from several days to just a few hours”. For finishing of blisks Walther Trowal is recommending the special finishing media, type V 2030. This media produces very smooth surface finishes on materials and shapes, which are typical for blisks. Of course, the V 2030 media is globally approved for the aerospace industry. For further information: www.walther-trowal.com
international PAINT&COATING magazine - MARCH/APRIL 2018 - N. 50
161
SPECIAL
BRAND-NEW
Flexible High-Performance Coating Plant for Aluminium Wheels
S
uperAlloy Manufaktur GmbH
is automatically adapted to suit the
wheels from the pre-treatment line and
in Lossburg has put one of the
downstream process. Pre-heating
supplies them directly to the individual
most flexible coating plants in the
temperatures and cooling sections are
coating areas. The plant concept still
wheel industry into operation (Fig. 1).
also individually adaptable. Thanks to the
has further potential for future coating
The wheel-coating plant makes a
high level of automation, SuperAlloy can
variants, coating patterns and special
large number of coating processes
track the wheels precisely and thus carry
coatings.
possible and is thus equipped not only
out detailed quality assurance checks.
for the present-day requirements of
A special distribution conveyor ensures
For further information:
the market, but also for those of the
the plantâ&#x20AC;&#x2122;s high flexibility. It fetches the
www.rippert.de
forged aluminium wheels coated at SuperAlloy
Š Rippert
future, too. The
Manufaktur GmbH are destined for exclusive car manufacturers in Europe. The goal of achieving maximum flexibility through a high level of automation of the conveying equipment and robots was implemented perfectly. The flexibility of the wheel plant necessitates the exact definition and planning of the flow of material in order to achieve an optimum mode of operation. To this end, SuperAlloy creates a coating plan each day. The pre-treatment
162
1
Figure 1: SuperAlloy Manufaktur GmbH in Lossburg has put one of the most flexible coating plants in the wheel industry into operation.
N. 50 - MARCH/APRIL 2018 - international PAINT&COATING magazine
SPECIAL
BRAND-NEW
T
© Freilacke
FREOPUR Polyurea Gel Coats in Series Production he new FreiLacke gel coat based on an aliphatic polyurea system allows a reduction of the coating thickness
in comparison to conventional polyester gel coats. A further advantage is its exceptional UV resistance. The advantages are obvious and they are now being implemented in series production at Liebherr/Lienz (Fig. 1) and Aquaproduction
SAS in France (Fig. 2), amongst others. Due to the very short curing time, very short cycle times can also be achieved during component manufacturing. The application of such materials takes place using 2C highpressure coating lines and special moulds. An investment in production processes, coating line technology and mould construction is therefore required. However, by applying the coating system as a liquid component, additional interesting possibilities can be implemented. In both
Figure 2: Polyurea gel coats for the production of shower trays at Aquaproduction SAS in France.
© Freilacke
cases, the process is implemented specifically
2 1
due to its versatility with regard to design, the profitability of the production process as well as the variety of colour shades. The combinations and possibilities of composites are endless and, due to their outstanding properties, their range of application is enormous. Thanks to FreiLacke’s many years of experience in the area of Durelastic, the results can be used during the development of new application solutions. Many other interesting applications are possible and are pursued intensively in the Sales and Development departments. More system coatings and application-solutions from on source: PaintExpo hall 1, booth 1420.
1
Figure 1: Use for freezers at Liebherr/Lienz.
For further information: www.freilacke.com
international PAINT&COATING magazine - MARCH/APRIL 2018 - N. 50
163
© ipcm ®
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INNOVATIONS: PRESENT&FUTURE
NitroBoxSpray® Revolutionises the Nitrogen Coating Concept: Better Performance at Low Costs Both In-House and On Site Ottavio Milli Eurosider, Grosseto, Italy
info@eurosider.com
E
urosider, an Italian company
amount of nitrogen necessary for the
Benefits of NitroBoxSpray®
based in Grosseto, designs
consumption required by spray guns.
- Overspray reduction;
and builds coating systems
This helps eliminate any pressure
- better spreading of the film applied;
using nitrogen as the paint carrier
drops due to the disparity in the
- improved performance and,
instead of compressed air. This
production of nitrogen compared
therefore, coating results;
ensures greater effectiveness
with the actual application needs.
and better application yield for
Thanks to a Eurosider patent,
- reduction of the spray paint booth’s maintenance and cleaning times;
any type of coating system. For
- reduction of investment
several years now, Eurosider has
costs;
been providing the market with its devices NitroThermSpray® (Fig. 1), internationally patented and suitable for feeding liquid coatings, and Polifluid®, designed for thermosetting powder coatings (Fig. 2) and already described on the ipcm® magazine. The latest innovation developed by Eurosider is the NitroBoxSpray
®
system (ref. Opening photo), which represents the technological evolution of NitroThermSpray®. This compact and economical nitrogen production machine is
- reduction of coating
Eurosider, an Italian company based in Grosseto, designs and builds coating systems using nitrogen as the paint carrier instead of compressed air. This ensures greater effectiveness and better application yield for any type of coating system. For several years now, Eurosider has been providing the market with its devices NitroThermSpray®, internationally patented and suitable for feeding liquid coatings, and Polifluid®, designed for thermosetting powder coatings.”
consumption by 20 to 50%.
Overspray reduction At any given pressure, compressed air moves at a velocity of nitrogen of 7.2 m per second, while nitrogen at 13.7 m per second, i.e. almost double. This results in a lower pushing pressure, so much so that the pressure values are halved in the atomisation phase. This,
installed between the compressor
in turn, greatly reduces
and the coating application point and it can be integrated directly
the absence of tanks simplifies
overspray and, therefore, any risk
into the spray paint booth or
the management, control, and
of contamination of the coated
placed in its vicinity, depending
maintenance of this system, thus
surface due to paint rebound
on the space available. One of the
making it particularly suitable for
and of any coating emission. It
most innovative characteristics of
robotised coating lines such as, for
also facilitates the maintenance
this new system is the absence of
example, cupboard door coating flat
and cleaning operations of the
tanks, since it produces the exact
lines.
booths.
Opening photo: The new NitroBoxSpray® system designed by Eurosider.
international PAINT&COATING magazine - MARCH/APRIL 2018 - N. 50
165
© ipcm ®
Thanks to a Eurosider patent, the absence of tanks simplifies the management, control, and maintenance of this system, thus making it particularly suitable for robotised coating lines such as, for example, cupboard door coating flat lines.”
Better spreading of the film applied Used to transport paint, compressed air can create charges within the coating layer that can compromise its spreading quality and uniformity. Used as a carrier, nitrogen prevents this from happening. An additional advantage is the elimination of micro bubbles formed on surfaces due to the impact of the air with the relative humidity present on the substrate. With varying temperatures, this can cause spreading problems that, on the other hand, are eliminated by nitrogen, which ensures better adhesion and greater durability of coatings. NitroBoxSpray® also enables to adjust the temperature of nitrogen and, therefore, of the coating itself, thus increasing or decreasing its density. Nitrogen is kept at a constant temperature and it ensures that also the paint maintains consistent thermal conditions, regardless of the external temperature. With automatic coating systems, keeping the viscosity parameter constant also ensures consistent and uniform film thicknesses.
166
1
Figure 1: The NitroThermSpray® device, suitable for the application of liquid coatings.
N. 50 - MARCH/APRIL 2018 - international PAINT&COATING magazine
INNOVATIONS: PRESENT&FUTURE
The evolution of the membrane technology NitroThermSpray® is based on the membrane separation technology: it exploits the selective permeability of membranes made of hollow fibre polymers to separate gaseous nitrogen from air. In order to design the new NitroBoxSpray® system, the R&D centre has developed a membrane project that is now one of the numerous Eurosider patents: the new device is equipped with membranes able to guarantee a fibre service life of 20 years. The second significant advantage of the new system is an airnitrogen ratio equal to 2 (i.e. 2 m3 of air needed to produce 1 Nm3 of nitrogen), compared with the previous device with a ratio of 4. This evolution is the result of the greater efficiency of membranes, which separate a higher quantity of nitrogen in relation to the guns’ consumption and therefore do not require any tank.
