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CONTENTS JULY/AUGUST 2018
SPE C IAL O N T RANSPO RTAT I ON
FOCUS ON TECHNOLOGY
Fainsa, Where Cutting-Edge Technology Meets Tradition: Double Production Speed and Higher Coating Quality for Public Transport Seats © Savim
38
Flawless Finishes for Alloy Wheels: The Secret Is in the Spray Gun
FOCUS ON TECHNOLOGY
© BASF
32
S P E CI A L O N T R A N S P O R TAT I O N
SPE C IAL O N T RANSPO RTAT I ON
50 05 06
HIGHLIGHT OF THE MONTH
Future Mobility and Human Needs Inspire BASF’s 2018-19 Automotive Color Trends
EDITOR’S LETTER
58
INNOVATIONS: PRESENT&FUTURE
Alternative and Innovative Technologies Implemented in Coating Booths for Railway Vehicles
HIGHLIGHT OF THE MONTH Doing Paint Inspection Offshore? Your Current Certificate Is Not Enough
ANALYSIS A New Standard in Corrosion Prevention: How Self-Healing Coatings Enable Significant ROI to End-Users
18
22
S P E CI A L O N T R A N S P O R TAT I O N
24
28
BUSINESS CARDS
S P ECIAL O N T RANS PORTAT I ON
INNOVATIONS: PRESENT&FUTURE IDROLIN/K DTM: Easy To Use with Good Anti-Corrosion Performance
HIGHLIGHT OF THE MONTH The Synergy between Dollmar and Noxorsokem Group Creates a New Specialised, High Added Value Business
BRAND-NEW
31 46
48
SUCCESS STORIES EcoInCure: Space-Saving Oven Technology for Electric Cars
THE FIRST VERTICAL POWDER COATING
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© Imel
CONTENTS JULY/AUGUST 2018
INNOVATIONS: PRESENT&FUTURE
Imel presents the i4paintshop Platform for 4.0 Management of Coating Plants and the Facilitation of Decision-Making Processes © ABL-TECHNIC Entlackung GmbH
80
DKC Group: Optimising the Pre-Treatment Process for Easier Plant Management and Constant Quality
© ipcm ®
72
FOCUS ON TECHNOLOGY
92 54 62
FOCUS ON TECHNOLOGY
BRAND-NEW SUCCESS STORIES The World’s Largest Preservation Line in the Ship Building Industry Goes to Finland
66
100
A Last-Generation Booth Can Make the Difference
INNOVATIONS: PRESENT&FUTURE Wet-on-wet Application in the Transport Sector. Technological Innovation, Automation, and Industry 4.0
86
HIGHLIGHT OF THE MONTH
Innovative Paint Stripping Solutions
INNOVATIONS: PRESENT&FUTURE The Evolution of Powder Spraying Systems: Digitalisation, Ergonomics, Connectivity
108 SUSTAINABILITY 110
STANDARD & LEGISLATION UCIF Informs The Importance of Design
98 BRAND-NEW 104 BRAND-NEW
112 113
TRADE FAIRS & CONFERENCES ZOOM ON EVENTS
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FASTRIP, for the easy, effective and rapid paint stripping of metals.
ALIT Technologies, the chemical paint stripping specialist. Products, machines, processes and consultancy.
www.alit-tech.com San Bonifacio – Verona - ITALY
AXLE COATING FORUM at InnoTrans ƐѶ ";r|;l0;u ƑƏƐѶ Ň ƖĹƐƔ Ŋ ƐƐĹƐƔ b| 0; ;uѴbm Ő;m|u-m1; -@࣐v|u-z;őķ ; ;Ѵ ƒķ !ool ƒ
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EDITOR’S LETTER
Sustainability and surfaces Richiedi la versione in italiano a info@ipcm.it
C
onventionally defined as a practice that «meets the needs of the present without compromisingbthe ability of future generations to meet their own needs», sustainability is an issue of great relevance and interest for everyone.
Understood as emission reduction, operational performance improvement with a view to energy saving, and functionality and service life enhancement, sustainability is currently an unbeatable USP (Unique Selling Proposition, that is, the sales argument of a product). There are many ways to be sustainable: the start of “green” projects, the search for natural alternatives to synthetic products, the implementation of operational and energy efficiencies, or the creation of projects for the community and about training, health, and safety. Sustainability practices are becoming a part of modern companies’ mission so much so that they are not just in an investment – they generate profits. The environmental profit value allows a company to assess the costs and benefits created for the environment with a monetary unit and, therefore, to make more sustainable operational decisions. In order to determine the real footprint of a productive activity, it is necessary to consider carbon emissions, the use of water resources and the rate of water pollution, air pollution, the amount of waste produced and their disposal operations, and even the amount of land occupied. These elements should be analysed for the entire value chain, from raw materials to retail stores. The surface treatment and coating industry, in particular, was one of the first to embrace this trend towards sustainability and it is now one of the most active sectors in terms of environmental, social, and economic projects. The coating industry can be sustainable for the end user: by making products more durable, paints increase their efficiency of use and reduce the disposal operations at the end of their service life. The supply of raw materials, energy, and water combined with production efficiency can have a significant impact on the environmental footprint of paint formulations. Improvements in the performance and functionality of coatings, in turn, can have a major impact on the sustainability of the whole life cycle of products. This issue of ipcm® inaugurates a new section on sustainability. Already widely discussed on our website www.myipcm.com and on our social channels (as I write this, the MyIpcm Coatings Community on LinkedIn has 9504 members),bthis topic will be dealt with in an even more organic and in-depth way on our publications. The brand new section will collect exclusive interviews, comparisons, projects, and activitiesbdevoted to environmental, social, and economic
Alessia Venturi Editor-in-chief Direttore Responsabile
sustainability. I will see you in September with an even richer content.
international PAINT&COATING magazine - JULY/AUGUST 2018 - N. 52
05
© Autonomic Materials
06
N. 52 - JULY/AUGUST 2018 - international PAINT&COATING magazine
ANALYSIS
A New Standard in Corrosion Prevention: How Self-Healing Coatings Enable Significant ROI to End-Users Gordon Fischer, Magnus Andersson Autonomic Materials, Inc., Champaign, Illinois (USA)
C
grant@autonomicmaterials.com
orrosion is an immediate and pressing
even as they improve iteratively, have severe
Self-healing additives arrest the
problem for anyone who builds,
performance limitations. Even with improved
propagation of corrosion. AMI’s
maintains, and utilizes steel equipment
formulation techniques, more effective resins,
self-healing additive technology has
and structures.
etc., exposure of the substrate, after damage
demonstrated the ability to repair the
Asset owners make significant investments
to the coating has occurred, remains a major
coating and prevent delamination,
in preventing the occurrence and spread of
challenge. Once exposed, the substrate
thereby preserving the anti-corrosion
corrosion, as well as in repairing corrosion
succumbs to corrosion at the exposed site.
functionality of the coating. Moreover,
damage. According to data from NACE
The coating-substrate interface then degrades,
this technology is autonomic,
International, the estimated annual direct
leaving the coating unable to adequately
meaning it requires no mechanical
cost of corrosion in the U.S. is $276
or human intervention to
billion – approximately 3.1% of the
provide healing at the site
nation’s total GDPI. That figure is not an
of damage. Self-healing
outlier; similar costs apply globally. In China, it’s $310 billion USD, or 3.34% of GDP . In turn, preventing corrosion II
could result in global savings between 15-35% of the cost of damage, or anywhere between $375 billion and $875 billion. Corrosion, of course, results in structural degradation that can, if untreated, lead to complete failure. Worse, problems with corrosion can start almost immediately. The U.S. Army, for example, has used a conventional epoxy system on some
Corrosion is an immediate and pressing problem for anyone who builds, maintains, and utilizes steel equipment and structures. Asset owners make significant investments in preventing the occurrence and spread of corrosion, as well as in repairing corrosion damage. According to data from NACE International, the estimated annual direct cost of corrosion in the U.S. is $276 billion – approximately 3.1% of the nation’s total GDP. That figure is not an outlier; similar costs apply globally.”
additives for anti-corrosive coatings represent a qualitatively new technology that enables protective coatings to self-repair. When such coatings are damaged in service, the healing agent flows out of the coating into the site of damage, where it forms a protective layer, passivates the damaged area and delays or prevents further corrosion of the
of its seaborne vehicles – only to find
underlying metal substrate
that the epoxy system would begin to oxidize and corrode within 6 months at sea.
protect the substrate. Corrosion subsequently
(Fig. 1). Consequently, formulating
Then, problems can be widespread, as well: an
advances rapidly by compromising the
these microcapsules containing a
inspection of Canadian army vehicles found
coating’s adhesion to the substrate and causing
self-healing agent into paint greatly
that 25% of the fleet suffered from severe
delamination of surrounding coating and
extends the coating’s serviceable
corrosion .
exposing more substrate. In this way, corrosion
lifespan by minimizing repaints and
Unfortunately, existing protective coatings,
spreads faster and faster.
constant touch-ups.
III
Opening photo: AMI’s self-healing additive technology has demonstrated the ability to repair the coating and prevent delamination, thereby preserving the anti-corrosion functionality of the coating.
international PAINT&COATING magazine - JULY/AUGUST 2018 - N. 52
07
© Autonomic Materials
Exterior coatings with self-healing agents incorporated into the formulation can extend the lifespan of each individual coating, potentially significantly; and municipalities can reap significant cost savings as a result. To determine the lifetime cost of coatings for a municipal water tower meeting the characteristics described in Table 1, we
Figure 1: Microencapsulated delivery of liquid healing agents.
include all painting operations required to protect the structure for its complete Self-healing additives also reduce total cost
serious. Corrosion was blamed in the
service life. We assume a typical maintenance
of ownership. Performance improvements
collapse of a Kentucky water tower in
sequence that includes:
are an important consideration for any asset
2014, for example. “I think it was very
• The original coating;
owner. However, the total cost of ownership
fortunate this was not a more serious
• Spot touch-ups and repairs;
is just as important. Hence, any discussion
incident,” Andrew Melnykovych, a member
• Maintenance repaints (spot priming and a full
of an improved anticorrosion solution must
of the Kentucky Public Service Commission,
consider the cost impacts of the solution.
told a local news affiliate at the time. “It
This paper presents financial models for
reinforces the importance of maintaining
multiple scenarios demonstrating how AMI’s
infrastructure.”
overcoat); • Full repaint (total coating removal and replacement).
IV
Table 1 - New water tower example.
self-healing additives are cost-beneficial. Specifically, AMI’s self-healing additives can
Indeed, even if most water towers escape
lower the cost of maintaining assets in both
such a fate, it’s only thanks to the continuous
moderate and extreme locations; from
effort and expense dedicated to maintaining
ubiquitous urban water towers to remote
and protecting these structures. Even mild
offshore oil rigs. In this case study, we will
corrosion at 10 mils per year will pierce
examine the economic benefit of using self-
¼-inch thick plate in 24 years, a fraction of
healing additives in both applications.1
the serviceable life of the structure – and
Asset Type
New Water Tower, Field Applied Paint
Standard Paint System
Three Exterior Coats of Standard Waterborne Acrylic Paint
Self-Healing (SH) Paint System
One Exterior Coat of SH Waterborne Acrylic Paint + Two Exterior Coats of Standard Waterborne Acrylic Paint
common urban pollutants, sun exposure,
Surface Preparation
SP-6 (Commercial Blast Cleaning)
Large urban water storage structures may
etc.
not face the extreme corrosive conditions
As a result, most water towers will require as
Square Footage
30,000
that can bedevil steel structures in more
many as half a dozen re-coatings during their
50
damaging environments, like those
lifespan, with each coating not only incurring
Service Life (Years)
encountered in marine settings, but the
direct added expense but also imposing
consequences of corrosion can be just as
service disruptions.
Service life and cost considerations for self-healing coatings in a moderate environment: municipal water towers
structural failure will occur long before total penetration. V Water towers are furthermore exposed to a series of environmental conditions that can contribute to corrosion: fluctuating temperatures, rainfall and relative humidity,
Water towers thus offer an excellent glimpse 1
The following calculations are based upon data from NACE International and utilize the same calculations NACE published in their Paper No. 7422, “Expected Service Life and Cost Considerations for Maintenance and New Construction Protective Coating Work.” That document details pricing information on paints and typical maintenance cycles and presents complete financial models for calculating lifetime costs of coating systems. This paper applies their model to coatings incorporating self-healing additives. An explanation of the specific factors incorporated into the cost and lifespan multipliers is outside the scope of this paper; we direct you to the NACE paper for more detail
08
into the impact of self-healing coatings on a steel structure; the nature and extent of
Environment
C3 (Medium – Urban and industrial atmospheres, moderate sulfur dioxide pollution; coastal areas with low salinity)
corrosion risks facing a water tower are very common. Modelling the impact of selfhealing coatings on this type of structure
Table 2 presents the total costs per square
thus helps to illustrate the impact on many
foot, including both materials and labour, of
kinds of structures.
each painting sequence.
N. 52 - JULY/AUGUST 2018 - international PAINT&COATING magazine
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Scenario
Table 2 - New water tower, exterior coating costs per square foot (Net Present Value) at 4% interest for 4 paint service life scenarios.
Paint Service Life
Original Painting
Touch-Up 1
Maintenance Repaint 1
Full Repaint 1
Touch Up 2
Maintenance Repaint 2
Full Repaint 2
TOTALS
Cost Savings
1
12 Years Standard
$13.41
Year 12 $ 4.80
Year 16 $ 8.00
Year 22 $ 14.60
Year 34 $ 3.90
Year 38 $ 6.50
Year 44 $ 11.80
$ 63.08
---
2
15 Years Self-Heal
Year 15 $ 5.00
Year 20 $ 8.40
Year 27 $ 15.10
Year 42 $ 3.90
Year 47 $ 6.40
--
$ 53.37
15.4%
3
19 Years Self-Heal
Year 19 $ 4.90
Year 25 $ 8.00
Year 34 $ 14.10
--
--
--
$ 41.52
34.2%
4
23 Years Self-Heal
Year 23 $ 4.60
Year 31 $ 7.50
Year 43 $ 13.00
--
--
--
$ 39.71
37.0%
$ 14.55
Net Present Value (NPV), in turn, works
For this scenario, we can reasonably estimate
into Net Present Value (NPV) costs.
backwards from NFV to tell us the present
the lifetime cost per square foot of a typical
Because of their long life, capital assets
worth, in today’s dollars invested at a current
three-coating system to be $63.08. This is the
require complex financial modelling to
interest rate of 4%, of the inflated cost of
baseline against which we will compare the cost
understand costs over their full lifespan.
future painting work. In other words, NPV
effectiveness of the self-healing agent.
Net Future Value (NFV – not represented
allows us to understand future costs in
in this table) incorporates inflation (here
today’s dollars and gives us an equal basis for
Self-Healing Paint Cost Savings Scenarios
assumed to be 3%) into the costs. In
comparing the costs of different scenarios.
The effectiveness of self-healing coatings
other words, NFV tells us how much the
Scenario #1 (the first row), based on a 12-year
depends on many factors, which makes it
touch up, maintenance repaint, and full
service life, is the control: this line assumes
difficult to pinpoint exactly how much the self-
repaint will cost in the (future) year in
three coats of waterborne acrylic, none of
healing technology will extend paint service life.
which it happens.
which contain self-healing agents. With an
Accelerated corrosion tests have shown that,
asset life of 50 years, this means two complete
depending on the paint system, service life can be
typical maintenance painting sequences
extended up to 9x. However, for our cost models,
(one initial painting, two touch ups, two
we kept estimates conservative, so our model
maintenance repaints, and two full repaints).
only examines examples that range from modest
Unfortunately, existing protective coatings, even as they improve iteratively, have severe performance limitations. Even with improved formulation techniques, more effective resins, etc., exposure of the substrate, after damage to the coating has occurred, remains a major challenge. Once exposed, the substrate succumbs to corrosion at the exposed site. The coatingsubstrate interface then degrades, leaving the coating unable to adequately protect the substrate.”
10
© Autonomic Materials
Note that all costs have been rendered
2 1
Figure 2: Adhesion test for self-healing additive vs. standard coating.
N. 52 - JULY/AUGUST 2018 - international PAINT&COATING magazine
ANALYSIS
Self-healing additives arrest the propagation of corrosion. AMI’s self-healing additive technology has demonstrated the ability to repair the coating and prevent delamination, thereby preserving the anticorrosion functionality of the coating. Moreover, this technology is autonomic, meaning it requires no mechanical or human intervention to provide healing at the site of damage. Selfhealing additives for anti-corrosive coatings represent a qualitatively new technology that enables protective coatings to self-repair.” life extension up to approximately double the standard service life, as shown in Table 2 (Scenarios #2-4). For example, in Scenario #2, we are extending paint service life by 3 years (from 12 years to 15). Although selfhealing paint is more expensive than the control (for the purposes of this exercise, we are assuming that the cost of the self-healing primer coat is double (2X) the cost of the standard primer coat), the extension in paint service life obviates the need for the second full repainting. As a result, the lifetime cost per square foot falls to $53.37, a cost savings of 15.4%. In Scenario #4, we are assuming paint service lifespan nearly doubles to 23 years. This means the initial coating lasts for almost half of the asset’s lifespan before even the first touch-up is required. As a result, the entire second maintenance painting sequence (second touch up, second maintenance repaint, second full repaint) is eliminated. Over the lifetime of the asset, the asset owner will pay a full 37.0% less. Table 3 shows an illustration of how this breaks down into total costs. Note, the Average Equivalent Annual Cost (AEAC) “converts the entire stream of present and future costs to a present worth (NPV) and then distributes that sum in equal annual amounts over the structure’s life,” as explained by NACE. In this case, total lifetime cost savings in these scenarios range from $678,209 for the most conservative estimate, up t to $1,631,5112. Table 3 Average Cost Equivalent Savings Annual Cost Per Year
Lifetime Cost Savings
12 Years (Standard Coatings)
$ 88,090
--
--
15 Years
$ 74,526
$ 13,564
$ 678,209
19 Years
$ 57,981
$ 30,110
$ 1,505,491
23 Years
$ 55,460
$ 32,630
$ 1,631,511
Paint Service Life
2 Again, for a more detailed explanation of the financial modeling behind these coating costs, please see NACE’s 2016 paper, “Expected Service Life and Cost Considerations for Maintenance and New Construction Protective Coating Work.”