Further advantages of NitroBoxSpray® Eurosider has also considered the outdoor application needs of construction sites, shipyards, refineries, pipeline maintenance specialists, and so on. That is why it has equipped NitroBoxSpray® with wheels for moving a fully-equipped machine in any place, making the application operations easier even in the most severe and harsh conditions. Another benefit is the possibility of working with hot nitrogen, which reduces the coating drying time by 50%. If high thicknesses are applied, it also reduces
NitroBoxSpray® enables to adjust the temperature of nitrogen and, therefore, of the coating itself, thus increasing or decreasing its density. Nitrogen is kept at a constant temperature and it ensures that also the paint maintains consistent thermal conditions, regardless of the external temperature. With automatic coating systems, keeping the viscosity parameter constant also ensures consistent and uniform film thicknesses.”
© ipcm ®
Eurosider has also considered the outdoor application needs of construction sites, shipyards, refineries, pipeline maintenance specialists, and so on. That is why it has equipped NitroBoxSpray® with wheels for moving a fully-equipped machine in any place, making the application operations easier even in the most severe and harsh conditions.”
Reduction of investment costs As mentioned, NitroBoxSpray® represents the evolution of the nitrogen production plant concept originally developed with NitroThermSpray®. Compared to the latter, the former is smaller, it is set up to produce the exact amount of nitrogen required by one or two spray guns, and it is much more economical. It has been designed for installation in medium and small companies
2 1
that cannot make large investments,
Figure 2: Polifluid by Eurosider optimizes powder feeding during application with the use of nitrogen.
operating in the most diverse sectors: automotive, general industry, aerospace, nautical, architecture, interior design, etc. – that is, wherever there is a need for coating operations.
dripping and the orange peel effect, thus
coating gun or robot. The peculiarities
becoming ideal for coating the walls of
of thermo-conditioned tubes ensure
ships and bridges.
constant temperatures and therefore
Safety regulations
The NitroBoxSpray device can be
consistent paint viscosity when the
Eurosider produces in compliance
connected to hoses with a maximum
environmental temperature varies. This
with all safety regulations and their
length of 30 m, patented for the transport
system is Atex certified and patented in
evolution, in particular those related to
of ionised nitrogen from the plant to the
Europe.
the ISO 13849-1 standard.
®
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+2.222%
© Cabycal
Opening photo: Diseños Y Decorados Ceramicos SL (Navalcarnero, Spain) specialises in the artistic decoration of ceramic and glass objects.
FOCUS ON TECHNOLOGY
A New Automatic Coating Line to Increase the Production Capacity of a Glass Objects’ Manufacturer: the Positive Result of the Industry Teaming Up with Craftsmanship Barbara Pennati ipcm®
I
some companies have chosen to employ technologically advanced
“Much of Diseños Y Decorados Ceramicos’ work is still done manually,
processes while maintaining an essentially artisanal approach. These
including loading and unloading. We believe in the importance of our
include Diseños Y Decorados Ceramicos SL (Navalcarnero, Spain),
operators’ control of all production phases,” explains general manager
n most industrial sectors, the general trend of the last few years has
established in 1946. Now managed by the third generation of the
been to automate processes as much as possible by implementing
Nogales family, the company has 62 employees and specialises in the
increasingly Industry 4.0-oriented advanced technologies. However,
170
N. 50 - MARCH/APRIL 2018 - international PAINT&COATING magazine
artistic decoration of ceramic and glass objects (ref. Opening photo).
FOCUS ON TECHNOLOGY
© ipcm ®
Figure 1: Diseños Y Decorados Ceramicos’ products require mostly manual and artisanal operations.
higher production rates. It became necessary to install a second automatic coating line, which now operates together with the first one,
1
installed eight years ago and also supplied
Cristina Nogales. Although the company philosophy and the peculiarities of Diseños Y
by Cabycal,” says Cristina. The new coating line is
Decorados Ceramicos’ products call for mostly
7.5 m long and it is equipped with a 45 m
© ipcm ®
manual operations, especially due to
Diseños Y Decorados Ceramicos deals, above all, with the artistic decoration of porcelain and glass products for the hotel, cosmetic, and promotional sectors. Precisely their intention to conquer the latter led the company to install a new coating line that could increase the productivity. That is why they turned to Cabycal, a Valencia-based company specialising in the construction of industrial coating systems.”
the artistic meticulousness required, the firm equipped itself with a new coating
“The second line is symmetrical to
plant that combines high-performance
the first one. The only change made
technology with craftsmanship (Fig. 1).
was the replacement of the old line’s
“We deal above all with the artistic
conveyor with the type used for the
decoration of porcelain and glass
new one, in order to achieve the same
products for the hotel, cosmetic, and
production level and the same timing
promotional sectors. Precisely our
on both plants,” states Cabycal’s
intention to conquer the latter led
project engineer Sergio Mateo. “The
us to install a new coating line that could increase our productivity,” states Cristina. “That is why we turned to Cabycal, a Valencia-based company
system is equipped with two coating
2 1
booths featuring only Atex-certified
Figure 2: Glasses are decorated by silk-screen printing or automatic liquid coating.
components; the first one has three guns and the second one two (Fig. 4). They are followed by a polymerisation
specialising in the construction of industrial coating systems with which we had
long SPINDLE type conveyor featuring 392
oven with a natural gas supply and an air-vein
already collaborated.”
pinion spindles and with a motorised rotator
burner that maintains a temperature of 200 °C
to ensure that all
“At the beginning, we mainly decorated
surfaces are covered.
ceramics for the contract sector. Over time, we
The chamber’s
have expanded to other industries, such as the
pre-filtration system
cosmetic and promotional (product branding)
ensures that the
ones, and we started decorating also glass
coating application
by silk-screen printing or automatic liquid
takes place in the best
coating (Fig. 2),” states Cristina from Diseños
cleanliness conditions
Y Decorados Ceramicos SL. “This choice has
(Fig. 3).
© Cabycal
The new coating line
in the chamber
enabled us not only to offer both standard and customised decoration options, but also to establish ourselves in the European and Eastern markets, for example in India.” “However, the promotional sector required
Figure 3: Cabycal’s new coating line with a SPINDLE type conveyor.
3 1
international PAINT&COATING magazine - MARCH/APRIL 2018 - N. 50
171
© Cabycal
4 1
Figure 4: The automatic application of liquid coatings provided by Pinturas Benicarlò (Grupo Ferro SL).
The coatings applied
Conclusions
are water-based two-
“Glass requires a lot of attention during
component products
application, mainly due to adhesion issues.
specifically formulated for
It is always necessary to make a correct
glass. “Our cycle includes
assessment of the quantity of product to be
a curing stage at 200 °C
applied and of the right curing temperature.
for about 20 minutes. We
A more limited range of colours can be used
use coatings supplied by
on glass than on porcelain, and some of
Pinturas Benicarlò (Grupo
them, such as gold and silver, require a very
Ferro SL). Although they are
precise manual decorative process,” explains
more difficult to apply than
Cristina. “Although glass is a difficult-to-treat
the solvent-based ones, we
material requiring artisanal skills, the adoption
chose to use water-based
of a flexible and robust advanced system
paints for environmental
that can work uninterruptedly and integrates
reasons and for better
perfectly with our manual processes proved
waste management,” states
to be the optimal solution for us.”
for 20 minutes. Dry filtration systems with
Cristina. “We also ran some tests, which showed
“We relied on Cabycal because we already
the Edrizzi technology have been installed
that the products treated with these coatings
knew their know-how and product quality
in the booths for overspray collection and
and polymerised with the cycle chosen by us can
level. In terms of capacity at the exit of the
®
environmental protection purposes (Fig. 5).”
withstand up to 500 washes.”
ovens, the new line, which is managed by
Diseños Y Decorados Ceramicos can therefore
“We use organic colours available in different
one operator, enables us to decorate and
count on four decoration lines, of which two
shades. We usually apply more than one layer,
coat around 80,000 products a day.
devoted to the automatic coating of glass
depending on the required effect. For one of
This investment has allowed us not only
products, one for porcelain, and a manual
our treatments, for instance, we coat the inside
to increase production and establish
silk-screen printing one, and on four ovens, of
of a glass with an aluminium-effect coating and
ourselves in the promotional sector, which
which three for glass and one for porcelain.
the outside with more evocative colours, such as
was our goal, but also to spread Diseños
The glass processing performed requires a
pink or light blue; if you look inside it, it feels like
Y Decorados Ceramicos’ craftsmanship to
pre-treatment stage that is usually entrusted to
you are drinking from an aluminium object, but it
a variety of sectors and markets,” states
manufacturers. “We receive already treated and
is actually glass,” says Cristina.
Cristina Nogales. © ipcm ®
cleaned parts. Only in some cases, when we notice that the paint has not adhered perfectly, we perform a glass annealing process from 450 to 600 °C, depending on the product,” says Cristina.
The new coating line is 7.5 m long and it is equipped with a 45 m long SPINDLE type conveyor featuring 392 pinion spindles and with a motorised rotator in the chamber to ensure that all surfaces are covered. The chamber’s prefiltration system ensures that the coating application takes place in the best cleanliness conditions.”
172
5 1
Figure 5: The line is equipped with dry filtration systems with the Edrizzi® technology.
N. 50 - MARCH/APRIL 2018 - international PAINT&COATING magazine
SPECIAL
BRAND-NEW
PPG Brings 2,500 Colours to Customer Fingertips © Colorware USA
P
PG is introducing the MeasureColor Mobile™ tool, an innovative and accurate colour
customers the freedom to work with experienced PPG representatives to compare colour standards and choose
platform that combines a colour-
the best colours for their specific job.
matching app with a handheld scanning
The mobile tool reflects PPG’s long-
device to immediately identify colour
standing commitment to customer
matches (Fig. 1). Within seconds, the
service and underscores its pledge
technology links customers to more
to provide customers with innovative
than 2,500 commonly specified colours
coatings solutions that meet specific
in PPG’s industrial powder coatings
customer needs.
colour library within ΔE 0.5.
Through MeasureColor Mobile, PPG’s
The easy-to-use device is about the
customers now have a fast and accurate
same size as a flashlight battery.
way to keep their colour-matching
Customers can place it on nearly any
projects moving ahead.
surface to begin the colour-matching process, including metal, plastic, wood
1
and even soft surfaces (Fig. 2). Within seconds, the device interprets
Figure 1: PPG is introducing the MeasureColor Mobile™ tool, a colour platform that combines a colour-matching app with a handheld scanning device to identify colour matches.
the colour data, calculates any colour differences and then, through the PPG MeasureColor Mobile app, sends an smartphone or tablet. This technology is cloud-based, eliminating costly and time-intensive
© Colorware USA
accurate PPG colour match to the user’s
lab work. But the device does more than match colours. It also provides customers with important ordering information, such as the colour name, product code, gloss range, resin chemistry, and if the product is made to stock based on the customer’s location. As a result, customers can order the PPG powder coatings they need right on the spot, saving them time and money. In addition, the search results give PPG
Figure 2: Customers can place it on nearly any surface to begin the colour-matching process, including metal, plastic, wood and even soft surfaces.
174
2 1
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MeasureColor Mobile and the MeasureColor Logo are trademarks of Colorware USA, Inc.
For further information: www.ppg.com www.measurecolormobile.com
SPECIAL
BRAND-NEW
Two Further Shareholders: IIoT Platform ADAMOS is Growing
T
he joint venture for the open digital
way, we are advancing with our customers in
providing the interface with the machinery
IIoT platform ADAMOS (ADAptive
the digital world with great momentum.”
operators are developed using ADAMOS as a
Manufacturing Open Solutions) has
With sales revenues of EUR 1.36 billion,
basis (Fig. 1).
Engel Austria is one of the leading plastics
Austria GmbH and the KARL MAYER Group.
processing machine manufacturers and
The Dürr Group offers two digital marketplaces
This strategic alliance for the Industrial
the global market leader in injection-mold
LOXEO (for Dürr and Schenk customers) and
Internet of Things (IIoT) was established by
equipment. KARL MAYER is an innovative
tapio (for HOMAG customers). Using LOXEO
Dürr, DMG MORI, Software AG, ZEISS and ASM
market leader in textile machine building
and tapio, plant operators can evaluate data,
PT and is available around the world with 200
and offers solutions for warp knitting and
map their production activities digitally and
experts.
warp preparation for weaving as well as for
purchase digital services and apps, e.g. for
Ralf W. Dieter, CEO of Dürr AG: “With the
technical textiles.
predictive maintenance, adaptive production
accession of these two new mechanical
All seven companies are contributing
planning or the management of operating
engineering companies, we are making further
extensive industry knowledge and innovative
materials. This helps to optimize production
progress in our efforts to establish ADAMOS
IT expertise to ADAMOS. The IIoT platform
and maintenance.
as an industry standard. Together, we have
is comparable to the operating system of
an installed base of several hundreds of
a computer and collects large volumes
For further information:
thousands of machines and systems. In this
of production data. Digital marketplaces
www.durr.com
© Dürr AG
gained two additional shareholders: Engel
1
Figure 1: The structure of ADAMOS platform.
international PAINT&COATING magazine - MARCH/APRIL 2018 - N. 50
175
SPECIAL
BRAND-NEW
New Coating Solutions: Standard Frames
A
ssuming that it is possible to
This new hanging system features a
dimensions, such as handle height,
improve a company’s operations
central supporting pole, called “column”,
hanging height, and hook distance and
through smart hanging and
number.
called “comb” (Fig. 1). There are two
The columns are combined with
working in the sector since 1990, has
types of columns, very similar to each
standard crossbeams, already in
always been committed to providing
other but differing in their robustness:
stock or customisable on request.
coating users with innovative and
the light version P20 is suitable for use
Any type of comb can be integrated,
versatile solutions. At the PaintExpo 2018
in small plants (up to 2 metres in height),
from simple rods with welded slings to
exhibition (Hall 2, booth 2520), the firm
whereas the P25 version is ideal when the
sheet bars with clips, or even complex
will present a preview of its new range
coating height exceeds 2 metres and the
hanging systems for special structures.
of modular frames, a solution conceived,
size and volume of parts call for a robust
All components used have been
field-tested, and improved over the years.
frame. Both versions can have custom
standardised. This ensures significantly
© Colorware
and a horizontal bar with welded hooks,
masking operations, Rostirolla S.r.l,
1
Figure 1: The hanging system features a central supporting pole, called “column”, and a horizontal bar with welded hooks, called “comb”.
176
N. 50 - MARCH/APRIL 2018 - international PAINT&COATING magazine
SPECIAL
shorter delivery times and streamlines the design and
Š Rostirolla
BRAND-NEW
difficult to store on pallets. However, columns and combs
sampling phases. Moreover,
can be disassembled, placed
since the components are
in small baskets, and stored on
already in stock, the costs for
shelves (Fig. 3). Stripping costs
small quantities are also greatly
are also significantly reduced
reduced (Fig. 2).
because it is possible to strip
The joint between the comb
the comb only, whereas the
and the column has been
column can be used for many
specially designed so that each
more coating cycles (a few
part remains clean despite the
users have gone beyond 100
numerous layers of paint that
cycles). Also in this case, the
accumulate cycle after cycle. The
reduced storage volumes help
system has already been tested
lower transport costs when
by numerous coaters and coating
paint stripping is entrusted to
contractors. The number of cycles
external companies. Since it
guaranteed before the parts are
has built special moulds and it
glued depends on many factors,
produces all components in-
first of all the customersâ&#x20AC;&#x2122; needs,
house, Rostirolla has managed
but in some cases several tens
to reduce its production costs,
of processing cycles have been
thus making these frames
achieved. A further advantage of this hanging system is perceived during storage. Welded frames
economical product.
Figure 2: All components have been standardised to ensure significantly shorter delivery times and streamlines the design and sampling phases.