© Autonomic Materials
Maintenance Costs Fall Under All Scenarios To reiterate, the
the damage is constantly rupturing new self-healing microcapsules; that’s why
effectiveness of self-healing
the slope of the blue line is
coatings depends on many
not as steep as the red line.
factors. The point of these
Service life and cost considerations for self-healing coatings in a harsh and highly damaging environment: offshore oil platforms
scenarios is to demonstrate that costs fall significantly with virtually any amount of paint service life extension – even when the cost of the coating is itself higher than normal paint. In fact, testing reveals that all these scenarios are
The example of a municipal
conservative. Doubling
water tower helps us to
the paint service lifespan
see that self-healing agents
might seem excessively
can yield significant savings
hopeful at first glance,
over time, but admittedly,
but extensive testing has
municipal structures typically
found that self-healing
face only moderate corrosive
agents can triple or greater
distress. Our next example
the effective paint service
3 1
lifespan. For example, the following test found a life
Figure 3: Impact of environment on corrosion rates: more extreme environments necessitate nearly twice as many repaint cycles.
extension exceeding 300% (Fig. 2). However, to be capped our financial modelling at twice the normal lifespan
additives yield similar benefits in more extreme conditions. An offshore platform faces some of the most extreme corrosive
© Autonomic Materials
conservative, we
demonstrates that self-healing
conditions that can be found in any industry or
to keep our estimates
environment. In
conservative.
fact, with parts
There are two
of the platform
mechanisms at work.
either immersed
First, due to the initial
in seawater or
release of healing
constantly exposed
agents, the onset
to a splash zone
of adhesion loss
and salt air, the
around the damage
steel corrosion
is delayed, so the
can exceed 100
coating lasts longer
mils per year – ten
before any loss of
times the typical
adhesion (the flat
rate of corrosion
portion of the blue line). Then, once the coating starts losing adhesion, the rate of loss is slower because
12
4 1
Figure 4: Impact on service life of self-healing additives to coating system. Note: these tests are not indicative of guaranteed performance.
N. 52 - JULY/AUGUST 2018 - international PAINT&COATING magazine
for our water tower example above. In turn, those high corrosion rates translate into
ANALYSIS
frequent maintenance repaint cycles: the more extreme the environment, the shorter the service life, the costlier the asset (Fig. 3). Complicating this situation, the repaint cycle may not be implemented as rigorously as desired because of the difficulties of working in harsh environments – further adding cost and eroding serviceable lifespan. The logistical requirements of working in a space-constrained environment in a remote location can put pressure on workers to work fast and light. That, in turn, can result in workers taking unhelpful shortcuts. KTA University, which provides education and instruction around protective coatings, writes: “Too often, the level of diligence in performing the surface preparation of welded or hotwork areas and the reinstatement of the coating systems after the consolidation, is atrocious. It is not unusual to see evidence of epoxy coatings being poured out onto an uncleaned deck and spread out with a yard broom. The indelible proof, including the tread pattern from the worker’s boots, was still visible months or years later. Stories are in circulation of a hardhat being used as a bucket to carry paint that was then just poured onto weld joints on deck plates.” VI In other words, touch-ups, maintenance painting, and full repaints are not just a matter of slapping on another coat of paint but requires intense coordination and downtime on a structure that normally runs 24 hours a day. Fortunately, self-healing paint can remediate these logistical issues in addition to reducing costs. As with the municipal water tower, we have modelled the costs for a variety of scenarios. We include the same sequence of paint operations to protect the hypothetical structure (detailed in Table 4) for its complete service life. Table 5 presents the total costs per square foot, including both materials and labour, of each painting sequence. As before, the first row is the control: a standard coating system with a 12-year service life. Given the structure’s
The high cost of the coating system for offshore oil platforms is exactly what makes the self-healing coatings even more costefficient for this application. By eliminating one or more entire elements of the standard paint cycle, it reduces the total cost enormously. In fact, the self-healing coating achieves even greater savings, up to 53.9% in the scenario positing that the self-healing coating system offers a 23-year service life.”
Š Autonomic Materials
5 1
Figure 5: The cost of the coating itself is typically only a fraction of total painting costs.
Self-healing additives can create a win-win scenario for everyone, including paint formulators and manufacturers as well as end-users. Indeed, paint manufacturers have an opportunity to extend market share through a highly differentiated product with enormous potential value, while charging a premium to account for the reformulation expense and thus improving margins per gallon of paint. Still, even with the increased cost, self-healing paints still enable the end-user to save money over the full lifecycle of the product.�
years, even the standard system sees only one touch up, maintenance repaint, and full repaint. Those paint cycles are quite costly, given the difficulties
Š Autonomic Materials
relatively short serviceable lifespan of 25
described above. However, the high cost of the coating system for offshore oil platforms is exactly what makes the self-healing coatings even more cost-efficient for this application. By eliminating one or more entire elements of the standard paint cycle, it reduces the total cost enormously. In fact, the self-healing coating achieves even greater savings, up to 53.9% in the scenario positing that the self-healing coating system offers a 23-year service life. Table 6 shows a breakdown of how this breaks down into AEAC costs. Is it possible for self-healing agents to extend the lifespan of the coating system up to 23 years and thus save nearly $10 million over its life?
14
6 1
Figure 6: Self-healing coatings yield an increasing cost benefit the longer the extend service life.
N. 52 - JULY/AUGUST 2018 - international PAINT&COATING magazine
ANALYSIS
Any paint system for a big structure – regardless of composition, complexity, environment, or surface preparation – will see improved service life and cost effectiveness by incorporating self-healing agents. Further, the more it costs to maintain a structure and the more severe the environment it faces, the greater the proportional cost savings will be.”
We had an asset owner request testing to determine the answer to that very question. In Figure 4, we see the results of that testing. Their structure was deployed in a harsh environment, and with the customer’s current coating system, it consequently experienced a short paint service lifetime (the red line) of about 8-10 years. Their performance improvement target was for an increase in the service life to 10-12 years (the blue line), and as the NACE financial model demonstrates (Table 5), even such a modest increase would pay for itself very quickly. However, to determine the actual increase in paint service life and cost savings when using self-healing additives, we took this end-user’s system, added our self-healing capsules, and tested service life side-by-side over six months. Overall, testing indicates as much as 9x life extension with the autonomic self-healing coating (the green line), far exceeding the 23-year life extension included in our model. Table 4 - New off-shore oil platform example. Asset Type
Offshore Oil Platform Shipyard first paint, field applied thereafter
Standard Paint System
One coating each of: Organic Zinc / Epoxy / Polyurethane
Self-Healing (SH) Paint System
One coating of self-healing Organic Zinc, one coating of self-healing Epoxy, one coating of standard Polyurethane
Surface Prep
SP-11 (Power Tool Cleaning to Bare Metal) + Containment
Square Footage
100,000
Service Life (Years)
25
Environment
C5-M (Very high, marine – coastal and offshore areas with high salinity)
G RT
Scenario
Table 5 - Offshore oil platform, costs per square foot (Net Present Value) at 4% interest for 4 paint service life scenarios. Paint Original Service Life Painting
Touch-Up 1
Maintenance Repaint 1
Full Repaint 1
Touch Up 2
Maintenance Repaint 2
Full Repaint 2
TOTALS
Cost Savings
1
12 Years Standard
Year 12 $ 13.20
Year 16 $ 22.20
Year 22 $ 40.40
--
--
--
$ 112.65
---
2
15 Years Self-Heal
Year 15 $ 13.60
Year 20 $ 22.70
--
--
--
--
$ 75.76
32.7%
3
19 Years Self-Heal
Year 19 $ 13.10
Year 25 $ 21.70
--
--
--
--
$ 74.20
34.1%
4
23 Years Self-Heal
Year 23 $ 12.60
--
--
--
--
--
$ 51.95
53.9%
$36.96
$ 39.39
Table 6 - AEAC Costs and Savings of Self-Healing Paint. Paint Service Life
Average Equivalent Annual Cost
Cost Savings Per Year
Lifetime Cost Savings
12 Years (Standard Coatings) 15 Years 19 Years 23 Years
$721,083 $ 484,950 $ 474,997 $ 332,562
-$ 236,133 $ 246,086 $ 388,521
-$ 5,903,336 $ 6,152,150 $ 9,713,023
Even an Increased Cost Per Gallon Yields
coating. Coatings must be reformulated to adjust
Lifetime Cost Savings
for pigment volume concentration, pigment size
It should be reiterated that these models,
distribution, resin chemistry to achieve desired
which show greatly reduced volumes of
glass transition temperature (Tg), etc. As a result,
frequency and size scale of recoating is
coating, assume a price premium of double the
reformulation does add some up-front cost in
reduced;
cost of standard. Consequently, self-healing
addition to the cost of the healing agents, but
additives can create a win-win scenario for
this cost is minimal in the context of the ROI to
everyone, including paint formulators and
end-users and coating suppliers.
manufacturers as well as end-users. Indeed,
Even if the cost of the coating doubles, the
paint manufacturers have an opportunity
extension in serviceable lifespan more than
to extend market share through a highly
covers the increased price. Fundamentally, the
In short, any paint system for a big structure
differentiated product with enormous potential
self-healing additive effectively makes every
– regardless of composition, complexity,
value, while charging a premium to account for
gallon of paint less expensive.
environment, or surface preparation – will see
the reformulation expense and thus improving
It’s also worth noting that the cost of the coating
improved service life and cost effectiveness
margins per gallon of paint. Still, even with the
itself is typically only a fraction of the total costs
by incorporating self-healing agents. Further,
increased cost, self-healing paints still enable
associated with the total paint maintenance
the more it costs to maintain a structure and
the end-user to save money over the full
sequence – particularly for structures that
the more severe the environment it faces,
lifecycle of the product.
present logistical difficulties, like offshore oil
the greater the proportional cost savings will
platforms (Fig. 5).
be (Fig. 6). Ultimately, almost any scenario
The extended lifespan, however, continues to
will benefit from using a self-healing coating
pay dividends throughout the asset’s lifespan by:
system.
The cost savings speak for themselves Using calculations provided by NACE, we have shown that end-users can reasonably save hundreds of thousands or millions of dollars if they can extend the lifetime of the paint by even just a few years.
VOC emissions released; • Reducing material and labor costs as the
• Reducing business disruption and lost opportunity costs; and • Increasing overall asset lifetime because of longer lasting coatings.
• Preventing corrosion of the underlying substrate; • Maintaining adhesion to the substrate even after coating damage occurs; • Providing additional protection in areas of
Furthermore, those potentially massive savings
marginal coating application and difficult-to-
even incorporate an increase in the cost of the
inspect areas;
16
• Reducing environmental impact by lowering
N. 52 - JULY/AUGUST 2018 - international PAINT&COATING magazine
References: I http://impact.nace.org/ II https://www.nature.com/articles/s41529-017-0005-2 III http://cradpdf.drdc-rddc.gc.ca/PDFS/unc53/p526285.pdf IV http://www.wlky.com/article/corrosion-blamed-in-water-towercollapse-last-year-1/3759831 V https://www.pnws-awwa.org/uploads/PDFs/.../Dist_FriAM_ RyderLarsen_Corrosion.pdf VI https://ktauniversity.com/maintenance-painting-practicespart-2/
BRAND-NEW
E
uropolveri recently introduced a new product line, 1R Arizona Series,
© Europolveri
1R Arizona, the Latest Series Introduced By Europolveri as a further extension of its product
range. The Series is made of 44 products, all Ral references, with wrinkled finishing and different gloss level. 1R Arizona was developed with particular attention to customers that require not only an always higher level of quality, but also an adjustment to the market needs that put aesthetic of the finished goods first. All the colours available are part of the Pural Series 1R and are formulated in accordance to Qualicoat Class 1 requirements, therefore they grant a high level of protection and durability. From an aesthetic point of view, the wrinkled finishing allows to hide possible defects
2 1
© Europolveri
Fig. 1 and 2: Due to its intrinsic characteristics and to its versatility, the products of 1R Arizona Series turn out to be ideal for the application in different sectors such as architecture, furnishings, illumination, doors and gates.
of the substrate, but it also satisfies the need of an attractive look in line with the design requests. Due to its intrinsic characteristics and to its versatility, the products of 1R Arizona Series turn out to be ideal for the application in different sectors such as architecture, furnishings, illumination, doors and gates. All of these 44 products are available in stock with a minimum order of 25kg. They all add to the 207 new articles of the 5L4 Matt Series and to the other 750 products always available. Market requests are growing and so it is Europolveri willingness to meet them. For further information:
1
18
www.europolveri.it
N. 52 - JULY/AUGUST 2018 - international PAINT&COATING magazine
BRAND-NEW
New End-Use Brochures of BYK-Gardner: QC Solutions for Coatings © BYK-Gardner
B
YK-Gardner, a global leader in the field of measuring color,
correlate to gloss, DOI and orange peel measurement?
appearance and physical
How can I control
properties announces
curing conditions in
new publications focusing
the baking process,
on QC solutions for
to assure optimum
specific end-use markets
mechanical and
like coatings, plastic and
decorative quality?
cosmetics.
Theory, customized
Coatings are fascinating.
to coating needs,
Not much thicker than a
is combined with
human hair, they combine
typical applications
a variety of functions.
including useful
Besides their protection
measurement
behavior and a perfect
techniques and best
finish, they are expected
practices. Typical
to retain their good look
measurement
and properties over a
needs with practical
long time. Consistent and
examples of the
uniform quality are of
various coating
particular importance when
applications from
parts are manufactured in
raw materials to
different production sites.
architectural and
The challenge is to find
decorative paints,
appropriate measurement
industrial and
procedures to guarantee
wood coatings are
defined quality over the
described in detail.
entire production chain.
At the end of the
BYK-Gardner’s new end-use
brochure, you will
brochure, “QC Solutions
find an overview of
for Coatings” (Fig. 1) covers
the BYK-Gardner
1
in an appealing way the various aspects of paint
solution for the Figure 1: The new end-use brochure “QC Solutions for Coatings” by BYK-Gardner.
testing, gives valuable
coatings industry. The QC Solutions
information and hints
metamerism? Color measurement of solid
for Coatings
for daily work in the lab or production
and metallic colors, flop index and sparkle
brochure is available in a variety of
site. The first section of the brochure
evaluation is explained in a compact
different languages.
describes the technical theory behind
and easy to understand way. How does
each method. How to define a “Honey
paint appear under different illumination
For further information:
Yellow” and what is the meaning of
angles or distances, and how does this
www.byk.com
international PAINT&COATING magazine - JULY/AUGUST 2018 - N. 52
19
BRAND-NEW
Collaboration Between KRÜSS and LINSEIS for High-Temperature Contact Angles
C
Concentration will be on the marketing
The system is also extremely flexible
specialists: KRÜSS GmbH,
of the Drop Shape Analyzer – DSA High
in the choice of ambient conditions.
global market leader in the
Temperature for analysis at up to 1550,
Measurements can be carried out
field of contact angle measurement,
1700 or 2000°C (Fig. 1).
in air (oxidizing atmosphere) or
and LINSEIS, as experts in thermal
The instrument, which is also capable
equally under inert gas, in reducing
analysis, have established a new
of measuring thermal expansion and
atmosphere or in vacuum.
cooperative venture. With immediate
deformation, provides everything
As a result of the collaboration,
effect, the two owner-managed family
needed for accurate wetting analysis
LINSEIS will benefit from KRÜSS’
companies will be following a common
at high temperatures with the help
expertise and market knowledge in
path in the field of high-temperature
of the contact angle. This includes
the field of wetting analysis, while
contact angle measurement.
precise and stable target temperatures,
KRÜSS will be able to call upon
High-temperature contact angle
the accurate control of temperature
LINSEIS’ expert knowledge in high-
measurements are of interest, for
ramps, the simple introduction of
temperature analysis and extend its
example, in energy recovery with
samples as well as contactless optical
market presence to new industrial and
mineral fuels, for investigating slag for
measurement with high-resolution CCD
research fields.
blast furnaces or in the production
camera and powerful image analysis
of robust enamel coatings. With such
software. Simultaneous measurements
For further information:
coatings in particular, synergies can
of the contact angle and thermal
www.kruss-scientific.com /
be utilized by combining the contact
expansion along with the melting
www.linseis.com
angle method and dilatometry.
deformation are particularly meaningful
Wetting between carrier material and
thanks to the continuous recording
coating is just as important for their
of the entire measurement in a video
stability as the thermal expansion of
image with documented temperature
the different phases.
characteristic.
© KRÜSS
ollaboration between two
1
Figure 1: KRÜSS Drop Shape Analyzer – DSA High Temperature powered by LINSEIS.