For further information: www.rostirolla.it Š Rostirolla
are notoriously voluminous and
a versatile, universal and 2 1
3 1
Figure 3: Stripped and stored combs.
international PAINT&COATING magazine - MARCH/APRIL 2018 - N. 50
177
SPECIAL
BRAND-NEW
Paintexpo: Eisenmann Presents Innovative Solutions for the Paint Shop of the Future
F
Efficient atomizer technology, innovative paint
mm, which enable precise adaptation to the
in Karlsruhe, Germany, the painting
supply solutions and modular high-pressure
workpiece, are also retained. The VarioBell v.3 is
system specialist Eisenmann will be
pumps for the supply of materials are shown
supplemented by an integrated mixer.
presented under the motto “Paint Shop
by Eisenmann, as well as the possibility of
This reduces the curing distance and simplifies
4.0. Digital – smart – efficient”. The focus is
achieving improved quality management in
the rinsing process.
on developments for application and plant
the coating process by means of a thermal
At PaintExpo, Eisenmann presents itself as
technology for surface treatment in various
imaging camera. In addition to the well-
an experienced system supplier offering
industries.
established VarioBell v.2 high-rotation
comprehensive solutions and services in all
In hall 1, booth 1220, Eisenmann presents
atomizer, which can be used for all component
areas of surface treatment. The portfolio ranges
its “Smart & Digital Solutions” for the Paint
requirements – from complex cavities and
far beyond high-quality coating and painting
Shop of the future. One of the highlights
undercuts to wide surface coatings - due
systems: from reliable and flexible conveyor
is the new era of the E-MES production
to its compact design, the newly developed
technology such as Moveable Hoist and
management system, which allows for
VarioBell v.3 opens up further possibilities
heavy-duty Power & Free, to the uncomplicated
consistent plant transparency and forward-
(Fig. 1). Combined with the dosing and
paint separation system E-Cube, to
looking intelligence in the paint shop. In
potential separation system VarioCharger,
comprehensive service and operator models.
addition, the spotlight will also be on “Smart
it enables the application of 2-component
Eisenmann at PaintExpo 2018 in Karlsruhe,
Engineering & Service Solutions”, such as
water-based varnish under high voltage.
Germany: Hall 1, Booth 1220.
the E-PASS VCI, which enables virtual plant
Direct charging at the atomizer tip leads to
commissioning on the Digital Twin. Remote
significantly higher application efficiency.
For further information:
support solutions will also be discussed.
The variable spray jet widths from 50 to 350
www.eisenmann.com
© Eisenmann
rom April 17 to 20 at PaintExpo 2018
Figure 1: VarioBell v.3 from Eisenmann enables the application of 2-component water-based coatings under high voltage.
1
178
N. 50 - MARCH/APRIL 2018 - international PAINT&COATING magazine
SPECIAL
BRAND-NEW
T
he German manufacturer Jürgen Emptmeyer GmbH, expert for
© ?????????W
Emptmeyer Launches New Products and Presents its Custom Made Solutions hanging and masking solutions for
industrial coating, presents its custom made solutions to the public during the PaintExpo (Fig. 1). Reliable hanging solutions, broad expertise and quick developments are of top priority when Jürgen Emptmeyer GmbH is involved in any project. Thereby the company makes sure to offer its customers the most efficient solution for each individual requirements. For further information: www.emptmeyer.de
1
Figure 1: Jürgen Emptmeyer GmbH will present its custom made solutions at PaintExpo.
New Back-Pressure Regulator
T
he new 3:1 back-pressure regulator “TimECO” (Fig. 1) was developed for the paint industry. Since the consumption rates of the paint spray guns are not constant in time, undesired pressure
fluctuations in the ring circuit system are possible. Back-pressure regulators (BPR) are intended to solve this problem. © Timmer GmbH
This is achieved through automatic control of the flow cross-section by the pneumatic BPR. Strong shear stresses in conventional BPRs that can damage the paint are well known. In the new BPR, the fluid is guided in a straight line so that dangerous shear stresses are hardly possible. To this effect, an innovative double diaphragm system was developed. The maximum flow defined by the manufacturer is 40 l/min, whereby the fluid pressure must not exceed 25 bar.
1
For further information: www.timmer-pumps.com
Figure 1: Back-pressure regulator from Timmer GmbH.
international PAINT&COATING magazine - MARCH/APRIL 2018 - N. 50
179
SPECIAL
BRAND-NEW
Deurotech Group Acquires Majority Stake in Exhaust Air Specialist Airprotech Srl
W
its market position in the field of exhaust
Wessel-Umwelttechnik, striving to
2018, Deurotech Group
air purification (Fig. 1) and decisively
promote the strategic expansion of the
acquires a majority stake in the
expands its portfolio in the field of
product sector exhaust air purification -
Italian exhaust air specialist Airprotech
environmental technologies.
in particular the biological and thermal
Srl, located in Magenta, Italy. The founding
The investment in Airprotech
exhaust air purification processes. In
Family Gatti remains with a minority stake.
complements the already existing
addition to innovative technologies and
With this decision, the group strengthens
product program of their subsidiary
qualified personnel, positive synergies
Š Airprotech
ith effect from February 8th,
1
Figure 1: A plant by Airprotech.
180
N. 50 - MARCH/APRIL 2018 - international PAINT&COATING magazine
SPECIAL
BRAND-NEW
in procurement, R & D as well as in
Wessel-Umwelttechnik offer coordinated
Wessel-Umwelttechnik is a
customer service are expected.
process technology in surface converting
professional partner in all questions
Airprotech and Wessel-Umwelttechnik
from a single source: impregnation
of exhaust air purification and heat
have a high level of know-how
and coating lines, systems for resin
recovery. The company provides
and innovation potential, which
preparation as well as exhaust air
turn-key installations for various
offer opportunities with regard to
purification and energy recovery.
environmental tasks. An extensive product range allows tailor-made system
diversification and global growth. In the light of these market opportunities,
Airprotech is a leading company
technology. In addition to cost-effective
the acquisition of Airprotech is a first
specialized in designing, manufacturing
delivery and installation, the company´s
step for a further significant expansion
in its own facilities and supplying
main focus is on optimal economic
of the business unit environmental
turn-key plants for the purification
operation of the system.
technologies.
of polluted gas emissions, based on
Airprotech´s proven management team
reliable and modern technologies,
For further information:
as well as the location remain the same.
deriving from more than 25 years of
www.airprotech.eu
experience applied to different product Deurotech Group is a group of
sectors. International customers
businesses specializing in the wood-
from the chemical, pharmaceutical,
based panels and paper industry.
petrochemical, print, paint industry and
The machinery and plant engineers
many other fields are supplied with
Vits Technology, IFA Technology and
custom-designed turn-key solutions.
9 - 13/10/2018 Macchine utensili a asportazione e deformazione, robot, automazione, digital manufacturing, tecnologie ausiliarie, tecnologie abilitanti. Metal cutting and metal forming machines, robots, automation, digital manufacturing, auxiliary technologies, enabling technologies.
THE DIGITAL ERA OF MACHINE TOOLS bimu.it
UCIMU-SISTEMI PER PRODURRE
BRAND-NEW
The Combination of a Self-Healing Polymer and Graphene Oxide Could Be the Future of Scratch Resistant Coatings combines a soft, self-healing polymer with a tough layer of
graphene oxide could one day form the
Figure 1: A bio-inspired material that combines a selfhealing polymer with a layer of graphene oxide could form the basis of scratch resistant coatings.
18percentgrey © Fotolia
A
bio-inspired material that
basis of new, ultra-tough scratch resistant coatings (Fig. 1). The researchers who developed the material say it combines the best properties of skin – which can heal itself from the inside out – with tooth enamel, which is hard but cannot self-repair (Fig. 2). ‘For a material to self-heal, it generally needs to be a highly dynamic polymer
1
network,’ says Ming Yang from Harbin Institute of Technology in China. ‘Unfortunately, this also means self-
When tested in isolation, neither layer on its
to initiate the healing process. This may be
healing coatings are typically made of soft
own was able to fully recover after scratching.
acceptable for indoor use but is unwanted
materials.’
But when the soft polymer and graphene
for outdoor applications or for electronic
Their material does feature a soft self-
oxide sheets were integrated correctly, the
devices,’ Yang explains. He adds that the
healing layer, a mixture of tannic acid
resulting skin-like hybrid could self-heal.
group are also working on versions of the
and polyvinylalcohol (PVA) which form
Yang suggests the material could be
coating that self-heal in response to light or
a dynamic hydrogen-bonded network.
used to make anti-scratch coatings or
heat.
But this is reinforced by an outer PVA
even coatings for medical devices, as the
Wayne Hayes, a polymer chemist at the
layer containing nanosheets of graphene
components are biocompatible. But there
University of Reading in the UK, says the
oxide – a tough material that gives greater
are still hurdles to overcome. ‘The current
use of relatively low-cost components such
scratch resistance. This is similar, Yang
coating system uses water as a stimulus
as PVA is ‘very impressive’. ‘It’s the way this material is processed, the
where hardened outer cells protect the
careful layer-by-layer assembly
soft, living tissue beneath, which can repair damage. ‘The more dynamic sublayer provides additional polymers to the top layer, while
© American Chemical Society
says, to the structure of the skin epidermis,
approach,’ he says. ‘What will be interesting to see is how well they can actually use this method to produce very precise structures. I think that
the top hard layer behaves like a barrier to trap these diffusing polymers,’ he says. ‘Graphene oxide is, however, much harder than the plate-like cells in skin, so we get the hard surface.’
182
2 1
Figure 2: Scanning electron microscopy images of the hierarchical coating (right) shows that it mimics the structure of human skin (left).
N. 50 - MARCH/APRIL 2018 - international PAINT&COATING magazine
will be the next challenge.’ For further information: www.chemistryworld.com
BRAND-NEW
Cabycal Provides Gestamp with an Automated Passivation Plant for Aluminium Parts
C
abycal has designed, built and
inside a recirculating convection oven
installed a passivation system
heated with a gas burner. The parts are
for aluminium components for
handled by three automatic bridge cranes,
Gestamp’s plant of Newton Aycliffe (UK –
a Power & Free conveyor, and two transfer
Fig. 1). The installation started at the end of
systems that move the workpieces from the
2017 and the plant will become operational
conveyor to a bridge crane and vice versa.
in the coming weeks.
Cabycal had already supplied Gestamp with
The workpiece pre-treatment is carried out
three cataphoresis plants for its production
in nine tanks with the following process:
sites in Zaragoza (Spain), Wroclaw (Poland),
degreasing, rinsing with industrial water, acid
and Chattanooga (USA).
bath for the passivation phase, and rinsing with demineralised water. After immersion
For further information:
in the tanks, automatic drying takes place
www.cabycal.com
1
Figure 1: The passivation system for aluminium components built by Cabycal for Gestamp’s plant of Newton Aycliffe (UK).
300 scenari per superfici perfette. SurfaceTechnology GERMANY 5 – 7 giugno 2018 Stoccarda ▪ Germania surface-technology-germany.com
t a te Pr e n o il su b i to o r t vos tto! biglie
già
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© waldemarus
STANDARD & LEGISLATION
What Changes with the ISO 9001:2015 Quality Certification? Fulvio and Marco Zocco Zeta Due Quality, Vimercate (Monza e Brianza) - Italy
A
fulvio.zocco@zetaduequality.it - marco.zocco@zetaduequality.it
nyone who has heard of quality
Therefore, all the previously certified
management system of an organisation is
certifications, whether because their
companies as well as those currently getting
based. A company should base its activities
company is certified or because
certified will have to update their systems.
on an organisational model in order to
they have worked with companies that
Here below, you will find the main changes
identify goals and possible risks. The
are, wonders if investing in them is really
in the standard.
elements that can positively or negatively
useful or just a cost incurred due to market
affect such objectives should be assessed.
processes. The legislation has recently
Context analysis and risk-based thinking
changed: the ISO 9001:2015 certification
Context analysis is a crucial aspect of the
response to the choices related to the
can be obtained by September 2018.
new standard, on which the whole quality
structure selected. Based on ISO 9001:2015,
impositions, resulting in rigid business
184
N. 50 - MARCH/APRIL 2018 - international PAINT&COATING magazine
Context analysis involves the assessment of “organisational” risks: it represents a
STANDARD & LEGISLATION
Defining the context in which a company operates
The legislation has recently changed: the ISO 9001:2015 certification can be obtained by September 2018. Therefore, all the previously certified companies as well as those currently getting certified will have to update their systems.”
The processes and activities carried out by a company and the risks it faces depend on the context in which it operates. The Paragraph 4.1 of the standard involves understanding an organisation and its context and requires the company itself to identify the internal and external factors that are relevant for its purposes and strategy because they can influence the ability of its quality management system to achieve the desired results. The standard does not define a method of analysis, but every action should be documented.
risks are a part of a process-based approach and they result in the
This issue can be understood better through a few definitions:
need for preventive actions. Risk-based thinking is the key principle of the whole standard: a company should plan its processes on the basis of its risk identification and assessment. What are these risks? The elements, factors, and situations that can
Risks
The effects of uncertainty on the company’s objectives
Risk management
Coordinated activities to lead and monitor an organisation with regard to risk
Context identification
Identification of the external and internal parameters to be taken into consideration with regard to risk management and to the determination of its scope of application and risk criteria
have a more or less important impact on the achievement of the defined objectives. A company should assess the severity of these risks and their effect with analyses supported by data; it should also implement appropriate actions to minimise the likelihood of them occurring and the damage they could cause to the organisation. To better clarify the concept of risk, let us take the example of an Italian company operating in the luxury good sector: it buys
According to the definition of the ISO 31000:2010 standard, the risk
its machines abroad to save money, but it does not analyse the
management reference structure it is the set of elements that provide
maintenance-related risks deriving from the fact that its supplier
the fundamental bases and the organisational aspects needed to
offers no technical assistance in Italy, and it must intervene from
plan, implement, review and continuously monitor risk management
abroad with significant costs and times. In order to minimise risk,
throughout a company. Understanding the organisation and its context
the company should consider these factors during the purchase
is the first step in the design of a quality system.
phase and analyse the actual downtime risk, the possibility to perform an ordinary maintenance intervention in-house, the
The external context
chance that the supplier will soon have a technical assistance
The external context is the external environment in which the company
office in Italy, etc.
operates. This includes the stakeholders’ objectives and concerns. What
This approach does not mean to remove all potential dangers from
are these stakeholders? They are people or organisations that have the
sight or have a cumbersome decision-making process: it should
ability to influence, be influenced, or perceive any company activity or
help the management analyse all the risks present in its operational,
decision as an influencing factor (Table 1).
commercial, strategic, etc. activities. Sich risk analysis and assessment enables to determine in what circumstances and ways damage can occur to the company and to identify the methods for coping with it. The FMEA technique has always been used in the quality management field. It is based on the analysis of the modalities and effects of possible failures – in other words, risk analysis. This technique can be applied to products, services and processes and requires the calculation of a risk index based on the probability of an event occurring in relation to its gravity. If the resulting detectability value exceeds a defined level, a corrective action should be planned and regular checks on its results should be performed. Risk management is required based on the following requirements: • Quality management systems and processes; • Customer focus; • After-sales activities.
The FMEA technique has always been used in the quality management field. It is based on the analysis of the modalities and effects of possible failures – in other words, risk analysis. This technique can be applied to products, services and processes and requires the calculation of a risk index based on the probability of an event occurring in relation to its gravity. If the resulting detectability value exceeds a defined level, a corrective action should be planned and regular checks on its results should be performed.” international PAINT&COATING magazine - MARCH/APRIL 2018 - N. 50
185
Table 1: Examples of main stakeholders.
MAIN STAKEHOLDERS
REQUIREMENTS
Company’s owners
• profit generation • economic-financial sustainability • compliance with applicable laws • operational continuity
Customers/clients (public administrations, private companies, private citizens)
• low prices • compliance with product delivery times • products made as per specifications • compliance with environmental and safety laws
Professionals appointed by the clients (designers, construction managers)
• products made as per specifications • compliance with the project • use of suitable materials • compliance with environmental and safety laws
Citizens of the area • no atmospheric and water pollution affected by the company’s • no waste or polluting substances activities released • minimised noise Company’s staff
“Critical” suppliers (subcontractors, maintenance workshops, technical-environmental consultants)
• adequate remuneration • compliance with the employment contract • supply of safe and good-quality clothing, PPE and equipment • good work organisation • possibility of dialogue with the management • regular payments • clear instructions about the services requested • continuity in orders
The processes and activities carried out by a company and the risks it faces depend on the context in which it operates. The Paragraph 4.1 of the standard involves understanding an organisation and its context and requires the company itself to identify the internal and external factors that are relevant for its purposes and strategy because they can influence the ability of its quality management system to achieve the desired results. The standard does not define a method of analysis, but every action should be documented.” The credibility, trust and value of an organisation are continuously influenced by its lack of recognition of opportunities to achieve its strategic, planning and business objectives. The analysis of the internal context should take into account at least as follows: • the set of rules (laws, regulations, etc.) governing the management of the company; • the organisational structure, roles and responsibilities; • policies and objectives as well as the strategies implemented to achieve them; • capacity and agreements in terms of resources and knowledge; • relations with the internal stakeholders; • the company culture; • systems, information flows and decision-making processes; • rules, guidelines and models adopted by the organisation; • the nature and extent of contractual relations.