20
N. 52 - JULY/AUGUST 2018 - international PAINT&COATING magazine
teerayuttae©fotolia
CHEMICAL SOLUTIONS
Dollmar and Noxor become
DN CHEMICALS SPECIALTY CHEMICALS
PRE-TREATMENT AND SURFACE TREATMENTS
WASTE WATER TREATMENT
INTEROPERATIONAL PROTECTION
CHEMICALS FOR MRO
NANOTECHNOLOGIES
CHLORIDE-FREE PAINT STRIPPERS
DEGREASING AND CLEANING MEDIA
BRAND-NEW
Digital Color Card App: Effect Pigments Go Digital
M
at any time provides a new © Merck
erck, a leading science and technology company, presented a
service experience for everyone working with the company´s
new Digital Color Card application
effect pigments or seeking new
for smartphones and tablets. It
inspiration: “Coatings experts,
brings a realistic representation
designers or brand owners have
of the company´s portfolio of
now direct access to Merck´s
coating effect pigments to the
extensive palette of effect pigments
screen. The app is now available
and can explore their possibilities”,
both for iOS and Android devices.
underlines Felten.
The application is unique in the
The Digital Color Card is useful for
industry and gives a realistic idea
getting inspiration as well as for
how the effect pigments appear in
checking technical details. The app
motion under direct light: sensing
provides two ways to explore the
the movement of the device, the
portfolio: the inspirational view gives
app simulates the behaviour of a
a visual access to the wide range of
real panel being tilted.
colourful pigments. Another view
This enables to inspect a pigment from different angles. Alternatively,
provides more technical information
1
on each pigment. In depth details
it is possible to watch a video of the moving panel. “Digitalization plays a vital role in Merck´s constant development, and the Digital Color Card is one more step in that direction”, explains Friedhelm Felten, Head of the Surface Solutions Business at Merck. The app´s easy accessibility and availability
with all the technical data are Figure 1: The application Digital Color Card by Merck is unique in the industry and gives a realistic idea how the effect pigments appear in motion under direct light: sensing the movement of the device, the app simulates the behaviour of a real panel being tilted.
PAINT SHOP 4.0 DIGITAL ∙ SMART ∙ EFFICIENT
www.eisenmann.com
available on fact sheets. This makes the app the digital supplement for Merck´s existing colour cards and a convenient resource both for designers and for more technically oriented users. For further information: www.merckgroup.com
HIGHLIGHT OF THE MONTH
Doing Paint Inspection Offshore? Your Current Certificate Is Not Enough Markéta Součková Paint-Inspector.Com s.r.o., Brno, Czech Republic
marketa.s@paint-inspector.com
Miguel Parra Corvera © Paint-Inspector.Com
A
s a paint inspector, you might be asked to go through different types of
training in order to oversee certain offshore projects. In order to work on an oil platform in the middle of
Even though the training is only three days, it takes a lot of courage and discipline to finish the course. The training includes physically difficult and potentially stressful elements. Before an acceptance
the sea, you will most likely have to
to the course, there is a need to
undergo the Basic Offshore Safety
provide a medical certificate.
Induction & Emergency Training
During these three days,
(BOSIET), including the Helicopter
participants learn theory as well as
Underwater Escape Training
go through a practical training.
(HUET) with Emergency Breathing
Safety induction, helicopter safety
System.
and escape, sea survival and first
Oil and gas companies worldwide
aid, and fire fighting and self-
require appropriate offshore
rescue are the topics to learn.
safety and emergency trainings
The first day is theoretical, the
from everybody who travels to
second day starts the real-life
their offshore assets such as oil
practice, which is most likely the
platforms (Fig. 1). Paint inspectors or those who already accepted the job must undergo these safety trainings as well.
hardest part of the entire training.
1
wanting to get a job at a platform
The demonstration of the rescue
Figure 1: Oil and gas companies worldwide require appropriate offshore safety and emergency trainings from everybody who travels to their offshore assets such as oil platforms.
boats and hands-on experience by visiting one of them is still not the worst part. The real challenge
The goal of these trainings is
starts in a swimming pool with
to teach attendees the generic
the helicopter underwater escape
hazards that can occur at the offshore oil and gas installations, potential risks associated with those hazards and how to eliminate or reduce them. Attendees also need to learn basic emergency response and skills from travelling to and from offshore installation by a helicopter and demonstrate (in a simulated environment) that they can use safety equipment during helicopter emergencies and follow procedures during a crash. This 3-day training might seem like an easy task to do before a fun ride in a helicopter, however, these impressions are deceptive.
22
training. Students have to actually escape
As a paint inspector, you might be asked to go through different types of training in order to oversee certain offshore projects. In order to work on an oil platform in the middle of the sea, you will most likely have to undergo the Basic Offshore Safety Induction & Emergency Training (BOSIET), including the Helicopter Underwater Escape Training (HUET) with Emergency Breathing System.”
N. 52 - JULY/AUGUST 2018 - international PAINT&COATING magazine
the helicopter simulator. They need to unstrap themselves and leave the helicopter, however, they need to overcome few bumps on the road such as orientate themselves after the simulator twists or kicking out the window on their way to the surface. “Going underwater and going upside down is the weirdest feeling,” says Richard van der Wal, managing director at Paint-Inspector.Com (Fig. 2), “even though you know there is no danger at the moment you need to calm down and think straight.”
HIGHLIGHT OF THE MONTH
Paint-Inspector.Com is able to provide inspectors with BOSIET and HUET certificates anywhere around the world and is currently working for a leading Oil & Gas company, PetroGas, to support their maintenance program, and provide needed paint inspectors with BOSIET and HUET certificates. Third day continues with CPR training, working with fire extinguisher and how to behave in a room full of smoke. Going through additional training after getting your paint inspector certificates (FROSIO, NACE, Icorr etc.) might seem like an unnecessary work, but be sure that you will be glad to have this one! As a paint inspector, there is still a need to educate yourself and overcome some obstacles. Paint-Inspector.Com is able to provide inspectors with BOSIET and HUET certificates anywhere around the world and is currently working for a leading Oil & Gas company, PetroGas, to support their maintenance program, and provide paint inspectors with BOSIET and HUET
Š Paint-Inspector.Com
certificates.
2 1
Figure 2: Richard van der Wal, managing director at Paint-Inspector.Com during Helicopter Underwater Escape Training (HUET).
teerayuttae Š fotolia
Opening photo: Dollmar Spa (Caleppio di Settala, MI, Italy) and Noxorsokem Group Srl (Cusano di Zoppola, PN, Italy) combined their activities and skills into one company devoted to the development of products and services for the surface pre-treatment, paint stripping, and water treatment fields: DN Chemicals.
HIGHLIGHT OF THE MONTH
The Synergy between Dollmar and Noxorsokem Group Creates a New Specialised, High Added Value Business Barbara Pennati ipcmÂŽ
T
he industrial coating sector is
technological innovations. Changes and
Very often, collaboration between
undoubtedly a complex market,
transformations are therefore a constant
companies proved to be a winning choice
rich in nuances and still with
that any firm should take into account
to attain both individual and common
wide margins of growth. Like many other
to develop effective strategies for the
goals and give added value even to
industrial sectors, it is greatly affected by
achievement of its objectives.
products already known and established
24
N. 52 - JULY/AUGUST 2018 - international PAINT&COATING magazine
HIGHLIGHT OF THE MONTH
for the surface pre-treatment, paint
The two divisions have therefore
two companies with over thirty years of
stripping, and water treatment fields (ref.
merged into a new company with its
history that decided to embark on a path
Opening photo).
own corporate identity. Fulvio Truant
of cooperation: Dollmar Spa (Caleppio
“The right synergies had been created
(Noxor) will be the technical manager,
di Settala, MI, Italy), established in 1947
in terms of both sales and R&D, so
André Bernasconi (Dollmar) the sales
and specialising in surface pre-treatment
we strengthened our collaboration
manager, and Gianluca Pinna (Noxor)
solutions, and Noxorsokem Group Srl
through the creation of one company,
the general manager (Fig. 2). “In
(Cusano di Zoppola, PN, Italy), established
DN Chemicals (Fig. 1), combining our
the first phase, the well-established
in 1983 and specialising in industrial
pre-treatment, paint stripping, and
brands Dollmar and Noxor will
chemicals for the waste water treatment
waste water treatment know-how under
still be present along with the new
and paint stripping processes.
one brand,” explains Noxor president
trademark. This will provide a sense
The two firms, which had long been
Gianluca Pinna. “The two companies had
of continuity between past, present,
collaborating in terms of sales and
already travelled a long way together and
and future while emphasising the
marketing, combined their activities and
this is a further step forward for us. It is
presence of a new, specialised
skills into one company devoted to the
a work in progress, officialised in March
structure,” says Dollmar CEO Andrea
development of products and services
2018.”
Zamberletti.
© DN Chemicals
on the market. This was the objective of
1
Figure 1: The business unit in Pordenone.
international PAINT&COATING magazine - JULY/AUGUST 2018 - N. 52
25
© DN Chemicals
2 1
Figure 2: From the left: Andrè Bernasconi and Gianluca Pinna, respectively sales manager and general manager of DN Chemicals.
A single identity for a variety of products and services
complete service. This is very important
development, and technical assistance
for us,” states Dollmar sales manager
synergies created.”
The new operational structure will
André Bernasconi. “We aim at developing
“With this operation, we especially aim at giving added value to all these
be devoted to the development of
elements,” says Zamberletti. “This
chemical specialties and it will be equipped with two R&D laboratories, but it will also be able to provide complete surface pre-treatment and paint stripping solutions. “By combining our experience in the field of pre-treatment and nanotechnology
The new operational structure will be devoted to the development of chemical specialties and it will be equipped with two R&D laboratories, but it will also be able to provide complete surface pretreatment and paint stripping solutions.”
is the most important factor of cohesion, because it enables us to specialise and clearly identify all our growth paths under one brand. We will therefore develop specific skills, but we will share them for a common goal of growth,
with Noxor’s expertise in flocculant products for the water treatment
complementary products to be offered
aiming for an increasingly cross-sectoral but
and paint stripping sectors, we will be
directly to our clients thanks to the
at the same time specialised service. We
able to provide our customers with a
wider sale network and the production,
used to do this as two separate companies,
26
N. 52 - JULY/AUGUST 2018 - international PAINT&COATING magazine
HIGHLIGHT OF THE MONTH
whereas now it will be the objective of this new company devoted to all the corollary activities of coating processes.”
Towards new markets “In this first phase, we aim at consolidating our presence on our two firms’ long-standing target markets and at making our synergy
PAINTING ROBOTS & SYSTEM INTEGRATOR We are able to provide the full range of articulated and cartesian robots for every painting need!
more active and efficient,” explains Gianluca Pinna. “The interaction is constant, not only among professionals but also with clients, within a dynamic framework and with qualified personnel able to formulate and produce customised chemical specialties for any industrial process. Our peculiarities and expertise have proved to be perfectly
LeBot MV A5-A6: 5 and 6 axis articulated robot with self-learning, point to point and 3D offline programming, also available in chariot, carriage and carousel configuration with 3D Lesta shape acquisition system.
overlapping and they enable us to effectively manage all orders, regardless of their volume. We can thus meet the demands of all types of customers, fulfil the needs of various market fields, and offer a broader and more complete product range.” “Initially, we will consolidate our presence on the Italian market. Then, we will optimise the right strategies to promote our presence also on the foreign markets with which both companies already work through different distribution channels,” says Bernasconi. “In terms of industrial segments, we will focus on the fields of car components,
LeBot C5: 5 axis cartesian robot with 3D Lesta shape acquisition system. acqui ystem.
earth moving machinery, and contracting coating; subsequently, we will try to improve our presence in the sectors of coils, profiles, and aluminium wheels.”
An active collaboration for a future of growth “During the development phases that led to the establishment of this new business, we were very pleased with the fact that all the players involved in the project collaborated in a completely natural way, integrating perfectly and successfully working on all kinds of products for the surface pre-treatment, water treatment, and paint stripping fields,” states Bernasconi. “The constant and spontaneous exchange of experiences has allowed us to work together and create a
LeBot IA6: articulated 6-axis industrial robots with jointed-arm kinematics for all point-to-point and continuous-path tasks, controlled by our LeCRob K-Manager software. LeBot IA6 robots can work with 3D Lesta shape system. aacquisition ac qu tem.
harmonious and functional corporate structure, as well as developing a wide range of products suitable for many industries and for the most diverse needs.” “Proactivity and versatility have allowed us to move towards new fields and they will enable us to plan the future strategies of our new and growing business,” says Bernasconi.
During the development phases that led to the establishment of this new business, Dollmar and Noxorsokem Group were very pleased with the fact that all the players involved in the project collaborated in a completely natural way, integrating perfectly and successfully working on all kinds of products for the surface pre-treatment, water treatment, and paint stripping fields.”
WWW.LESTA.IT
LESTA S.r.l.
Via D. Chiesa, 42 - 20020 Dairago (MI) - Italy +39 0331.430817 0331.1581053 +39 0331.158 info@lesta.it
BUSINESS CARDS
JOB OFFER Global leading company in the field of zero liquid discharge (ZLD) wastewater treatment for metal finishing line, with more than 30 years’ experience in design, development, manufacture and installation of wastewater plants, is searching for the following job candidates: CHEMICAL OR MECHANICAL ENGINEERS (or comparable preparation) DESIGNERS (Autocad 2D/3D) QUALITY, SAFETY AND MANUAL OFFICERS SOFTWARE TECHNICIANS, AUTOMATION (Siemens, A.B.) What you need to succeed: - Aged preferably under 35; - Good knowledge of MS Office and order management systems; - Written and spoken english (min. level required: B2); - Availability to travel abroad for medium-term periods; - Candidates coming from Metal Finishing sector appreciated.
Place of work: CIE Milano. Please send detailed CV to silvia.tamburini@cieeng.com and indicate availability for Skype interviews http://www.cieeng.com
28
N. 52 - JULY/AUGUST 2018 - international PAINT&COATING magazine
... On the road to
ipcm
®
n. 52...
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Incontrate fornitori e professionisti del settore. Scoprite le ultime tecnologie, ricercate prodotti e servizi.
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SPECIAL ON TRANSPORTATION
32
FOCUS ON TECHNOLOGY Flawless Finishes for Alloy Wheels: The Secret Is in the Spray Gun
38
FOCUS ON TECHNOLOGY Fainsa, Where Cutting-Edge Technology Meets Tradition: Double Production Speed and Higher Coating Quality for Public Transport Seats
46
INNOVATIONS: PRESENT&FUTURE IDROLIN/K DTM: Easy To Use with Good Anti-Corrosion Performance
48
SUCCESS STORIES EcoInCure: Space-Saving Oven Technology for Electric Cars
50
HIGHLIGHT OF THE MONTH Future Mobility and Human Needs Inspire BASF’s 2018-19 Automotive Color Trends
54
BRAND NEW
58
INNOVATIONS: PRESENT&FUTURE
JackF © Fotolia
Alternative and Innovative Technologies Implemented in Coating Booths for Railway Vehicles
© ipcm ®
Opening picture: Cevher is one of the most innovative alloy wheel suppliers of European OEMs.
FOCUS ON TECHNOLOGY
SPECI AL ON T R AN SPORTATION
Flawless Finishes for Alloy Wheels: The Secret Is in the Spray Gun Alessia Venturi ipcm®
A
lthough the reduction of
management costs; and the efficient
Cevher Wheels, a Turkish company
environmental impact and of raw
integration of modern and advanced
producing alloy wheels for cars (ref.
material consumption has been a
systems even in dated equipment,
Opening Photo), managed to achieve
priority for some time now, the main needs
because production devices can be
all these objectives by only updating the
currently expressed by the manufacturing
updated at different stages to cope with
spraying equipment integrated in its
industry include greater operational safety;
costs. In the industrial finishing sector,
already-existing coating system. This was
reduced production spaces, since space
all this must go hand in hand with an
possible thanks to the expertise of Graco in
has increasingly higher purchase and
impeccable finishing quality.
the electrostatic coating field.
32
N. 52 - JULY/AUGUST 2018 - international PAINT&COATING magazine
FOCUS ON TECHNOLOGY
The partner of the major European automobile groups
The parts are cured at 180 °C (Fig. 4),
of the primer and the base coat and
cooled, and subjected to quality controls
they are then subjected to the coating
With 1 million and 600 thousand
with the possible sanding of any defects.
cycle from the beginning, i.e. from the
workpieces produced, a turnover of
Then, we apply the liquid base coat – we
pre-treatment stage; finally, two layers
over 70 million Euros in 2017, and an
manage over 15 colours, although the
of clear coat are applied, a powder and
export rate of nearly 100%, Cevher
most used ones are 6 or 7 – and the
a liquid one, for a total of four layers of
Wheels (Izmir, Turkey) is one of the
acrylic clear coat (Fig. 5) with a wet-on-
paint.”
most innovative alloy wheel suppliers
wet process featuring a 12-minute flash
company covers an area
An investment in spraying quality and consumption reduction
of 44,000 m2, of which
From the beginning,
22,000 are covered. It
Cevher has
integrates vertically the
always been at
entire production process
the forefront of
of wheels, from casting to
experimentation
finishing through mould
and willing to
design.
implement new
© ipcm ®
of European automobile groups, including Volkswagen and FCA. Established in 2002, the
“Cevher’s production process is divided into five phases: melting of primary aluminium, low pressure die casting
technologies, as
1
proven by its recent
Figure 1: From left to right: Michael Lucas and Erbil Zerenler of Graco, Arda Cilantli of Cevher, Harun Dağteke of Genmar, Miranda Houbrechts of Graco, Alessia Venturi of ipcm and Semih Balkaya of Cevher.
of wheels, thermal
investment in the replacement of all automatic spray guns with Graco’s
treatments, machining, and coating,”
off stage between the two application
Pro XPc Auto
says Cevher coating manager Arda
operations. Polymerisation takes
(Fig. 6) devices. “We have always
Cilantli (Fig. 1). “We are equipped with
place in a hot air oven at 150 °C for
used the electrostatic technology for
3 melting furnaces, 28 low pressure
15 minutes. At the end of the coating
spraying liquid coatings. A year ago, we
presses, a continuous flow heat
cycle, the wheels proceed to the final
approved an investment to replace all
treatment line, 8 machining stations
control and packaging stations. In case
our equipment, especially atomisers and
with 3 lathes each, a mirror polishing
a diamond finish is required, the wheels
control units (Fig. 7),” says Arda Cilantli.
station with 5 lathes featuring an
are mirror polished after the application
“Graco was already our technological
tm
annual capacity of 300,000 wheels,
partner for the supply of both
and a coating line featuring an annual capacity of 2 million wheels (Fig. 2). Our factory also has a metallurgical testing laboratory for dimensional, dynamic, and balancing checks and a laboratory for the quality control of coatings.” For the finishing of alloy wheels, Cevher employs the mixed powderliquid coating systems conventionally used in the wheel sector. “After a 13-stage pre-treatment phase (Fig. 3) with Chemetall chemicals, we apply an epoxy-polyester powder primer.
application and paint feeding
Although the reduction of environmental impact and of raw material consumption has been a priority for some time now, the main needs currently expressed by the manufacturing industry include greater operational safety; reduced production spaces, since space has increasingly higher purchase and management costs; and the efficient integration of modern and advanced systems even in dated equipment, because production devices can be updated at different stages to cope with costs.”
devices. We decided to confirm this choice by opting for the implementation of Pro XPc Auto guns. We also considered Graco’s ProBell® rotating bells, but our coating plant does not allow to use them since it cannot guarantee the maintenance of some necessary parameters, such as air temperature and humidity. “We installed six guns in each of the two liquid coating application
international PAINT&COATING magazine - JULY/AUGUST 2018 - N. 52
33
© ipcm ®
© ipcm ®
SPECIAL ON TR ANSPORTAT I ON
2 1
3 1
Figure 2: Cevher painting installation has an annual capacity of 2 million wheels.
Figure 3: Wheels with the powder primer applied during the curing stage.
consumption depending on the
booths, mounted on fixed reciprocators same time: we have different spraying programs to be selected by the operator during loading depending on the wheel’s design and size, which require three or four guns at a time. For instance, for 15 and 16” wheels, we use the guns no. 1, 3, and 6, while for 17 and 18” wheels we use the guns no. 2, 4, and 6. The gun no. 5 is normally kept as a back-up.” “Since we have started using the new Pro XPc Auto guns, we have noticed a significant decrease in overspray,
colour used,” states Arda Cilantli. “This also led to an environmental benefit, because we produce less paint sludge and we consume less chemicals for its treatment. Moreover, the application of some metallic shades now achieves a far better quality level, since the guns’ electronic control units enable us to precisely adjust electrostatic properties such as voltage and current intensity. The old equipment had pneumatic controls that did not allow for the fine-tuning of these parameters.”
© ipcm ®
resulting in a 15%-20% reduction in paint
With 1 million and 600 thousand workpieces produced, a turnover of over 70 million Euros in 2017, and an export rate of nearly 100%, Cevher Wheels (Izmir, Turkey) is one of the most innovative alloy wheel suppliers of European automobile groups, including Volkswagen and FCA. Established in 2002, the company covers an area of 44,000 m2, of which 22,000 are covered. It integrates vertically the entire production process of wheels, from casting to finishing through mould design.”
4 1
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Figure 4: Pre- treatment tunnel.
34
© ipcm ®
(Fig. 8). We never use all the guns at the
N. 52 - JULY/AUGUST 2018 - international PAINT&COATING magazine
Figure 5: Application of the liquid base coat: each booth is equipped with 6 guns mounted on fixed reciprocators.
© Graco
FOCUS ON TECHNOLOGY
From the beginning, Cevher has always been at the forefront of experimentation and willing to implement new technologies, as proven by its recent investment in the replacement of all automatic spray guns with Graco’s Pro XPc Auto devices.”
6 1
Figure 6: Graco’s ProXPc Auto.
The Graco Pro XPc Auto technology
- their small size and weight allow them to
The electrostatic spray guns Pro XPc Auto
- the possibility to control the guns and
be used in confined spaces and corners;
transfer efficiency and reduced material consumption. A salient feature of these devices is safety.
are versatile, compact, and light, which
the coating parameters with a PLC or a
It is no secret that high voltage inside the
makes them the ideal choice for robots and
control unit provides spraying flexibility and
coating booth may involve risks: that is
process improvement;
why the Pro XPc Auto guns have been
reciprocators with low payloads. They are safe, durable, and designed for efficient integration in various types of coating systems:
- their patent pending charge points enable to maximise profits through high
designed with a 100 kV power supply and a low voltage connection cable.
We create chemistry that makes lines love curves. Coatings give a car more than just long-lasting protection. Brilliant gloss and innovative colors transform contours into dynamics and design into emotion. Lines and curves are united and edges and contours are brought to life. When color and shape come together, and paint evokes passion, it’s because at BASF, we create chemistry. www.basf-coatings.com
SPECIAL ON TR ANSPORTAT I ON
© ipcm ®
Figure 7: The spray guns electronic control units.
© ipcm ®
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Figure 8: Application of the acrylic clear coat with Graco’s ProXPc Auto spray guns.
36
8 1
N. 52 - JULY/AUGUST 2018 - international PAINT&COATING magazine
FOCUS ON TECHNOLOGY
Since Cevher has started using the new Pro XPc Auto guns, they have noticed a significant decrease in overspray, resulting in a 15%-20% reduction in paint consumption depending on the colour used. This also led to an environmental benefit, because they produce less paint sludge and consume less chemicals for its treatment. Moreover, the application of some metallic shades now achieves a far better quality level, since the guns’ electronic control units enable them to precisely adjust electrostatic properties such as voltage and current intensity.”
Their external controller, which generates and manages the voltage, features software that detects the presence of electric arcs and automatically stops the electrostatic charge when a workpiece is too close to the gun.
Perfect finishing quality, reduced maintenance, and ease of use “It was difficult to improve the quality of our coating process, but with our new guns and electronic control units we have achieved a perfect finishing level,” states Arda Cilantli. “Graco’s Pro XPc Auto guns are user friendly and feature a smaller number of constructive components, which results in less frequent and easier maintenance operations, since they are easy to disassemble. These devices are practical and reduce system downtimes. Among their main advantages, however, they ensure significant paint savings, nearly 15% for some colours, and thickness uniformity, thanks to the possibility of performing fine adjustments of the coating parameters, such as air pressure and electrostatics. Therefore, our investment in new spraying equipment supplied by Graco has enabled us to achieve a global improvement of our finishing process.”
© ipcm ®
Opening photo: Fainsa is a European leader in the production of passenger seats.
FOCUS ON TECHNOLOGY
SPECI AL ON T R AN SPORTATION
Fainsa, Where Cutting-Edge Technology Meets Tradition: Double Production Speed and Higher Coating Quality for Public Transport Seats Barbara Pennati ipcm®
T
he history of Fainsa (Fabricación
motorcycle accessories in 1935. Since its
seats. In 2015, it became part of the French
Asientos Vehículos Industriales
modest beginnings, Fainsa has recorded
group Compin (ref. Opening photo).
Sa) started in Martorelles, in the
a considerable growth, developing its
The Martorelles-based company currently
northern suburbs of Barcelona (Spain),
technical knowledge and increasingly
covers 24,000 m2 distributed among six
where Aleix Singla Vila opened a small
specialising to establish itself among the
buildings and it produces 150,000 seats per
workshop manufacturing bicycle and
main manufacturers of passenger transport
year, exporting almost 80% of production
38
N. 52 - JULY/AUGUST 2018 - international PAINT&COATING magazine
FOCUS ON TECHNOLOGY
globally. “Fainsa’s strength and key to success lies in
were equipped merely with two manual powder
its ability to combine the craftsmanship and human
application stations. We needed to invest in order
skills earned in over eighty years with the cutting-edge
to improve our productivity, quality, and consistency
production technologies needed to guarantee the
in terms of coating. We looked for a technological
high quality levels required
partner able to offer us
by its target market – public
a functional solution
transport and, in particular,
that was both advanced
the rail and tram sector”, explains Fainsa general manager Salvatore Esposito (Fig. 1). “A large part of our production is intended for foreign markets, with stringent regulatory requirements. The need to cope with the most diverse technical specifications and the exponential growth
Fainsa’s strength and key to success lies in its ability to combine the craftsmanship and human skills earned in over eighty years with the cuttingedge production technologies needed to guarantee the high quality levels required by its target market – public transport and, in particular, the rail and tram sector.”
and able to integrate with Fainsa’s production equipment, including structures dating back to 1935 and, therefore, with a few limitations in terms of logistics.” Fainsa relied on System Pulver (Sant Just Desvern,
KMU LOFT – because resources are limited
Spain), representing Gema on the Spanish market and offering automated
of our company in the
powder coating solutions
last few years forced us
since 1994 (Fig. 2). Thanks to the integration of a new
Moreover, we have always strived to manage all key
generation automatic powder coating system, the
processes in-house: until one year ago, only the
optimisation of some phases such as the hanging
coating phase was largely outsourced because we
one, and the lengthening of its one-rail conveyor,
© ipcm ®
to rethink our factory’s capacity and quality levels.
Impresa leader nel trattamento dei reflui industriali e artigianali attraverso la tecnologia dell’evaporazione. Offriamo • tecnologie di evaporazione a basso consumo energetico e ridotta manu-tenzione; • esperienza e know how ventennale nella realizzazione di più di pro-getti; • soluzioni economicamente all’avan-guardia nella riduzione degli scarichi e nel recupero delle risorse 1
Figure 1: Salvatore Esposito, the general manager of Fainsa.
www.kmu-loft.it
© ipcm ®
SPECIAL ON TR ANSPORTAT I ON
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Fainsa managed to achieve an increase
© ipcm ®
Figure 2: The new powder application booth installed by Gema (Sant Just Desvern, Barcelona, Spain).
Fainsa relied on System Pulver (Sant Just Desvern, Spain), representing Gema on the Spanish market and offering automated powder coating solutions since 1994. Thanks to the integration of a new generation automatic powder coating system, the optimisation of some phases such as the hanging one, and the lengthening of its one-rail conveyor, Fainsa managed to achieve an increase in productivity and an impressive quality level in terms of coating, thickness, and film distension even on the hidden surfaces of its seats.” The need for greater production
in productivity and an impressive quality
versatility is one of the reasons
level in terms of coating, thickness, and film
that led Fainsa to completely
distension even on the hidden surfaces of
automate and insource the
its seats (Fig. 3).
coating process. “The products intended for the public transport
Products and experience behind eighty-three years of history
field are subject to a very high degree of wear, and therefore
At the Martorelles factory, the production
their coating has a purely
process starts with the raw material,
functional purpose. It is essential
especially sheet metal and steel pipes,
to ensure effective corrosion
which is cut, folded, and welded to form
protection, a long service life,
the seat frames (Fig. 4). “Fainsa’s products
and great cleaning ease in case
are divided into two main lines: the seats
of graffiti and vandalism acts,
intended for trains and undergrounds
which are recurrent problems
and those intended for buses,” says
in the sector,” states Salvatore
Salvatore Esposito. “All parts are designed,
Esposito. “For the rail and tram
approved, and treated in-house. We then
sector, however, coatings also
subject our products to strict quality
have an aesthetic function:
controls before sending them to the end
an automotive-level quality is
customers. The in-house management
required, with surfaces free of
of our entire production process is a
any defects and orange peel
significant advantage for us, because it gives us the flexibility to adapt our products to customer needs as much as possible (Fig. 5).”
40
3 1
Figure 3: Fully coated seat frames waiting to be assembled.
N. 52 - JULY/AUGUST 2018 - international PAINT&COATING magazine
effects. That is why we only apply high quality polyester or easy-toclean clean polyurethane
powders with anti-graffiti properties. We
© ipcm ®
FOCUS ON TECHNOLOGY
rely on different paint manufacturers whose expertise is recognised worldwide, including AkzoNobel, Adapta, Tiger Drylac, and Ripol,” says Esposito. “Based on our experience, however, anti-graffiti polyurethane powders are difficultto-manage products, perhaps not yet perfected in terms of formulation. In fact, we find a high variability between different batches as well as problems of adhesion, application and, above all, material recovery, which most manufacturers do not recommend performing.” “We are sure that the coating manufacturers will acquire more and more know-how thanks to the increase in the industrial use of these powders, but for us it was necessary to find a solution to automate our coating process and integrate it within our production flow.
4 1
Figure 4: The automated welding of the seats.
Aluminium Wheel Painting
Excellence in surface finishing For the painting of aluminum wheels, Dürr delivers powerful technologies along the whole process, starting with wheel surface cleaning and chemical conversion for effective corrosion protection, painting and curing, to the purification of air exhaust. Dürr offers their own application technology with specially patented features that fit best with the requirements of quality-oriented aluminum wheel surface painting. www.verind.it
© ipcm ®
SPECIAL ON TR ANSPORTAT I ON
5 1
© ipcm ®
Figure 5: Finished seats waiting to be packaged.
We also aimed at reducing the waste generated by our manual stations, where powders were not recovered, and their disposal costs, while further increasing our quality level,” states Esposito.
The investment on the coating line Fainsa worked with Gema to find a solution that could increase the company’s flexibility and capacity, while optimising the application phase, the process costs, and the consumption levels related to the use, in particular, of polyurethane and polyester paints. “Together with Gema, we developed a project that required the increase of the length of the already-existing one-rail conveyor in order to improve the performance of the line in terms of
42
The need for greater production versatility is one of the reasons that led Fainsa to completely automate and insource the coating process. The products intended for the public transport field are subject to a very high degree of wear, and therefore their coating has a purely functional purpose. It is essential to ensure effective corrosion protection, a long service life, and great cleaning ease in case of graffiti and vandalism acts, which are recurrent problems in the sector. For the rail and tram sector, however, coatings also have an aesthetic function: an automotive-level quality is required, with surfaces free of any defects and orange peel effects.”
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Figure 6: The loading area of the coating plant.
N. 52 - JULY/AUGUST 2018 - international PAINT&COATING magazine
capacity and speed, as
© ipcm ®
FOCUS ON TECHNOLOGY
of Gema’s
well as the optimisation
guns and
of the hanging phase
reciprocators,
with specifically
which ensure
designed frames (Fig.
optimal
6),” explains Marc
distribution of
Garriga, the general
the product,”
manager of Coating
says Salvatore
Point. This consulting
Esposito (Fig.
firm supported Fainsa
11). “Fainsa is
during the setting up
an ISO 14000
of the new coating
certified
line (Fig. 7). “We then
company
replaced the two
and it is very
manual stations with
attentive to
Gema MagicCompact
environmental
booth featuring a quick colour change system, an automatic application station equipped with two
issues. The
7 1
OptiCenter
Figure 7: From left to right: Fainsa coating manager Andrés Barba (jokingly nicknamed “the emperor of coatings”), Alessia Venturi (Ipcm), Marc Garriga (Coating Point), and Juan Carlos Gómez (Gema).
recovery system (Fig. 12) allows us to recover the polyester
reciprocators with three guns each (Fig. 8), and two
amount of product applied for
powders, thus reducing waste levels and
manual pre and post-retouching
the same thicknesses – in other
disposal costs and, therefore, achieving
stations (Fig. 9). The booth is
words, greater transfer efficiency.
another important goal. Our working
equipped with optical bars that
The thickness homogeneity
environment has also benefited from this
recognise the workpieces and
achieved by this system is really
because the booth cleaning operations are
automatically activate the guns only
impressive: although manual
easier and faster, as is the colour change process, now requiring about 8 minutes.
to the complex shapes of parts,
Unfortunately, we cannot recover the
immediately ensured a significantly
the application results have greatly
polyurethane powders due to their reactive
lower overspray level and a smaller
improved thanks to the quality
chemical nature that prevents their reuse.”
© ipcm ®
retouching is always necessary, due
© ipcm ®
as they pass (Fig. 10).” “The new spray paint booth
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Figure 8: The booth is equipped with two opposing reciprocators with three guns each and two manual stations.
9 1
Figure 9: The pre and post-retouching stations.
international PAINT&COATING magazine - JULY/AUGUST 2018 - N. 52
43
© ipcm ®
SPECIAL ON TR ANSPORTAT I ON
A future 4.0 for a wellestablished industrial group “The new coating plant has been in operation since August 2017. Although we cannot claim to have solved all the problems related to anti-graffiti powders, Gema’s booth has optimised the consumption levels and improved the thickness uniformity in a relatively short time. This, of course, positively influenced the final quality of parts,” states Marc
© ipcm ®
Garriga.