Risks arising from customers In its risk analysis, a company should consider the context related to the
Let us consider customer-defined acceptance criteria, which are often
whole organisation and assess, in particular, the requirements arising
neglected or examined very superficially by both parties. Precise
from the stakeholders’ perception and from any other aspect concerning
customers will identify all defects and limits of acceptability, whereas
the management of a risk.
others will neglect this aspect and, in case of any problems, they will try to
The internal context The internal context is the internal environment in which the company operates trying to achieve its objectives. Anything that can influence the way it handles risk should be considered as a part of its internal context.
prove they are right (and not to pay) in every way. This leads us to some conclusions: • with precise customers, who clearly define what they want, the risk of making mistakes is low; • with more superficial customers, the risk not to meet their requirements is high. This is a risk analysis – not very detailed, but still a risk analysis! In this
As mentioned in the standard, it should be considered that:
case, without any risk analysis, a production process could turn out to be
• risk management takes place in the context of the organisation’s
ineffective due to the lack of well-defined requirements; such inefficiency
objectives; • the objectives and criteria of a specific project, process or activity should
would not depend on the process itself, but rather on the customer. For some clients, a risk analysis should be performed to understand how
be considered with respect to the objectives of the organisation as a
to minimise error: ultimately, this is one of the suggestions of the ISO
whole.
9001:2015 standard.
186
N. 50 - MARCH/APRIL 2018 - international PAINT&COATING magazine
www.feitintas.com.br @/feitintas
Paints, Varnishes and
/feitintasbrasil
Related Products Industry Fair
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12-15 | SEPTEMBER | 2018
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Organization and Promotion
STANDARD & LEGISLATION - UCIF Informs
Energy Efficiency in Italy: the Implementation Decree on the National Fund Has Been Published Marcello Zinno UCIF – Italian Surface Treatment Equipment Manufacturers’ Association, Milan, Italy
T
info@ucif.net
he Decree of December 22, 2017
The Fund works based on a rotatory
granted to the Public Administration
entitled “Mode of operation of
principle and it is divided into two sections
(art.15) can be combined with other
the National Fund for energy
that work for as follows:
incentives, up to a maximum total
- the granting of guarantees on individual
funding of 100 per cent of the eligible
efficiency” was published on the Official Gazette of the Italian Republic no. 54 of March 6, 2018. It describes the priorities, criteria, conditions and
financing transactions, for which 30% of
costs.
the Fund’s annual resources are allocated; - the provision of loans at reduced rates, for
The Fund management will be
methods of operation, management and
which 70% of the Fund’s annual resources
entrusted to Invitalia based on a
intervention of the National Fund for
are allocated.
special agreement with the Ministry DKcomposing © Fotolia
energy efficiency, which is aimed at favouring the financing of interventions necessary to achieve the national
of Economic Development and the Ministry of the Environment
energy efficiency
and Protection
targets, based on
of Land and
established objectives
Sea. For the
and priorities.
start of the
As illustrated in the
operational
presentation of the
phase, the
Ministry of Economic
Fund will count
Development, the Fund
on 150 million
supports the energy
Euros already
efficiency measures
made available
implemented by
by the Ministry
companies and the
of Economic
Public Administration
Development,
on properties, plants
which will
and production processes as follows:
The benefits granted to companies can
allocate another 100 million Euros in
- reduction of energy consumption in
be combined (art.10) with contributory
2018-2020. The Fund will also be fed
or financial benefits provided for by
with the resources made available by
other European, national, and regional
the Ministry of the Environment.
industrial processes, - construction and expansion of district heating networks, - improvement of the efficiency of public
regulations, subject to the de minimis rule, where applicable, or within the
UCIF continues to give prominence to
services and infrastructures, including
maximum aid intensities permitted by
energy efficiency and saving measures,
public lighting,
the current European Union legislation
one of the prides of the surface
on state aid. Similarly, the benefits
treatment plants produced in Italy.
- energy redevelopment of buildings.
188
N. 50 - MARCH/APRIL 2018 - international PAINT&COATING magazine
May 22nd, 23rd & 24th 2018 Biarritz • FRANCE
22th International congress
SURFACE FINISHING IN THE AERONAUTIC AND AEROSPACE INDUSTRIES • Environmental regulation : where we are • Adaptation to new material and technologies • Advanced Materials and Innovative Coating Application Processes A unique programme that gathers every other year all the surface finishing professionals from more than 20 countries: ALENIA, ADERA, AEROPROTEC, AIRBUS DEFENCE AND SPACE, AIRBUS HELICOPTERS, AIRBUS CENTRAL R&T, AIRCELLE, AKZO NOBEL AEROSPACE COATINGS, ARIANE GROUP, BODYCOTE, CELESTE CORPORATION, CHEMETALL, CNRS, CORELEC EQUIPEMENTS, DELFT UNIVERSITY OF TECHNOLOGY, DURR SYSTEMS, EUROLINK, FISCHER INSTRUMENTATION, H2O, HENKEL, KGAA, HENTZEN COATINGS, HISPANO SUIZA, INDESTRUCTIBLE PAINT LTD, ITALIAN AEROSPACE RESEARCH, JET METAL TECHNOLOGIES, KIMBERLY CLARK, MADER GROUP, MANKIEWICZ, MAPAERO, MASA, MCGEAN, CEE BEE, METAL IMPROVEMENT COMPANY, NITTO EUROPE, PEXA, PPG AEROSPACE, PROTEC INDUSTRIE, RAYTHEON MISSILE SYSTEMS, SAFRAN, SOCOMORE, TECNALIA, THALES, THE BOEING COMPANY, UITS, ZODIAC, ...
Surfair contact: Julie Coutellier Phone : +33 (1) 77 92 92 92 julie.coutellier@infopro-digital.com Sales contact: Bin Wu Phone : +33 (1) 77 92 98 08 bin.wu@infopro-digital.com
Organised by:
Supported by:
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APRIL 2018 WORLDBUILD MOSCOW
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A&T
EXPO SURFACE
EXPO MECÂNICA
Moscow, Russia April 03-06, 2018 www.worldbuild-moscow.ru/en-GB/
Milan, Italy April 17-22, 2018 www.salonemilano.it/en/
Indianapolis - IN, USA April 09-12, 2018 american-coatings-show.com
Tokyo, Japan April 18-20, 2018 www.medteceurope.com
Birmingham, UK April 09-13, 2018 www.machexhibition.com
Turin, Italy April 18-20, 2018 www.affidabilita.eu/aet/default.aspx?site=ENG
Kielce, Poland April 10-12, 2018 www.targikielce.pl/en
Porto, Portugal April 20-22, 2018 www.expomecanica.pt/en/
EMPACK
Utrecht, The Netherlands April 10-12, 2018 www.easyfairs.com/empack-utrecht-2018/empack-utrecht-2018/
São Paulo, Brazil April 10-13, 2018 www.feicon.com.br/en/Home/
Hanover, Germany April 23-27, 2018 www.hannovermesse.de
INTERMAT
WIRE
MECÂNICA
MEDTEC EUROPE
CONTROL
Paris, France April 23-28, 2018 paris.intermatconstruction.com
Düsseldorf, Germany April 16-20, 2018 www.wire-tradefair.com
São Paulo, Brazil April 24-27, 2018 www.mecanica.com.br/en/Home/
Stuttgart, Germany April 17-19, 2018 www.medteceurope.com/europe
Stuttgart, Germany April 24-27, 2018 www.control-messe.de/en/
PAINTEXPO
León, Mexico April 17-20, 2018 expomaq.org.mx/?lang=en
N. 50 - MARCH/APRIL 2018 - international PAINT&COATING magazine
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Cleveland - OH, USA April 11-12, 2018 www.fastenerfair.com/usa
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HANNOVER MESSE
FASTENER FAIR USA
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METAL & STEEL SAUDI ARABIA
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Riyadh, Saudi Arabia April 29 - May 02 www.metalsteelsaudi.com
AGRISHOW
Ribeirão Preto, Brazil April 30 - May 04, 2018 www.agrishow.com.br/en/Home.html
MAY 2018 COATECH
Mexico City, Mexico May 02-04, 2018 http://mexico.fabtechexpo.com
MACH-TECH INDUSTRY DAYS
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Budapest, Hungary May 15-18, 2018 http://iparnapjai.hu/en
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INDOBUILDTECH
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BUILDEXPO AFRICA
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ARCHITECT@WORK SPAIN
INDUSMACH KENYA
COATING JAPAN
SURFEX
SF EXPO CHINA
SURFAIR
Jakarta, Inodnesia May 02-06, 2018 www.indobuildtech.com
Nairobi, Kenya May 03-05, 2018 www.expogr.com/buildexpokenya/
Prishtina, Kosovo May 08-10, 2018 www.ceokos.com/en
Barcelona, Spain May 08-11, 2018 www.hispack.com
Madrid, Spain May 09-10, 2018 www.architectatwork.es
Osaka, Japan May 09-11, 2018 www.coating-japan.jp/en/
Chongqing, China May 09-11, 2018 www.sf-expo.cn/En/
Bangkok, Thailand May 16-19, 2018 www.mta-asia.com
Kuala Lumpur, Malaysia May 17-19, 2018 www.coatcorrosionasia.com
Brescia, Italy May 17-19, 2018 www.fierabie.com
Nairobi, Kenya May 17-19, 2018 www.expogr.com/kenyaauto/
Nairobi, Kenya May 17-19, 2018 www.expogr.com/kenyaind/
Coventry, UK May 22-23, 2018 www.surfex.co.uk
Biarritz, France May 22-24, 2018 http://surfair-congres.com/
COMPLAST MYANMAR
METALTECH
METALLOOBRABOTKA
BIEMH
Yangon, Myanmar May 10-12, 2018 complastexpo.in/myanmar2018/
Moscow, Russia May 14-18, 2018 www.metobr-expo.ru/en/
FOR INDUSTRY
Prague, Czech Republic May 15-18, 2018 http://forindustry.cz/en/
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Bilbao, Spain May 28 - June 01, 2018 biemh.bilbaoexhibitioncentre.com
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COATINGS FOR AFRICA Johannesburg, South Africa May 29-31, 2018 www.coatings-group.com/cfa
international PAINT&COATING magazine - MARCH/APRIL 2018 - N. 50
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ZOOM ON EVENTS
© ipcm ®
Helmut Fischer Srl Tecnica di Misura Turns 40
1
© ipcm ®
Figure 1: Group photo of all Helmut Fischer’s employees with Adriano Colombo, the second from the left, and Wolfgang Babel, the fourth from the right.
H
elmut Fischer Srl Tecnica di Misura
di Misura. Helmut Fischer specialises in
celebrated 40 years of activity
the production of tools for measuring the
and the expansion of its Italian
thickness of paint and galvanic coating
headquarter with the addition of new
layers; however, it has recently expanded
laboratories on February 20, 2018 in Sesto
its range with ultrasonic devices for metal,
San Giovanni (Milan, Italy – Fig 1).
enabling to measure no longer just the
Its parent company Helmut Fischer AG,
thickness of films but also the total thickness
established in Germany in 1956, is a world
of substrates. Its production is divided into
leader in the production of measuring and
two large categories: bench tools, more
control devices. Initially, its products were
suitable for galvanic coatings, precious
distributed in Italy by representatives of
metals, and hard depositions, and portable
the German company, but in 1977 two
tools, which are ergonomic, highly precise,
farsighted control tool experts, Luciano
and able to measure even the thinnest films.
Marcomini and August Von Wartburg, decided to establish an independent company in Italy: Helmut Fischer Srl Tecnica
192
2 1
N. 50 - MARCH/APRIL 2018 - international PAINT&COATING magazine
Figure 2: The new device Dualscope®FMP100.
© ipcm ®
ZOOM ON EVENTS
Its most famous tools belong to the
“Our strengths are our well-stocked
Deltascope® and Dualscope® ranges.
warehouse and our highly qualified
For example, Dualscope FMP100 (Fig.
customer support,” states Colombo.
2) is its most advanced thickness gauge.
“They differentiate us from our
It can measure thicknesses even on
competitors, as they enable us to
very small parts with complex shapes,
promptly meet any need. In fact,
generating a PDF document with the data
technical assistance accounts for about
collected, which can be sent with the final
30% of our turnover. I would like to
measurement report.
give special thanks to Helmut Fischer’s
®
whole staff, who have allowed this wellThe protagonist of the event was Adriano
established company to continue to
Colombo (Fig. 3), who entered the
stand out from the competition and triple
company as the sales director back in 1988
its turnover in just fifteen years through
and became its CEO in 2001. The Italian
their dedication to customers.”
branch of Helmut Fischer is located in
During the party of February 20, Adriano
Sesto San Giovanni, it has 11 employees,
Colombo and Helmut Fischer Group CEO
and it is equipped with a modern tool testing lab, a maintenance and repair workshop, and a warehouse that can
the employees a gift as a token of thanks
Figure 3: Cutting the cake dedicated to Helmut Fischer Italia’s 40th anniversary.
for their professionalism and dedication to the company.
© Helmut Fischer
quickly supply any type of product (Fig. 4).
and President Wolfgang Babel gave all
3 1
4 1
Figure 4: A bird’s eye view of the Helmut Fischer plant in Sesto San Giovanni, Milan, Italy.
international PAINT&COATING magazine - MARCH/APRIL 2018 - N. 50
193
ZOOM ON EVENTS
© PaintExpo
PaintExpo: Innovations and Solutions from More than 520 Exhibitors
1
Figure 1: PaintExpo will take place from the 17th through the 20th of April, 2018, in Karlsruhe, Germany.
P
aintExpo 2018 is stepping up to the
innovations and further developments for
exhibitors and roughly 165,000 square feet
starting line with record-breaking
the optimisation of liquid painting, powder
(15.500 square meters) of net exhibition floor
participation once again. More than
coating and coil coating processes on
space – a 15% increase as compared with
520 exhibitors will be on hand when the 7th
165,000 square feet of net exhibition floor
2016 – the 7th edition of world’s leading trade
edition of the world’s leading trade fair for
space.
fair for industrial coating technology will be
industrial coating technology opens its doors
PaintExpo will transform the Karlsruhe
the largest to date and will be held for the first
on the 17 of April (Fig. 1). Companies from
Exhibition Centre into a hub for industrial
time in three halls at the Karlsruhe Exhibition
29 countries, including all of the sector’s
coating technology from the 17th through
Centre (Germany). The exhibiting companies
market and technology leaders, will present
the 20 of April, 2018. With more than 520
come from 29 countries – roughly 36% from
th
194
th
N. 50 - MARCH/APRIL 2018 - international PAINT&COATING magazine
outside of Germany (Fig. 2). And thus internationalism is also on the rise once
© PaintExpo
ZOOM ON EVENTS
again for PaintExpo.