The new coating plant has been in operation since August 2017. Although Fainsa cannot claim to have solved all the problems related to anti-graffiti powders, Gema’s booth has optimised the consumption levels and improved the thickness uniformity in a relatively short time. This, of course, positively influenced the final quality of parts.” level guaranteed by Gema. They were able to fulfil our needs by showing commitment, respect of the timeline, and the flexibility
10 1
needed to design a modern coating line in a historic infrastructure like that of Fainsa.”
Figure 10: The optical recognition bar at the entrance of the booth.
“The group management is very pleased with the results obtained by Fainsa and they intend to make further investments to implement these technologies also in other plants, in order
44
to offer our customers increasingly greater and, above all, constant production and quality levels,” states Salvatore Esposito. © ipcm ®
Together with Gema, Fainsa developed a project that required the increase of the length of the alreadyexisting one-rail conveyor in order to improve the performance of the line in terms of capacity and speed, as well as the optimisation of the hanging phase with specifically designed frames. Then, they replaced the two manual stations with Gema MagicCompact booth featuring a quick colour change system, an automatic application station equipped with two reciprocators with three guns each and two manual pre and postretouching stations. The booth is equipped with optical bars that recognise the workpieces and automatically activate the guns only as they pass.”
11 1
Figure 11: The paint coverage and spreading are optimal even in undercuts and in the most difficult-to-reach points.
“The current line speed is of 2.6 to 4 metres per minute, depending on the type of product. This has enabled us to speed up our production, increase our production capacity, and completely insource our coating operations, but also to manage the production volume of another company within the group, which is based in Llinares (Andalusia, Spain) and previously relied on coating contractors,” says Salvatore Esposito. “This investment has been very important for
12 1
our firm and we could not have achieved our objectives without the support and quality
N. 52 - JULY/AUGUST 2018 - international PAINT&COATING magazine
Figure 12: The new Gema OptiCenter.
Š Grayson Thermal Systems
Opening photo: Grayson Thermal Systems have been designing and manufacturing bespoke heating, cooling and HVAC products for the Coach, Bus and Commercial Vehicle markets for 40 years and have partnered with Sherwin-Williams after trials of INVER brand paint from the water soluble IDROLIN/K DTM range.
INNOVATIONS: PRESENT&FUTURE
SPECI AL ON T R AN SPORTATION
IDROLIN/K DTM: Easy To Use with Good Anti-Corrosion Performance Christian Lucano Sherwin-Williams, Bologna, Italy
T
christian.lucano@sherwin.com
he technological challenges in the
recent years, one particularly stands
carried out in the past led to formulations
paint industry are increasingly
out fully satisfying the customers:
with those properties, but somehow
focusing on products with high
the development of one component
failing in aesthetic terms. In fact, to ensure
performance in terms of mechanical and
acrylic, water soluble IDROLIN/K DTM
corrosion resistance, it was necessary to
chemical resistance, with good aesthetic
range.
use anti-corrosion pigments, which reduced
properties and, possibly, at reasonable
This is the next generation of the
the brightness on application.
prices. Most part of the research is carried
well-known Idrolin brand, with which
The new IDROLIN/K DTM range performs
out on water based coatings, in which
especially the Italian customers are
well against corrosion, resisting from 300
Sherwin-Williams, with its fifty years of
familiar. The goal is to satisfy the
to 500 hours NSST (Neutral Salt Spray
know-how built up with Inver brand, plays
market demand for a fast, easy to
Test), depending on the substrate, without
a leading role on the market.
apply water soluble product with good
compromising the brightness, which can
Out of the many projects developed in
corrosion resistance. The studies
remain up to 80 gloss at 60° (Figs. 1 and 2).
46
N. 52 - JULY/AUGUST 2018 - international PAINT&COATING magazine
1
© Sherwin-Williams
© Sherwin-Williams
INNOVATIONS: PRESENT&FUTURE
2 1
Figures 1 and 2: The results obtained by IDROLIN standard version (left) and IDROLIN/K (right) after 300h of NSST (Neutral Salt Spray Test).
In addition, the new, high performing acrylic resin,
requirement was for easy to use products, typical
which is the backbone of this product, imparts
for single component paints, but with good anti-
excellent adhesion on various substrates, which lets
corrosion performance, needed in the case of a
us classify the products as DTM, or Direct-To-Metal,
global customer which makes steel piping, this
that is products that can be applied directly to metal.
series fully satisfies all the initial requirements.
Good mechanical properties are also retained, as
Even if it was not one of the main requirements,
confirmed by the direct and inverse impact and
this series exceeds the aesthetic expectations as
cylindrical mandrel bending tests. The surface
well.
hardness after full drying of the film is very good
“Grayson Thermal Systems have been designing
and resistance to light is outstanding, like any other
and manufacturing bespoke heating, cooling
acrylic product. The water and chemical resistance
and HVAC products for the Coach, Bus and
are excellent.
Commercial Vehicle markets for 40 years and
Being a water soluble range, the average level of
are now a market leading supplier around the
VOC (Volatile Organic Compounds) is approximately
globe (ref. Opening photo). We decided to
40 g/l.
partner with Sherwin-Williams after trials of INVER
Last but not least, a very appreciated feature is
brand paint from the water soluble IDROLIN/K
that the drip limit of this product range is over
DTM range and the business has already seen
150μm DFT (Dry Film Thickness). This means that
the benefits from its ease of use, corrosion
high thicknesses may be applied without negatively
protection and consistent cosmetic finish”, said
influencing the final appearance of the painted
Stuart Hateley, managing director of Grayson
surface.
Thermal Systems. “Using this product over a
A very important customer in the UK which
standard solvent based paint has also allowed
manufactures cooling, heating and air conditioning
us to reduce our carbon footprint and adhere to
systems pointed out that they have achieved, thanks
our environmental policy, further securing our
to Idrolin/K DTM product range, a measurable
position as an ethical and environmentally aware
technical improvement. Even though the initial
business across our 5 manufacturing facilities”.
SUCCESS STORIES
SPECI AL ON T R AN SPORTATION
E
lectric, fully networked, highly automated: the new car brand Byton is consistently designed
© Dürr Systems AG
EcoInCure: Space-Saving Oven Technology for Electric Cars for the mobility of the future. The Chinese start-up also insists on stateof-the-art standards for manufacturing and commissioned Dürr to construct a complete paint shop. Distinguishing features are a 20% reduction in footprint and the use of pioneering technologies. An example of this is the EcoInCure oven, which is ideal for electric vehicles. From October 2019, the new Chinese OEM Future Mobility Corporation (FMC) will produce electric vehicles under the Byton brand at its company site in Nanjing. The new paint shop is initially designed for 150,000 vehicles per year – equivalent to 30 units per hour. Growth has already been factored in, since the capacity can easily be doubled. Electric mobility goes hand in hand
1
Figure 1: Improved paint quality thanks to EcoInCure by heating the body from the inside.
with modified body concepts that use new materials or combine materials in
from the inside out reduces the risk
with the body. The robots in the
new ways. Conventional ovens reach
of pinholing. In addition, minimized
spray booths are equipped with the
their limits when steel, aluminum, and
flow velocities along the freshly
latest EcoBell 3 atomizer generation.
composite materials are used together.
painted surfaces ensure a completely
The semi-automatic EcoDryX dry
This is because it is vital that all body parts
undisrupted top coat appearance.
separation system, which separates
are heated uniformly, otherwise thermal
Dürr’s scope of delivery for the new
the overspray in the paint booths
stresses occur. For this challenge, Dürr
paint shop for Byton FMC includes
for primer and top coat, requires
developed a fundamentally new concept
the RoDip® rotational dip process
absolutely no water or chemicals.
in vehicle drying with EcoInCure: bodies
for pretreatment and electrocoating
This simple and robust technology
are heated from the inside out by two
– already equipped for 60 units
works on the basis of cardboard
jet nozzles through the opening for the
per hour – as well as all the robotic
filters.
windshield and two nozzles directed into
and application technology for the
In addition, Dürr is designing a
the engine compartment opening (Fig. 1).
sealing and painting processes. The
downstream exhaust air purification
This enables unprecedented uniformity
electrocoating stage uses the energy-
system made up of the highly
of heating. Compared with conventional
saving and fail-safe system EcoDC
efficient Ecopure® KPR VOC
ovens, there is also a significant
MACS (Fig. 2). This technology uses
adsorptive concentration system
improvement in top-coat quality and
its modular anode control to create a
with combined thermal exhaust air
process performance - because heating
voltage profile in the tank that moves
purification using the Ecopure® RTO.
48
N. 52 - JULY/AUGUST 2018 - international PAINT&COATING magazine
SUCCESS STORIES
© Dürr Systems AG
SPECI AL ON T R AN SPORTATION
Figure 2: The fail-safe EcoDC MACS electrocoating solution is based on a voltage profile in the tank that moves with the body.
saving – also thanks to EcoInCure. This is because the oven transports bodies transversely, halving its length compared to conventional systems. In addition, a central high-bay warehouse saves the space required
2 1
for multiple intermediate buffers and enables intelligent material flow
The scope of delivery of the order
exhaust air from the ovens is purified via the
control. All in all, this Eco+Layout
placed at the beginning of 2018 includes
Ecopure® TAR recuperative thermal process,
from Dürr reduces the paint shop’s
material feeding for PVC and paint,
which also provides all the heat for heating the
footprint by 20 percent.
shop ventilation, fire protection for the
oven in an energy-efficient way.
process systems, and a reverse-osmosis
Despite the extensive equipment, the design
For further information:
plant to reduce the water hardness. The
of the plant will be very compact and space
www.durr.com
join us at
hall 12 - booth E05
www.cieeng.com
info@cieeng.com
© BASF
Opening photo: The 65 colours of BASF’s Automotive Color Trends 2018-19 – Keep it Real.
HIGHLIGHT OF THE MONTH
SPECI AL ON T R AN SPORTATION
Future Mobility and Human Needs Inspire BASF’s 2018-19 Automotive Color Trends Joerg Zumkley BASF Coatings GmbH, Muenster, Germany
T
joerg.zumkley@basf.com
continues to blur the lines between reality and artificiality is
Dark colours, blue hues and complex effects represent the omnipresence of technology
the driving force behind the BASF’s 2018-19 Automotive Color
Advancements in digitalization make technology become
he need to stay authentic in a world where technology
Trends theme – “Keep it Real” (ref. Opening photo).
less visible and more intertwined with reality. Augmented
As innovations such as artificial intelligence, autonomous driving and
reality applications and smart gadgets that simplify everyday
robotic industrialization take hold, the return to the human element –
life merge the real with the digital world. People seem to
people’s needs and emotions – becomes increasingly important. The
spend more time on online platforms, striving for perfection
designers at BASF’s Coatings division translated these observations into
on social media, than in the real world. This omnipresence
a collection of 65 colours for automotive surfaces.
of technology is reflected in the Automotive Color Trends.
50
N. 52 - JULY/AUGUST 2018 - international PAINT&COATING magazine
Shades of grey and blue are the focal
Š BASF
HIGHLIGHT OF THE MONTH
point of the collection. Achromatic colours are combined with complex effects that add colourful and natural accents and represent the merging of reality and the virtual world. Blue hues – mirroring the colour of screens and digital light – appear as strong saturated colours. Natural textures and colour effects symbolize the search for human qualities in a virtual world.
Shifting functions – new mobility concepts will influence colour choices Car sharing concepts, ride hailing services and autonomous driving will shift a car’s function from a personally owned object
1
Figure 1: The Urbanist.
to a more public mode of transportation.
EMEA – Life in urban spaces
of creating an atmosphere of comfort and
For cars that are designed for sharing,
In the EMEA region, the use of
luxury, forms and materials are increasingly
colour pallets with a universal appeal will
urban spaces is changing, with real
displaying straight edges.
play a significant role. The trend collection
places becoming more significant in
These trends are reflected in the colour range
shows how elaborate textures and
metropolitan areas. This is reflected in
for EMEA. Grey nuances stand for urbanity.
intricate effects can make each colour truly
innovative design concepts for semi-
Combined with haptic effects, they build on
unique.
public spaces such as shops, museums
the significance of what can be experienced
In addition, BASF addresses future
and restaurants. The product becomes
for real. The off-white “Grand Blanc�, with
mobility with the continued development
less important while the space itself
its rough texture and its associations with
of functional colours. Select colours of
turns into an experience. It invites digital
concrete, alludes to life in urban spaces.
the collection feature a coatings system
nomads to sit down and stay a while.
Effect particles included in the clear coat
that mitigates heat build-up on the
At the same time, the question of how
accentuate the special nature of a car as
vehicle surface, which reduces the rise of
to attract attention in the face of so
an emotional product. “The Urbanist�, as a
the temperature inside the car. Further
many virtual offerings arises. What is
dark grey, metallic anthracite, represents the
innovations include colours with state-of-
worth looking up from the smartphone
blending of humans and technology (Fig. 1).
the-art functionality, increasing reflectivity
for? One answer may be architectural
The pronounced metallic effect creates
for enhanced LiDAR detectability, without
elements that are rough and in some
unanticipated reflections and conjures up the
compromising their aesthetic appeal.
cases evoke archaic impressions. Instead
desire for attention.
/D 0,*/,25( WHFQRORJLD SHU LO 782 ULYHVWLPHQWR
# &+8+5+10 1(
ĹĞĜ ħĜ ĹĞńŠĜ ÄŽ ĨĜŇĞĜ ÄžĹƒ ĥĜġŇĞĜğń ÄÄœ
įĺŠĥĜĹ? ĹŒĹŒĹŒ Ĺ‰ÄşÄ¸ĹƒĹ„ĹˆĹŠĹ…Ĺ…Ĺ ĹŽ ĸńł ÄžĹƒÄťĹ„#Ĺ‰ÄşÄ¸ĹƒĹ„ĹˆĹŠĹ…Ĺ…Ĺ ĹŽ ĸńł
#0%+ g 664'<<#674# g #5%*'4#674# g 2'55+/'64+ g 7.+5%+ #6'0#
© BASF
SPECIAL ON TR ANSPORTAT I ON
South America – Transformation of classic colour spaces The colours for South America offer a visual connection to the diversity of the region. Two of the most popular colour spaces in the automotive market – black and white – are transformed into elegant, eclectic coatings for cars. Coriolis Force, the region’s key colour, reflects on care and respect of traditional crafts and knowledge handed down over generations. The dark hue exudes a luxurious effect, which is
2 1
created by using a reddish gold flake. Under a strong light source, it creates a
Figure 2: Grey Ambivalence.
genuine aesthetic for the region.
Asia Pacific – Quest for quality in the real life
in North America, Atomium Sky: a deeply saturated blue with a
Colour expertise of the Coatings division
People in the Asia Pacific region
medium coarseness that transitions
The designers of BASF’s Coatings division
have an ambivalent relationship with
to a softer, semi-opaque hue in
observe technological and societal
technology.
longer grazing angles (Fig. 3).
changes and use them as inspiration and
They freely give their personal data
The colour exudes playfulness and
starting point for intensive research into
to companies that make everyday
demonstrates a futuristic spirit
future trends. Every year they translate
life more convenient and embrace
and forward thinking. This is the
their findings and predictions into a
emotional bonds to machines with
second consecutive year that BASF
collection of 65 new colours that reflect
artificial intelligence. At the same
has selected blue as its key colour
on global trends and developments within
time, a desire for human and real-life
in North America, which is a result
the regions of Europe, the Middle East and
contacts and experiences reshapes
of its growing prominence in the
Africa (EMEA), Asia Pacific (AP) and North
public spaces in the cities. Grey
region.
America (NA).
stands for the integration of high performance technology in everyday
© BASF
Ambivalence, a glaring metallic grey,
life (Fig. 2). It is balanced by a solid flop that connects to the real world.
North America – Expanding colour horizons The dismantling of public heroes makes room for new idols. Flaws are accepted as part of being human and diversity is celebrated. A new enthusiasm for science and especially space travel draws attention to far away worlds. The connection of the real and virtual world as well as the relationship of earth and space is captured in BASF’s key colour
52
3 1
Figure 3: Atomium Sky.
N. 52 - JULY/AUGUST 2018 - international PAINT&COATING magazine
New 2018
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BRAND-NEW
SPECI AL ON T R AN SPORTATION
AkzoNobel and Icelandair Let Fly With Stunning New Livery
I
© AkzoNobel
celand’s rich and vivid history is being celebrated with colourful new livery launched by Icelandair, which was specially
created using AkzoNobel products. The Icelandic national airline’s new Boeing 757300 looks stunning with its tri-colour red, white and blue fuselage, which represents the colours of Iceland’s flag (Fig. 1). It was developed
to mark the 100th anniversary of Iceland’s independence and sovereignty. Featuring the company’s latest generation base coat/clear coat system and Aerodur 3001/3002 range, the aircraft is also coated with Aeroflex wing coatings and Aerofine interior cabin coatings. One of its first jobs was to fly Iceland
1
Figure 1: The Icelandic national airline’s new Boeing 757-300 coated using AkzoNobel products.
coatings will continue to provide the kind
these milestones in Iceland’s history,
“We have been partners with Icelandair for
of protection and endurance that has
Iceland’s sovereignty and the Icelandic
many years and were delighted to supply
helped Icelandic culture and heritage to
National team’s debut at the World Cup,
products for their eye-catching new livery,”
thrive for so many years.”
and are thrilled with the result. AkzoNobel
said John Griffin, Director of AkzoNobel’s
Added Icelandair’s Jón Skafti Kristjánsson,
products are used on the entire Icelandair
Aerospace Coatings business. “The design
Director of Marketing: “We wanted to
fleet and we couldn’t be happier with the
looks stunning and our high performance
do something remarkable to celebrate
quality and efficiency of the solutions the
© Icelandair
football fans to Russia.
2 1
Figure 2: The Boeing 757 ‘Hekla Aurora’ based on the Northern Lights.
54
N. 52 - JULY/AUGUST 2018 - international PAINT&COATING magazine
BRAND-NEW
SPECI AL ON T R AN SPORTATION
© Icelandair
The company’s recent acquisition of Disa Technology has also allowed AkzoNobel to expand its product portfolio to include film technology used on aircraft. Added Griffin: “Our emphasis is on producing sustainable, high performance, cost-effective coatings that are easy to use. These qualities have been fundamental to our relationship with Icelandair, which is built on trust, service, quality and reliability.” Icelandair’s new Boeing 757-300 is the carrier’s
3 1
third aircraft to feature special livery. The other
Figure 3: The Boeing 757 ‘Vatnajökull’, representing Europe’s second largest glacier.
two are based on the Northern Lights (Fig. 2) and Europe’s second largest glacier, Vatnajökull (Fig. 3). Both were created with AkzoNobel products.
company supplies. It’s a winning partnership in
waterborne coatings, base coat/clear coat
every sense.”
systems, high solids/low VOC coatings, peelable
AkzoNobel has pioneered and developed
coatings, selectively removable systems and
For further information:
many of the coatings technologies used in
special effects coatings, as well as chrome-free
www.anac.com /
the modern aerospace industry. This includes
systems.
www.akzonobel.com
OptiStar 4.0 The benchmark for the efficient gun control
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Gema Europe Srl | Via Goldoni, 29 Via Carlo Goldoni 29 | 20090 Trezzano Sul Naviglio (MI) | ITALY | T. +39 02 48 400 486 | F. +39 02 48 400 874
www.gemapowdercoating.com
BRAND-NEW
SPECI AL ON T R AN SPORTATION
Major Upgrade Using Flexible Equipment
E
isenmann, the international plant
4.0 production environments. This
out any surface unevenness. “As there
engineering specialist, has been given
underscores the suitability of E-Shuttle
is no need for a solvent-based primer,
overall responsibility for expanding
200 as a component of a smart factory,”
there is a significant improvement in the
the paint shop at BMW Group’s plant in
adds Berger.
paint shop’s eco-efficiency. Furthermore,
Leipzig. Within the scope of the contract,
Eisenmann will also convert an existing
the primerless process is more cost-
Eisenmann will convert the top coat line
top coat line at BMW Group’s Leipzig
effective and cuts the time required to
and perform reengineering work on
plant to a primerless painting process,
paint each body. This makes it possible to
pretreatment and electrocoating.
and reengineer the finishing line. Primer
increase capacity considerably,” explains
This large-scale project includes a new
is conventionally applied to car bodies as
Berger. Installation work will commence
pretreatment/electrocoating system
a second layer. The specially formulated
in December 2018 and the project is
equipped with E-Shuttle 200 conveyors and
water-based base coat, a component of
scheduled to be completed by early 2020.
e-coat dryers. The E-Shuttle 200 conveyor
the integrated paint solution, performs
system moves the car bodies through the
the traditional functions of a primer: to
For futher information:
process tanks on individual shuttles. Its
protect against UV radiation and smooth
www.eisenmann.com
height make it particularly suitable for retrofitting to existing facilities (Fig. 1).
© Eisenmann
compact design and low
“Furthermore, we recommend E-Shuttle 200 to our customers when high throughputs are required, as is the case here,” explains Thomas Berger, Vice President, Sales, Automotive Systems, at Eisenmann. In addition, the flexible dip-coating conveyor is not only an excellent basis for achieving high finish quality, but also enables a variety of vehicle models to be treated on a single production line. “In light of the trend towards ever-greater customization, E-Shuttle 200 is an outstanding investment in the future. Moreover, the system’s intelligent control unit means that it is easily integrated into Industry
56
1
Figure 1: The E-Shuttle 200 conveyor system.
N. 52 - JULY/AUGUST 2018 - international PAINT&COATING magazine
© Savim
Opening photo: When designing a large-sized coating booth, as happens to Savim in the field of the railway vehicles, it is no longer sufficient to perform a mere mathematical calculation to determine the airflow, air change, and electrical and thermal power values.
INNOVATIONS: PRESENT&FUTURE
SPECI AL ON T R AN SPORTATION
Alternative and Innovative Technologies Implemented in Coating Booths for Railway Vehicles Renzo Scavini Savim Europe Srl, Arbizzano (VR, Italy)
58
info@savim-europe.com
N. 52 - JULY/AUGUST 2018 - international PAINT&COATING magazine
INNOVATIONS: PRESENT&FUTURE
W
© Savim
hen designing a largesized coating booth, as
The new air delivery plenum concept creates air intake flows from the booth’s ceiling without
happens to Savim in the
field of the railway vehicles, it is no
generating any interference
longer sufficient to perform a mere
and turbulence among its
mathematical calculation to determine
various segments. The system
the airflow, air change, and electrical
is managed by a PLC that can
and thermal power values (ref.
handle each area and modify
Opening photo). It is necessary to
the operating parameters
analyse each parameter and see
through a point-to-point
how any unnecessary waste can be
process. The PLC also enables
avoided without sacrificing the booth’s
to pre-set the air speed and
efficiency and safety.
air change values also based
In particular, the size and shape
on the different types of
regularity of railway vehicles should
coatings used. The coating
be taken into consideration. For
booth becomes therefore like
obvious reasons of size, these booths are equipped with several identical ventilation and heating devices installed along its length, in order to cover the entire coating
a series of adjacent identical
1
booths without any separation
Figure 1: The coating booth becomes like a series of adjacent identical booths without any separation between them.
between them (Fig. 1). Each of these booths has an autonomous functioning, identical or different from the
application area. Conventional booths alternately act as a coating booth, a
vehicle in the booth and therefore the
others. The PLC manages the cycle,
flash-off station, and a drying oven. By
lead time, thus increasing the paint shop’s
whereas the operator only gives consent
productivity.
based on his position (Fig. 2).
taking into consideration the size and shape regularity of the structure to be
This enables to reduce the plant’s
Savim made this possible by creating
coated, however, it is possible to create
energy consumption, process times, and
air delivery plenums with a technology
different properly sized segments and
management costs. The expertise of
fine-tuned over the last fifteen years in
to assign them to various operating
Savim and its new heating and air diffusion
the coating of large workpieces and in
phases. This ensures three important
technologies make all this possible. The
the field of composite materials. The air
advantages:
application of new technologies is always
entering the plenums passes through
• Saving electrical and thermal energy.
costly, since new equipment must be
micro-perforated diffusers that evenly
• Simultaneously performing coating
implemented in the booths, but the
distribute it among the filters and
and flash-off operations in different
considerable savings guaranteed make this
introduce it in the booth in a perfectly
areas of the same booth.
a very convenient, profitable, and easily
perpendicular way, from top to bottom.
amortisable investment.
This is especially important when it is
• Reducing the staying time of each
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© Savim
The air entering the plenums passes through micro-perforated diffusers that evenly distribute it among the filters and introduce it in the booth in a perfectly perpendicular way, from top to bottom. This is especially important when it is also necessary to control the humidity in the booth.” by a micro-flame burner. The exhaust air exhaust chimneys are also used. A control unit continuously monitors the
2 1
operating parameters and air quality
Figure 2: Each of these booths has an autonomous functioning, identical or different from the others. The PLC manages the cycle, whereas the operator only gives consent based on his position.
levels. The attainment of the right temperature is almost immediate and manageable with precision, since there are no heavy exchangers with their related thermal flywheel, which also
60
also necessary to control the humidity in the
lengthens the air heating and cooling
booth. Controlling and managing accurately the
times.
amount of circulating air enables to limit and
These concepts can be applied
maximise the investment and management
successfully not only to large-sized
costs of expensive and costly equipment.
booths, but also to smaller booths and
This also applies to the booth’s air heating
systems for coating components.
equipment: for decades, Savim has used direct
© Savim
Conventional booths alternately act as a coating booth, a flash-off station, and a drying oven. By taking into consideration the size and shape regularity of the structure to be coated, however, it is possible to create different properly sized segments and to assign them to various operating phases. This ensures three important advantages: saving electrical and thermal energy; simultaneously performing coating and flash-off operations in different areas of the same booth; reducing the staying time of each vehicle in the booth and therefore the lead time, thus increasing the paint shop’s productivity. The expertise of Savim and its new heating and air diffusion technologies make all this possible.”
fire heating units that ensure energy savings, as confirmed by a 30% reduction in consumption costs, as well as constant temperatures in the booth (Fig. 3). Direct fire heating units have a nearly 100% yield. They do not require a conventional combustion chamber with tube bundles
3 1
nor a flue exhaust chimney, replaced
N. 52 - JULY/AUGUST 2018 - international PAINT&COATING magazine
Figure 3: Direct fire heating units for Savim’s coating booths.
SUCCESS STORIES
SPECI AL ON T R AN SPORTATION
The World’s Largest Preservation Line in the Ship Building Industry Goes to Finland
T
in 2014 was a strategically important
go with the Rösler concept was the
of a preservation line at ND
milestone for the Meyer family. It
high productivity and reliability of the
Coatings, a strategic partner of
coincided with substantial investments
preservation line Rösler had supplied
the Meyer Werft shipyard in the German
in state-of-the-art equipment for the
to ND Coatings, the strategic partner of
town of Papenburg, Rösler has now
production of cruise ships. These
the Meyer Werft shipyard in Papenburg
delivered a second line for the Meyer
included a preservation line with leveling
for corrosion protection, insulation and
Werft shipyard in Turku, Finland (Fig. 1).
stations for bulb flat steel, straight
surface treatment (Fig. 2).
This is the largest equipment project ever
flat steel profiles and steel plates, all
This is one of the most modern and
undertaken by Rösler.
designed and built by Rösler. A key
eco-friendly preservation lines in the
The acquisition of the shipyard in Turku
factor in the customer’s decision to
world! © Meyer Turku Oy
hree years after the commissioning
1
Figure 1: Three years after the commissioning of a preservation line at ND Coatings, a strategic partner of the Meyer Werft shipyard in the German town of Papenburg, Rösler has now delivered a second line for the Meyer Werft shipyard in Turku, Finland.
62
N. 52 - JULY/AUGUST 2018 - international PAINT&COATING magazine
SPECI AL ON T R AN SPOR TAT I ON
© Rösler
SUCCESS STORIES
2 1
Figure 2: A key factor in the customer’s decision to go with the Rösler concept was the high productivity and reliability of the preservation line Rösler had supplied to ND Coatings, the strategic partner of the Meyer Werft shipyard in Papenburg for corrosion protection, insulation and surface treatment.
Fully automatic line including two shot blast machines
the control system automatically determines if the
The 225 meter (740 feet) long shot blast and
with which color they must be painted, or if they
leveling preservation line was completely
must only undergo a partial process. For every
work pieces must be cleaned, shot blasted, leveled,
custom engineered
finished component
to the needs of Meyer
all process parameter
Turku and consists of an inter-linked work piece transport system, pre-heaters, two independent shot blast machines, suitable leveling systems for beams and plates and a paint station with dryer. All system components
The acquisition of the shipyard in Turku in 2014 was a strategically important milestone for the Meyer family. It coincided with substantial investments in state-of-the-art equipment for the production of cruise ships. These included a preservation line with leveling stations for bulb flat steel, straight flat steel profiles and steel plates, all designed and built by Rösler.”
are linked with each
are reported back to the production control system allowing for complete and precise documentation. The steel profiles, which are stored outdoors, are covered with rust or scale from the roll forming process. Depending on the season, they
other and integrated into the production
may also be covered with snow and ice. Seven
control system of the shipyard. Upon arrival
work pieces are combined into a single batch on
of the work pieces at the line entrance,
the transport system and are passed through the
SUCCESS STORIES
The steel plates, stored in a roof-covered outdoor area, can be up to 100 mm (4”) thick, 3,300 mm (130”) wide and 24,000 mm (945”) long. They are picked up by a magnetic portal crane and placed in a centered position on the load station of the roller conveyor, the so-called main transport line. A sensor monitors the entire loading process. In the first stage the steel plates are passed through a blow-off station for the removal of water and other debris followed by a pre-heating step. From there they enter the RRB 35/6-HD roller conveyor shot blast machine at an average speed of 5 m (16 feet) per minute.”
SPECI AL ON T R AN SPORTATION
subsequent batching station with batch
with spray guns from above and below
widths of up to 3,200 mm (126”).
the work pieces. To minimize overspray,
The steel plates, stored in a roof-covered
the spray guns are controlled by a work
outdoor area, can be up to 100 mm (4”)
piece recognition and displacement
thick, 3,300 mm (130”) wide and 24,000
measuring system. The solvent used for
mm (945”) long. They are picked up by
rinsing and cleaning is conditioned and
a magnetic portal crane and placed in a
recovered in a processing plant allowing
centered position on the load station of
the recovery and recycling of 98% of the
the roller conveyor, the so-called main
material.
transport line. A sensor monitors the
The drier was designed to ensure
entire loading process. In the first stage
fast and optimum curing of the paint.
the steel plates are passed through a
It is equipped with gas burners and
blow-off station for the removal of water
recirculation nozzles at the top and
and other debris followed by a pre-heating
bottom of the cabin.
step. From there they enter the RRB 35/6-
In a last step the plates and profiles are
HD roller conveyor shot blast machine
staged at various unload stations for
at an average speed of 5 m (16 feet) per
downstream manufacturing operations
minute. The blast machine is equipped
as prescribed by the production control
with eight (8) high performance turbines,
system.
type Rutten Gamma 400, with an installed drive power of 37 kW each. To minimize
For further information:
the wear rate and facilitate maintenance,
www.rosler.com
the blast chamber, fabricated from manganese steel, is lined with overlapping, easy to replace manganese steel plates.
cleaning station/pre-heater for de-icing
After the removal of residual blast media
– if required - at a speed of 3 m (10 feet)
in a brush- and blow-off station the work
per minute. In a subsequent stage the
pieces undergo a leveling process.
work pieces undergo a blast cleaning
To allow for the channeling of shot
process in a roller conveyor shot
blasted batches of profiles onto the main
blasting machine, type RRB 16/5. Four
transport line for painting, the loading
Gamma 400 G turbines with a drive
of raw steel plates stops automatically,
power of 15 kW each ensure optimum
as soon as a finished batch of profiles is
blasting results. They are mounted
standing by. These batches are passed
on the roof and bottom of the blast
through the various stations, even
chamber made from manganese steel.
permitting the profiles to be pre-heated
Easy to replace, overlapping manganese
and undergoing a secondary blast
steel liners provide additional protection
process.
against premature wear. After travelling
in single file for passing through the
Coating with a minimum of overspray and solvent recovery
subsequent leveling system at a speed
The paint process at the end of the
of 30 m (100 feet) per minute. Faulty
line takes place with solvent-based
profiles are immediately discharged
2-component paint types in two colors,
from the system. The profiles within
which are automatically and instantly
specs are combined into batches in the
mixed as required. The paint is applied
through a blast media brush- and blow-off station the profiles are aligned
64
N. 52 - JULY/AUGUST 2018 - international PAINT&COATING magazine
The paint process at the end of the line takes place with solvent-based 2-component paint types in two colors, which are automatically and instantly mixed as required. The paint is applied with spray guns from above and below the work pieces. To minimize overspray, the spray guns are controlled by a work piece recognition and displacement measuring system. The solvent used for rinsing and cleaning is conditioned and recovered in a processing plant allowing the recovery and recycling of 98% of the material.”
© Dürr
Opening photo: The railway sector requires productivity, cost optimisation, safety, and a highly durable finishes with excellent anti-corrosion performance.
INNOVATIONS: PRESENT&FUTURE
SPECI AL ON T R AN SPORTATION
Wet-on-wet Application in the Transport Sector. Technological Innovation, Automation, and Industry 4.0 Alessandro Soba Verind S.p.a., Rodano, Milan (Italy)
verind@verind.it
Preliminary remarks
friendly technologies are those that can
materials, and design, and on the other
People who have the ability to innovate, to
contribute to building a modern industrial
hand productivity, cost optimisation,
believe in what they do, to have the courage
business able to compete in the global
eco-friendliness, innovation, and safety.
to question themselves, designing systems
market. Today’s main issues in the industry
All of them combined may help to build a
that implement energy efficient and eco-
concern on the one hand shapes, surfaces,
technological vision that can integrate in
66
N. 52 - JULY/AUGUST 2018 - international PAINT&COATING magazine
INNOVATIONS: PRESENT&FUTURE
(Fig. 1) and with systems that may include as
production processes requiring excellent surface finishes with a protective and corrosion protection function. These are the characteristics required by the transport sector, especially in the railway field (ref. Opening photo).
Characteristics required from a modern coating plant A modern coating plant must possess some essential characteristics and ensure the achievement of certain quality and efficiency results, such as: • excellent finishing quality in terms of
People who have the ability to innovate, to believe in what they do, to have the courage to question themselves, designing systems that implement energy efficient and eco-friendly technologies are those that can contribute to building a modern industrial business able to compete in the global market.”
aesthetics;
follows: • electrostatic technology • electronic 2K dosing • automatic colour change • paint recovery • application system supervision • laser positioning.