Solutions for all sectors, all materials and all applications Globally unique offerings for coating and painting all materials, in all industry sectors and for all applications will await visitors from companies with in-house coating operations and jobshop coaters. PaintExpo’s exhibition programme covers coating equipment for liquid, powder, UV, immersion and coil processes, paints and enamels for all processes, application systems, spray guns and atomisers, automation and conveyor technology, cleaning and pre-treatment, drying and curing,
2 1
Figure 2: 520 exhibitors from 29 different countries will attend the 7th edition of PaintExpo.
environmental technology, pneumatics, compressed air supply and exhaust
visitors at the trade fair – often in
and atomisers, as well as alternative
purification, water treatment, recycling
the form of live presentations”, adds
atomising gases, are increasing material
and disposal, accessories, masking,
Jürgen Haußmann. Amongst others,
efficiency and improving quality. Product
measuring and test technology,
these include a self-programming
developments with optimised functional
quality assurance, identification, paint
painting cell for the efficient coating
and decorative properties are opening
stripping, job-shop coating, services
of products with a manufacturing
up new opportunities and making
and technical literature.
lot quantity of 1, as well as highly
it possible to reduce the required
flexible, easy-to-program painting
number of painting steps in the case of
robots and automation solutions
liquid paints, UV paints and powdered
“Whether for liquid painting, powder
which have been specially developed
enamels. Current innovations for dry
coating or coil coating, the exhibitors
for industrial applications. New
scrubbing solutions, test and inspection
will present new and further developed
solutions for blasting, grinding and
systems, accessories such as covering
products, processes and services in
ionising metal, plastic and wooden
materials, painting hangers, filters
all segments, and will highlight current
surfaces will be premiered at
and pumps, as well as paint stripping
trends. These solutions are laid out
PaintExpo, as well as products and
and packaging solutions are no less
to further enhance quality, energy
processes for more economic and
interesting.
and materials efficiency, flexibility
environmentally friendly cleaning and
PaintExpo will take place at the
and sustainability”, reports Jürgen
pre-treatment, along with system
Karlsruhe Exhibition Centre from the
Haußmann, managing director of
concepts which reduce energy
17th through the 20th of April, 2018. The
event promoters FairFair GmbH. A
consumption for powder coating
world’s leading trade fair for industrial
further issue on which attention will
and liquid painting processes,
coating technology will be open Tuesday
be focused at this year’s PaintExpo is
and at the same time increase
through Thursday from 9 a.m. to 5 p.m.,
the digitalisation of painting processes
flexibility with regard to coating,
and on Friday from 9 a.m. to 4 p.m
and the integration of Industry 4.0 into
lot quantities and expandability.
painting operations. “New products are
Where application is concerned,
For further information:
traditionally presented to the expert
new and enhanced paint guns
www.paintexpo.com
Experience innovations live
international PAINT&COATING magazine - MARCH/APRIL 2018 - N. 50
195
ZOOM ON EVENTS
Aluminium 2018 – New Topics to Meet the Future
G
transport sector are driving demand
mechanical engineering, aerospace
for light metals. The precise trajectory
and the construction sector. The
Technical education programme to deliver
might vary from country to country,
well-known theme pavilions will serve
industry and science know-how
but all around the world, the industry is
as points of contact to lead visitors
Expert presenters from industry and science
making new investments to gear up for
through the structured exhibition halls.
at the ALUMINIUM 2018 Conference and
an economy that continues to boom.
In the new special exhibition area
the ALUMINIUM Forum will discuss the
This positive mood is felt as well at the
“Digital Manufacturing”, visitors will
trends and innovations of the aluminium
ALUMINIUM World Trade Fair – even with
experience what Industry 4.0 means
sector. Organised by the GDA, the umbrella
lobal production of aluminium
at providing better orientation for
industry is leading the way when it comes to
has reached a record high level;
visitors from user segments such
emerging topics such as energy and resource
the energy transition and the
as automotive engineering (Fig. 1),
conservation in one’s own production chain.
© B&R
ten months still to go before it opens its doors in Düsseldorf.
association of the German Aluminium industry,
From 9 to 11 October 2018,
the ALUMINIUM 2018
the Exhibition Centre on the
Conference will focus
Rhine will again become the
on the material’s future
global marketplace of the
prospects. Exhibitors at
aluminium industry. Spread
the ALUMINIUM Forum
across six exhibition halls,
will present their latest
global players, specialists and
solutions and technologies
young innovative companies
covering the areas of
will showcase the industry’s
lightweight technologies,
complete range – from
e-mobility and additive
aluminium production to
manufacturing, among
machines and plants for
others.
processing to finished goods
1
and recycling. The exhibition area will grow to 80,000 square metres, more than 80 per cent of which
All roads lead to Düsseldorf
Figure 1: Automotive is one of the industry sectors on which Aluminium 2018 focus.
is already booked. “A clear
More than 27,000 trade visitors from 100 countries are expected to attend ALUMINIUM 2018. Boasting
indication of the current momentum in
for the aluminium industry and what
a 60 per cent share of visitors from abroad,
the aluminium industry”, says Olaf Freier,
kinds of productivity benefits can
ALUMINIUM is among the major trade fairs
ALUMINIUM’s event director. “We’re
already be achieved today by deploying
with the highest level of internationality
confident we’ll crack the 1,000-exhibitor
high-performance IT solutions in
worldwide. The 20 per cent share of foreign
mark at the upcoming event.”
production.
visitors from overseas was remarkably high
Another new exhibition area dubbed
at the last event – a gauge of ALUMINIUM’s
New topics: digitalisation and
“Environmental Engineering” will cover
worldwide relevance.
environmental protection
water treatment, air filtration systems
Special exhibits like the Innovation Areas
and oil/oil mist vacuuming systems
For further information:
and themed guided tours are aimed
– and show how the aluminium
www.aluminium-messe.com
196
N. 50 - MARCH/APRIL 2018 - international PAINT&COATING magazine
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ZOOM ON EVENTS
Modules for Smart Chemical Plants
“A
competitive advantage in
other words, second to none.”
the process industry will be
For the special display “Process
NAMUR and ZVEI study groups have been
increasingly dependent on
working together with Dechema and
Production” and for the second
VDI on multi-vendor specifications for
is organized,” says Felix Seibl, Director
time since 2017, members of ZVEI
modules. “With a Module Type Package
of Measurement Technology and
and users are demonstrating how
(MTP) the individual unit type operations
Process Automation with the Electrical
the process industry is significantly
can quickly be interconnected into
and Electronic Manufacturer’s
increasing the flexibility of such plants
an overall process to ensure superior
Association (ZVEI). According to Seibl,
by standardizing interfaces using
production,” explains Seibl. MTP is
plant operators need their production
modular concepts and intelligent,
the heart of automation for modular
to be “more flexible, faster, and cost-
decentralized automation (Fig. 1).
plants. The approach, which consists
efficient than their competition – in
For the past several years, the
of distributing control intelligence from
© Deutsche Messe AG
INDUSTRIE 4.0: The Age of Modular
how effective and efficient production
1
Figure 1: For the special display “Process INDUSTRIE 4.0: The Age of Modular Production”, it will be demonstrated how the process industry is significantly increasing the flexibility of plants by standardizing interfaces.
198
N. 50 - MARCH/APRIL 2018 - international PAINT&COATING magazine
© Deutsche Messe AG
ZOOM ON EVENTS
2 1
Figure 2: Hannover Messe will take place from 23 to 27 April 2018.
the process control system to the plant
effort has been addressed. At the most
be held from 23 to 27 April 2018 in
modules, specifying plant modules digitally,
recent NAMUR committee meeting the
Hannover, Germany, and will provide
and providing for a neutral interface between
results were presented. NAMUR Director
a comprehensive overview of the
plant module and control system, is a “clear
Heinrich Engelhard is convinced “that
latest visions and technologies for
break with existing automation paradigms in
manufacturers can begin introducing
the digitization of production and
the process industry,” says Seibl.
this technology.” At any rate, visitors to
energy systems (Fig. 2). The upcoming
One demonstrator at HANNOVER MESSE
HANNOVER MESSE 2018 can see that a
HANNOVER MESSE will feature five
2017 helped the initiative prove that
great deal of progress is being made.
parallel shows: IAMD (Integrated
human-machine interfaces can be used
Automation, Motion & Drives), Digital
according to Dr. Linus Schulz of Dechema,
HANNOVER MESSE – Get new technology first!
“functionality, situation-based process
HANNOVER MESSE is the world’s leading
be co-staged with CeMAT, the world’s
control, diagnosis, and maintenance” have
trade fair for industrial technology. With
leading trade fair for intralogistics and
been advanced and the issue of how to
its core focus on “Integrated Industry” and
supply chain management. Mexico
upload multivendor information into the
“Integrated Energy”, it is the No. 1 global
will star as the Partner Country of
process control system without much
platform for Industry 4.0. The show will next
HANNOVER MESSE 2018.
regardless of manufacturer. Since then
Factory, Energy, Industrial Supply and Research & Technology. It will also
international PAINT&COATING magazine - MARCH/APRIL 2018 - N. 50
199
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