Process objectives: a contribution in terms of application technologies The design and implementation criteria adopted in industrial sectors such as automotive, aircraft, and energy can be © Dürr
• high productivity and low operating costs; • the protection of the safety
extended to the railway field. Reduced energy consumption and
and health of operators and
environmental impact
respect for the environment;
levels are required
• VOC reduction thanks to
for the production
coating solutions with water-
processes. OEMs’ main
based systems, powder
needs/trends in terms
systems, mixed systems,
of coating quality are as
high solid paints (>70% of
follows:
weight), and the elimination
• premium aesthetic
of one or more layers, e.g.
level, increasingly
though the Direct To Metal
comparable with the
(DTM) technology; • implementation of reliable application equipment and techniques suitable for the coating products currently
automotive one; • extreme mechanical,
1
chemical, and corrosion resistance based on the
Figure 1: Two robots coating the ceiling of a railway car.
products’ intended use.
available on the market; • high transfer efficiency with the use of LVLP, electrostatic, airless, or air assisted
predictive maintenance, tele-assistance.
In order to meet these needs and control the process application variables, it is possible to
consumption monitoring controls, in
Application and automation technologies for coating railway vehicles and rolling components
particular with the use of 2k paints;
In this industrial sector, anti-corrosion coating
as follows:
systems are normally applied with single
• an electrically and pneumatically driven
technologies; • implementation of dosage, mixing, and
• automation integrated in compliance with the SCADA concept and the
component (1K) and two component (2K)
Industry 4.0 paradigms: reciprocators,
equipment specifically designed for:
integrate a complete line of Dürr equipment operating according to the new flexibility and Industry 4.0 concepts. A typical line includes
EcoPump with the “4 ball” technology (Fig. 2); • dosing equipment with gear pumps;
robots, coating management units,
• underbodies
• LVLP automatic guns;
automatic colour change devices, paint
• rolling components.
• the EcoBell electrostatic technology with
recovery systems; • digitisation and flexibility of the production cycle (smart factory); • smart solutions, remote service,
rotating bells; • automation devices integrated with the
The vehicles’ internal and external coating systems, on the other hand, are applied with robots integrated in the application booths
reciprocators; • electronic dosing systems EcoDose 2K
international PAINT&COATING magazine - JULY/AUGUST 2018 - N. 52
67
© Dürr
SPECIAL ON TR ANSPORTAT I ON
“Coriolis” for 2K and 3K paints and
Particular attention should be paid to variables such as:
coatings (Fig. 3);
• reliability in the dosing and mixing
• a robotic arm (Fig. 4) to ensure finishing quality, reliability,
of coating products (catalyst, paint,
production improvement, and
additives);
process repeatability.
• reliability in the monitoring of pot life with automatic risk
The coating process: objectives and challenges
management actions by the devices; • ability of the equipment to
For a conventional base coat and top coat system, the goal is combining
2 1
resistance with stability and
Figure 2: An EcoPump device with the “4 ball” technology.
(temperature, viscosity,
dosing, mixing, and application support the operators in the reduction of all potential risks and in the performance of a proper process, as well as
The design and implementation criteria adopted in industrial sectors such as automotive, aircraft, and energy can be extended to the railway field. Reduced energy consumption and environmental impact levels are required for the production processes.”
© Dürr
ensuring high quality results.
3 1
Figure 3: EcoDose 2K electronic mixers.
68
sensitive parameters of coating products
colour gloss properties. The technologies must increasingly
monitor the application KPIs; • ability to monitor all the
mechanical, chemical, and corrosion
N. 52 - JULY/AUGUST 2018 - international PAINT&COATING magazine
density, consumption); • ability of the application equipment to guarantee stable and reproducible operations and thus ensure quality consistency.
© Dürr
INNOVATIONS: PRESENT&FUTURE
FATI
srl
CATENE PER TRASPORTATORI CUSCINETTI A SFERA
CATENE AD ALTE PRESTAZIONI HIGH PERFORMANCE CHAINS LEISTUNGSFÄHIGE KETTEN
NOVITÀ NEW NEUHEIT
HPCOAT
4 1
Figure 4: A robotic arm under construction.
Electronic dosing technologies for 2K products Electronic dosing equipment is the industrial response to 2K coating processes in order to guarantee the best automatic dosing and mixing performance for the paints (be they epoxy, polyurethane, high solid, DTM one-layer, or UV products) on
Particolare dei cuscinetti con HPCOAT Detail of bearing with HPCOAT Ausschnitt der Lager mit HPCOAT
different types of surfaces: metal, steel, plastic, wood, glass, marble, composites. Modern electronic dosing devices are suitable for handling water-based and solvent-based 2K coatings manual or automatic application processes. Moreover, they are suitable for integration into an automatic system (Figs. 5 and 6) with the full control of all application process parameters in order to obtain as follows: • flexibility and reliability;
con | with | mit HPCOAT
• higher surface finishing quality; • reduced production costs;
For a conventional base coat + top coat system, the goal is combining mechanical, chemical, and corrosion resistance with stability and colour gloss properties. The dosing, mixing, and application technologies must increasingly support the operators in the reduction of all potential risks and in the performance of a proper process, as well as ensuring high quality results.”
MORE
• greater productivity and efficiency.
A tt dopo Aspetto d 2 200 ore in nebbia salina Surface after 200 hours of salt spray test senza | without | ohne Aussehen nach 200 Stunden in Salzsprühtest HPCOAT
Coefficiente Resistenza alla d’attrito corrosione Friction factor Corrosion protection Reibwert Korrosionsfestigkeit Costi di Durata alle alte manutenzione temperature Maintenance costs Life-time at high Wartungskosten temperatures Corrosione Beständigkeit gegen Corrosion hohen Temperaturen Korrosion Autolubrifcazione Abrasione alle Self lubrification alte temperature Selbstschmierung Wear at high Produttività temperatures Productivity Abrieb bei hohen Produktivität Temperaturen
FATI srl
LESS
intended for low or high pressure, conventional spray or AA gun,
Via C. Porta, 14 | 23861 Cesana B.za (LC) | Italy t. +39 031 655688 | f. +39 031 656772 info@fatisrl.com | www.fatisrl.com
© Dürr
SPECIAL ON TR ANSPORTAT I ON
5 1
Figure 5: Integrated controls for manual applications.
to the component A and the component B;
Verind’s dosing system EcoDose
The configuration with a higher technological
2K was specifically developed for
content provides for the measurement of
high quality applications. It features
component flow with the Coriolis technology,
system per channel, with alarm thresholds for
the Direct Injection Technology
because:
complete process control.
(DIT), with two independent
• there are no rotary gears flow meters;
channels with automatic injection.
• there is no integrator mixer (A + B sequential
Both channels – A for the coating and B for the catalyst – work simultaneously for a very precise
• no maintenance is required on the fluid dosing section; • there are two separate cleaning circuits devoted
Automatic coating stations with EcoRP and Ready2Spray robots Robots designed to automate the application of coatings on railway vehicles or rolling stock can be installed: © Dürr
and reliable dosing process.
injection technology);
• there is a temperature and density control
6 1
Figure 6: Integrated controls for automatic applications.
70
N. 52 - JULY/AUGUST 2018 - international PAINT&COATING magazine
INNOVATIONS: PRESENT&FUTURE
â&#x20AC;˘ on the floor
robot programs, parameterise the associated
enhanced analysis and diagnostic
â&#x20AC;˘ on the wall
process data, and simulate an entire robotic
functions. EcoScreen 3D-OnSite
â&#x20AC;˘ on the ceiling.
station. The new version of this software
combines all the typical functions
DĂźrrâ&#x20AC;&#x2122;s robots allow for offline coating
of parameterisation, programming,
simulations of cars, locomotives and
simulation, and optimisation of DĂźrrâ&#x20AC;&#x2122;s robots EcoRP. The software is also a
buses. They can be programmed 100% offline thanks to the import of 3D models with a dedicated software and to the automatic calculation of application trajectories. Moreover, it is possible to run offline a verification of the reachability of different surface areas in the framework of the feasibility studies of a coating automation project.
DĂźrrâ&#x20AC;&#x2122;s robots allow for offline coating simulations of cars, locomotives and buses. They can be programmed 100% offline thanks to the import of 3D models with a dedicated software and to the automatic calculation of application trajectories.â&#x20AC;?
part of the smart factory concept that is one of the pillars of the â&#x20AC;&#x153;digital@ DĂ&#x153;RRâ&#x20AC;? strategy. Thanks to its complete simulation functions, EcoScreen 3D-OnSite speeds up the start-up process of systems. It also offers as follows: â&#x20AC;˘ the automatic generation of application trajectories;
EcoScreen 3D-OnSite: increased performance and speed
package can also be used on already-existing
EcoScreen 3D-OnSite is DĂźrrâ&#x20AC;&#x2122;s 3D
systems and it offers additional features
of any other component included
visualisation and programming software.
such as the ability to import models in all
in the installation process (valves,
It was designed to create and process
the main CAD formats, a new 3D library, and
drives, wiring, dosing pumps, etc.).
â&#x20AC;˘ a database manager of spraying parameters; â&#x20AC;˘ perfect integration and management
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international PAINT&COATING magazine - JULY/AUGUST 2018 - N. 52
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71
© DKC
Opening photo: The DKC Group is a leading manufacturer of cable tray systems, especially in the industrial automation sector.
FOCUS ON TECHNOLOGY
DKC Group: Optimising the Pre-Treatment Process for Easier Plant Management and Constant Quality Barbara Pennati ipcm®
I
n the age of digitisation, high tech,
quality degree. That is why the DKC Group
different markets through 6 divisions – DKC
and the pursuit of ever-increasing
has recently made significant investments
Europe, DKC Russia, DKC Ukraine, DKC
quality levels, sometimes the ease of
to simplify the management of its coating
Hungary, DKC Romania, and DKC Maghreb –
management of the plants themselves
systems without sacrificing product quality
the Group is a leading manufacturer of cable
can be neglected despite its actually
and process consistency.
tray systems, especially in the industrial
important role in achieving a high final
Established in 1998 and now present on
automation sector (ref. Opening photo).
72
N. 52 - JULY/AUGUST 2018 - international PAINT&COATING magazine
Over the years, it has diversified its
© DKC
FOCUS ON TECHNOLOGY
treatment and finishing systems
production through the acquisition
(Fig. 4). “Our coating cycle starts
of local companies. Its product
with a pre-treatment phase
range now includes metal cable
including phosphodegreasing,
trays, protection systems for
rinsing with mains water, rinsing
electric cables, mounting modules
with demineralised water,
for photovoltaic panels, carpentry
nanotechnology conversion
components, and air conditioners
application, drying, and coating
for electric boards. In Italy, DKC
(Figs. 5 and 6),” says Oberti.
has production sites in Novi Ligure
“Since the sheets often undergo
(AL), Villanova sull’Arda (PC), Rome,
further processing after coating,
Travagliato (BS), Collegno (TO), and
such as punching or drawing,
Bellinzago Novarese (NO).
it is crucial for us that they are
The Ram Block production unit of
properly treated to ensure
the Bellinzago Novarese factory,
optimum adhesion and flexibility
formerly known as Costel, was the
of the paint film.”
first to modify its coating process with a view to cost efficiency
“However, we had noticed that
1
the coating tended to chalk, with © DKC
and quality improvement and management. “Our unit produces
both aesthetic and qualitative problems. Moreover, our
cabinets, boxes, and pulpits
specifications require a 200
for industrial automation and
hours salt spray resistance value,
low voltage energy distribution
which we could not achieve
processes. We perform in-house
with the chemical process we
every sheet metal processing
used. This also entailed rather
phase, from technical design to
high management costs, mainly
delivery (Figs. 1 and 2),” explains
due to the high replacement
Michele Oberti, the manager of
frequency of the pre-treatment
the Ram Block production unit.
active baths,” states Oberti.
“However, we used to face various
Therefore, DKC developed a new
paint adhesion issues and high
pre-treatment process together
management costs, mainly due
with DN Chemicals, which could
to inadequate pre-treatment.”
adapt to its production needs
Therefore, DKC turned to
and solve its performance, costs,
DN Chemicals Srl, a Milan-based
management, and quality issues.
company specialising in the
“We decided to keep the plant
production and distribution of
installed in 2012 and only modify
industrial chemicals. Together, they
the pre-treatment chemicals.
developed a new pre-treatment
First of all, in order to solve the
process ensuring higher quality
critical issues found by DKC, we
and better plant integration and
integrated a conventional cycle
management (Fig. 3).
featuring a phosphodegreaser
The critical aspects of the pre-treatment process The plant dates back to 2012 and it was supplied by O.M.SA. (Besana in Brianza, MB, Italy), specialising in the design of automatic surface
for carbon steel additivated with surfactant mixtures for higher degreasing power and a final 2 1
passivation stage with Dollcoat
Figure 1 and 2: Cabinets for industrial automation and low voltage energy distribution processes, produced by DKC’s plant in Bellinzago Novarese (Italy).
SA116,” says DN Chemicals technical sales specialist Roberto Rebuffo. “The acidic nature of
international PAINT&COATING magazine - JULY/AUGUST 2018 - N. 52
73
© ipcm ®
Figure 3: From left to right: Maurizio Bovio from DKC, Roberto Rebuffo from DN Chemicals Srl, Alessia Venturi from ipcm, and André Bernasconi from DN Chemicals Srl.
phosphodegreaser able to maintain a constant pH value lower than 4 as well as a final nanotechnology conversion stage with Dollcoat SA111. This product contains silane-based oligomers, whose quantity varies depending on the product to be treated and its intended use. The oligomers’ silanic characteristics allow the product to interact with the coating through the creation of chemical bonds that increase the
3 1
adhesion of paint,” states DN Chemicals sales manager André Bernasconi. “We the material (Fig. 7).”
chose this nanotechnology passivation
adhesion issue without sacrificing quality.
“Based on the improvements obtained
product because DKC’s plant includes
Indeed, since they also treat very glossy
after the adoption of this first process,
no nebulisation system for the last
laminate sheets, it was essential to adopt a
we conducted several tests and created
pre-treatment stage; therefore, the
functional but not too aggressive product,
a tailor-made cycle for DKC. The current
product is recirculated, unlike what
able to preserve the aesthetic properties of
process includes a better performing
happens when using spraying bars © ipcm ®
the phosphodegreaser solved the coating
4 1
Figure 4: The pre-treatment tunnel supplied by O.M.SA. (Besana in Brianza, MB, Italy).
74
N. 52 - JULY/AUGUST 2018 - international PAINT&COATING magazine
© ipcm ®
FOCUS ON TECHNOLOGY
5 1
Figure 5: Components at the entrance to the pre-treatment tunnel.
In the age of digitisation, high tech, and the pursuit of ever-increasing quality levels, sometimes the ease of management of the plants themselves can be neglected despite its actually important role in achieving a high final quality degree. That is why the DKC Group has recently made significant investments to simplify the management of its coating systems without sacrificing product quality and process consistency.”
© ipcm ®
© ipcm ®
DKC developed a new pre-treatment process together with DN Chemicals, which could adapt to its production needs and solve its performance, costs, management, and quality issues. They decided to keep the plant installed in 2012 and only modify the pre-treatment chemicals. First of all, in order to solve the critical issues found by DKC, they integrated a conventional cycle featuring a phosphodegreaser for carbon steel additivated with surfactant mixtures for higher degreasing power and a final passivation stage with Dollcoat SA116.”
6 1
Figure 6: A stage of the spray pre-treatment process using DN Chemicals products.
with an always fresh product. The more the oligomers contained in the formulation, the greater the product’s sensitivity to pollution. With Dollcoat SA111, the DN Chemicals’ product featuring the best anti-corrosion properties, the lower content of oligomers enables to replace the passivation bath only once every two months, or when the conductivity of water exceeds 800 μS.” The coating process is performed by applying polyester or epoxy polyester powders in a quick colour change booth supplied by Gema (Fig. 8), equipped with 2 reciprocators with 4 guns each (Fig. 9) and two pre and post-retouching stations. “Our products are generally intended for indoor use, but for several customisation requests calling for higher performance levels we prefer to apply outdoor coatings or a two-coat system with a zinc primer,” explains Michele Oberti. “With the adoption of this pre-treatment process, the salt spray test results achieved by our workpieces range between 250 and 300 hours, which enables us to fulfil DKC’s specifications. Also the film adhesion properties have improved considerably, allowing us to further process our parts without any quality problems,” states Oberti.
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7 1
Figure 7: Components at the end of the coating process.
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© ipcm ®
FOCUS ON TECHNOLOGY
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
8 1
Figure 8: The quick colour change booth supplied by Gema.
Based on the improvements obtained after the adoption of this first process, DN Chemicals conducted several tests and created a tailor-made cycle for DKC. The current process includes a better performing phosphodegreaser able to maintain a constant pH value lower than 4 as well as a final nanotechnology conversion stage with Dollcoat SA111. This product contains silane-based oligomers, whose quantity varies depending on the product to be treated and its intended use. The oligomers’ silanic characteristics allow the product to interact with the coating through the creation of chemical bonds that increase the adhesion of paint.”
ANTARES S.r.l. 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 ®
A gradual transformation for higher yield
Towards ever higher production versatility “DKC is constantly growing
The first phase of intervention
and it has managed to expand
required the adoption of a
thanks to the acquisition
process that could minimise
of several local companies,
the problems caused by the
reorganised according to the
previous pre-treatment, in
group’s standards in order to
order to enable DN Chemicals
guarantee constant quality
to design a new optimal cycle
to all our global customers,”
for DKC’s plant configuration.
states Michele Oberti. “The
“The current process with a
pre-treatment process
phosphodegreaser and the
currently performed by our
passivating product Dollcoat
Bellinzago Novarese plant has
SA111 was implemented a year
been adopted also by DKC
and half ago. Since then, it has
Romania, whereas O.M.SA.,
ensured optimal paint adhesion,
which installed the system at
higher final quality levels, and
our premises, subsequently
the achievement of the salt
upgraded also the DKC
spray resistance values required
Hungary factory’s line.”
by our customers and the DKC
“In future, we intend to make
specifications,” explains DKC
further investments in coating.
production technology specialist
Our Bellinzago Novarese plant
Maurizio Bovio.
has 95 employees working
“Since we mainly treat
on two shifts and our paint
carbon steel with our
shop is currently saturated.
phosphodegreasers, our
The current space is limited,
sludge production is quite high
but we could make new
compared to those dealing with
space by fully exploiting the
metals of different nature. In
area available. In this way, we
order to avoid any qualitative
could add a rinsing stage to
problems and based on the
the pre-treatment process,
optimal management parameters
thus making it even more
provided by DN Chemicals, we
functional and suitable for the
replace our active baths around
use of an alkaline pH product
once every three months. This
that, if not rinsed properly,
has ensured higher quality degrees and reduced operating costs and waste,” says Michele Oberti. “This performance improvement went hand in hand
9 1
Figure 9: The automatic coating booth is equipped with 2 reciprocators with 4 guns each and two manual pre and post-retouching stations.
inhibits polymerisation; we could also install a second spray paint booth to speed up the application and colour change operations. Our goal
with an increase in the ease
is to become even more
of management of the plant
competitive on the market, offering our customers
itself, which is a very important factor for us. Our operators can manage the entire production cycle more easily, thus achieving a process consistency level that we could not obtain in the past.”
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The coating process is performed by applying polyester or epoxy polyester powders in a quick colour change booth supplied by Gema, equipped with 2 reciprocators with 4 guns each and two pre and post-retouching stations.”
N. 52 - JULY/AUGUST 2018 - international PAINT&COATING magazine
maximum customisation levels while ensuring reduced delivery times and a high quality level,” says Michele Oberti.
© Imel
Opening photo: Imel started to develop i4paintshop at the beginning of 2017 based on the idea of a think tank, which offered to survey the needs of different clients and analyse trends and opportunities deriving from the new SW and HW tools related to digitisation.
INNOVATIONS: PRESENT&FUTURE
Imel presents the i4paintshop Platform for 4.0 Management of Coating Plants and the Facilitation of Decision-Making Processes From an interview with Imel Spa general manager Stefano Bianchin
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INNOVATIONS: PRESENT&FUTURE
I
delivery of a service component as
mel Spa is a company specialized in the design of coating systems based in Codroipo (UD, Italy).
Always focussing on the continuous improvement of products thanks to its technical expertise, it has recently decided to re-engineer its organisation with the addition of new management personnel in key positions (Fig. 1). Also its R&D, electrical and software design, and service departments have been improved. As for the service department, both its processes and its staff are being reorganised aiming
an added value, when providing products1. “Servitisation” is an integral part of the company’s 4.0-oriented approach. “For Imel, Industry 4.0 is synonymous with demand and opportunity,” says Stefano Bianchin, the general manager of Imel. “Why ‘demand’? Because the most advanced customers increasingly tend to ask for real-time processing of the big data generated by their plants’ PLCs. Their aim is making quick and 1
http://international-dictionary.com
© Imel
at the so-called “servitisation”, i.e. the
Imel Spa is a company specialising in the design of coating systems based in Codroipo (UD, Italy). Always focussing on the continuous improvement of products thanks to its sound technical expertise, it has recently decided to re-engineer its organisation with the addition of new management personnel in key positions.”
1
Figure 1: IMEL Spa (Codroipo, UD, Italy), a company specialising in the design of coating systems, has decided to re-engineer its organisation with the addition of new management personnel in key positions; also its R&D, electrical and software design, and service departments have been improved.
international PAINT&COATING magazine - JULY/AUGUST 2018 - N. 52
81
Imel started to develop i4paintshop at the beginning of 2017 based on the idea of a think tank, which offered to survey the needs of different clients and analyse trends and opportunities deriving from the new SW and HW tools related to digitisation.”
sound decisions about consumption and cost reduction; global efficiency parameter control and, therefore, shift and production planning; and quality management and improvement through the traceability over time of batch process parameters. Moreover, it is now clear that the concept of competitiveness in the strict sense is not sufficient for customers in order to prevail in the market. The assessment and monitoring of the environmental impact of one’s own production processes is an indirect cost that should be controlled and improved.” “All this is made possible by the i4paintshop platform, which, on the other hand, embodies the concept of “opportunity”, since Imel was able to launch this platform in advance of its competitors, thus presenting itself as the preferred partner of advanced customers,” says Bianchin. Imel started to develop i4paintshop at the beginning of 2017 based on the idea of a think tank, which offered to survey the needs of different clients and analyse trends and opportunities deriving from the new SW and HW tools related to digitisation (ref. Opening photo). “In mid-2017, two teams were created. The first one was devoted to developing the data communication protocol and the platform architecture, including the management and security of data. The second team dealt with the creation of the data processing software and the user interface,” explains Bianchin. “i4paintshop was officially presented during the Paint Expo trade fair held in Karlsruhe (Germany) in April 2018, that is, one year after the start of the
INNOVATIONS: PRESENT&FUTURE
project. Feedback was very positive and Imel immediately started several negotiations.” i4paintshop is for well-structured companies with professionals able to understand the information provided by the platform and
INTERNATIONAL PATENT
translate it into decisions, such as energy engineers, maintenance managers with a predictive maintenance-oriented approach, planning managers, and environmental managers (Fig. 2). The platform can adapt the processes automatically, but the final choice rests with the user, who should progressively switch from an operator to a decision maker. “Given the nature of the product and its end users, i4paintshop is particularly suitable for the automotive industry, but we are also getting excellent feedback from different suppliers intending to implement the Industry 4.0 concepts regardless of their end users. Actually, the first i4 plant was installed at the premises of Global, a leading manufacturer of home radiators. We will complete other two installations within December 2018” states Stefano Bianchin. The creation of the platform i4paintshop went hand in hand with the development of Imel’s
NITROROBOT Eurosider, a company with vast experience of using various fluid carriers for liquid painting, has developed a new system to produce a high density carrier in order to obtain better atomization which brings the advantages listed below. Nitrorobot can keep all day long the same settings and guarantee the best working conditions, independently from the conditions of the environment. The equipment, in Touch Screen version, is provided with the system of control of various settings, possible to monitor from any coating system control panel. Ideal application for Nitrorobot is on automatic coating systems with rotary bells, or it can be applied on conventional pneumatic guns, HVLP or electrostatic guns.
new process control software standard. This software package features algorithms that
i4paintshop is for wellstructured companies with professionals able to understand the information provided by the platform and translate it into decisions, such as energy engineers, maintenance managers with a predictive maintenanceoriented approach, planning managers, and environmental managers. The platform can adapt the processes automatically, but the final choice rests with the user, who should progressively switch from an operator to a decision maker.
NITROTHERM The performance is reffered to fluid enriched in nitrogen with concentration of 93% ± 1%, at environment temperature of 20 °C and atmospheric pressure of 1013 mbar. Inlet compressed air must be free from impurities (water, oil, solid particles). We advise to use filter elements supplied by Eurosider. All the data and images are merely approximate and can be changed; the performance vary in accordance with environment and working process pressure and temperature. Eurosider reserves a right to make modifications, even without advanced notice.
EUROSIDER Piazzale Thailandia 6 | 58100 GROSSETO | ITALY ph. +39 0564 425117 | fax +39 0564 418833 www.eurosider.com | info@eurosider.com
© Imel
2 1
Figure 2: i4paintshop is for well-structured companies with professionals able to understand the information provided by the platform and translate it into decisions.
are necessary to the transfer of process and plant data to the platform. “By discussing the 4.0-oriented customisation level required by the customer since the offer phase, Imel can immediately assess both the costs related to the additional devices to be integrated into the system and the time needed to adapt the standard platform. This enables us to make the platform operational within a month after the system’s start up,” states Bianchin. “With a third-party software, the process would take no less than a year,
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with poorer results due to lack of full
The creation of the platform i4paintshop went hand in hand with the development of Imel’s new process control software standard. This software package features algorithms that are necessary to the transfer of process and plant data to the platform.”
N. 52 - JULY/AUGUST 2018 - international PAINT&COATING magazine
integration with the system control software and certainly with higher costs linked to the management of additional equipment.” Imel has already defined its next 4.0-oriented steps. “We do not want reveal too much, but we can say that our goal is offering innovative solutions for the whole customer follow up process, starting from the offer phase,” says Bianchin.
Zaniolo CdA - 1.18
RISPOSTE ANSWERS RI S P O S T E A D OGN I RICH IESTA Europolveri, offre una diversificata varietà di Vernici in Polvere caratterizzate da elevato standard qualitativo, ottime performances ed un basso impatto ambientale. Un'ampia gamma di prodotti standard disponibili in più di 1800 toni cromatici ed una serie di 240 effetti speciali formulati per garantire un plus in termini di valore estetico e durabilità. Cinque linee di prodotti innovativi formulati ad hoc per rispondere ad esigenze ed applicazioni specifiche. Europolveri: Esperienza, Efficienza, Evoluzione. A N S WE RS TO EAC H R EQUEST Europolveri offers a wide range of Powder Coatings characterized by high quality, great performances and an environmentally-friendly formula. A wide range of more than 1800 chromatic tones are available and a series of more than 240 “Special Effects” have been designed for increasing durability and enhancing surface appearance. Europolveri designed five innovative product lines for special needs and applications. Europolveri: Experience, Efficiency and Evolution.
Seguici su Facebook Follow us on Facebook info@europolveri.it www.europolveri.it P O W D E R C O AT I N G S I N C E 1 9 8 2
© ipcm ®
Opening photo: The operator can manage the coating operations also via smartphones and tablets.
INNOVATIONS: PRESENT&FUTURE
The Evolution of Powder Spraying Systems: Digitalisation, Ergonomics, Connectivity From an interview with Massimo Ricci, Zeus Electrostatic System, Argenta (FE, Italy), riccim@zeus-el.it
I
n international card games, the Joker
spraying systems “J”. These systems are
programs, application parameters, paint
is the card that matches all others – a
fully evolved in terms of materials thanks
consumption data, and so on. They are
symbol of extreme versatility.
to the switch to injection moulded plastic
also extremely easy, ergonomic, and
gun casings, versatile, and able to easily
intuitive to use.
That is why Zeus Electrostatic System chose
connect with the outside world, as well as
Precisely this change in shapes,
to call the latest version of its powder
to provide real-time information on coating
materials, and connectivity resulted in
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N. 52 - JULY/AUGUST 2018 - international PAINT&COATING magazine
© ipcm ®
INNOVATIONS: PRESENT&FUTURE
In international card games, the Joker is the card that matches all others – a symbol of extreme versatility. That is why Zeus Electrostatic System chose to call the latest version of its powder spraying systems “J”. These systems are fully evolved in terms of materials thanks to the switch to injection moulded plastic gun casings, versatile, and able to easily connect with the outside world, as well as to provide real-time information on coating programs, application parameters, paint consumption data, and so on. They are also extremely easy, ergonomic, and intuitive to use.”
1
the first generation of a complete system
the new pump NEA415, with a 4-stroke
composed of a generator, automatic
operating cycle. By next autumn, we will
guns, a powder management unit, and
launch the first machines featuring a
manual equipment with conventional
high-flow dense phase pump for paint
Venturi injectors, following a four-year
feeding and a dense phase pump for
development process that involved a
spraying. The development of our J
team of thirty people and saw various
Series is the result of a large investment
companies in the sector collaborate.
in integration, calling for a complete
However, Zeus’ R&D efforts did not stop
modification of the Zeus equipment’s
at this first goal, but they continued with
electronics, software, design, and
a focus on the Industry 4.0 concepts to
materials. This coordinated project
equip the new J Series with a complete
also enables us to convey the image of
booth management system, able to
a technological company that can be
make all information available on mobile,
a partner, and not just a supplier, for
PC, and remote devices and to provide
coaters. Today, we find ourselves selling
predictive maintenance indications (ref.
much more than the equipment in our
Opening photo). The third development
catalogue: first of all, we sell advice,
phase is currently underway: Zeus is
as well as a solution to any coating
integrating its J Series with the dense
problem.”
phase powder transport technology. “We started by adding high-flow dense
The origin of success
phase pumps developed by Verne
The J Series was designed following an
Technology to the plants’ recovery devices
analysis of the coating market’s needs
and to the powder management units’
for greater integration, automation,
paint loading systems,” says Massimo
and digitisation without neglecting
Ricci, the general manager of Zeus
ergonomics, ease of use, and user
Electrostatic System (Fig. 1). “We are
friendliness. “It was created for fun:
currently integrating our spray guns with
we invented a smart function for our
© ipcm ®
Figure 1: Massimo Ricci with Alessia Venturi (ipcm).
2 1
Figure 2: Since 2016, the casings of Zeus’ guns have been made of moulded plastics, definitely lighter than processed plastics.
international PAINT&COATING magazine - JULY/AUGUST 2018 - N. 52
87
© ipcm ®
3 1
Figure 3: The new generator for the manual unit.
guns that made
The development of the J Series is the result of a large investment in integration, calling for a complete modification of the Zeus equipment’s electronics, software, design, and materials. This coordinated project also enables Zeus to convey the image of a technological company that can be a partner, and not just a supplier, for coaters.”
the whole system multi-functional,” explains Ricci. “Then, we started focussing on materials, design, production techniques, and 4.0-oriented connectivity.” Injection moulded gun casings require a higher investment cost compared with processed plastics, but they allow to reduce production costs later on. Moulded plastic is
lighter and, therefore, it enables to create better balanced and more comfortable to use products with a lower molecular weight and a more accurate degree of finish. Indeed, design and finishing are important even for spray guns, not just for the objects they help to coat (Fig. 2). “Zeus certainly invested also on aesthetics, but our guns’ design is primarily functional and not an end in itself,” states Ricci. “The investment for the injection moulding of all our technologies’ components forced us to change all CAD design systems in order to adapt to our suppliers, with which we have built a mutually stimulating relationship and an interface to enhance our R&D activities. Our technological equipment is now complete. The next step will be to reach the foreign
© ipcm ®
INNOVATIONS: PRESENT&FUTURE
4 1
Figure 4: The Zeus automatic booth.
markets, also because we have invested a lot to obtain the ATEX certification for the European markets. We are currently starting the procedures to obtain the FM certification for the American market.”
jGun: technology at its finest jGun is a concentrate of technology, starting from its materials, its high mechanical and electrical resistance properties, and its low molecular weight not to tire the operator during use. The core of this gun is the high voltage generator, which transfers all its energy to the powder with a high charge efficiency thanks to its high insulation degree (Fig. 3). The automatic jGun represents the latest generation of Zeus’ guns: it can house any type of nozzle. It is available in the conventional short version or in the integrated and connected arm version that can be used with the cleaning systems of Zeus’ booths (Fig. 4). All jGun devices are certified according to the requirements of the ATEX standard.
Injection moulded gun casings require a higher investment cost compared with processed plastics, but they allow to reduce production costs later on. Moulded plastic is lighter and, therefore, it enables to create better balanced and more comfortable to use products with a lower molecular weight and a more accurate degree of finish. Indeed, design and finishing are important even for spray guns, not just for the objects they help to coat.”
HIGH
PERFORMANCE POWDER COATINGS
© ipcm ®
The control units jGen Digital feature a 485 interface enabling them to connect one each other in order to share settings and programs. The J connectivity does not only involve the J modules, but also other Zeus devices such as reading systems, powder management units, and so on.” Technical characteristics of the control units
allow to better manage the coating
System opened the world of
operations.
Digital feature a 485 interface enabling them to connect one each other in order to share settings and programs (Fig. 5). The J connectivity does not
coating programs, each with different pneumatic and electrostatic settings.
systems, powder management units,
or combined with the Wildcard function
and so on (Fig. 6).
to clean any parts during the colour
In the J machines, all functions take
change operations or to clean the
higher productivity:
6 1
Figure 6: The powder management unit.
N. 52 - JULY/AUGUST 2018 - international PAINT&COATING magazine
other connected ones. - the P function allows to create up to 50
- the Clean function can be used alone
© ipcm ®
90
of the parameters set in a unit in all the
other Zeus devices such as reading
performance, powder saving, and
The automatic jGun represents the latest generation of Zeus’ guns: it can house any type of nozzle. It is available in the conventional short version or in the integrated and connected arm version that can be used with the cleaning systems of Zeus’ booths. All jGun devices are certified according to the requirements of the ATEX standard.”
- the Cloning function enables copying
only involve the J modules, but also
a new dimension, ensuring better
Figure 5: The control units jGen Digital.
which can be modified by the operator,
With its J Series, Zeus Electrostatic connectivity. The control units jGen
5 1
- the three pre-set working modes,
electrode with a simple click. - the Smart Coat function facilitates the coating process by reducing the
INNOVATIONS: PRESENT&FUTURE
rebound effect: as the electrode moves close to the inside of a cavity, the gun automatically reduces the amount of air used and the powder flow rate to avoid over-accumulation; as the nozzle moves away from the cavity, the pre-set values are restored. - the Wildcard function is synonymous with versatility:
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
combined with one or more functions, it enables the operator to customise the machine according to his needs by deciding which parameters to change. This can be done simply by double clicking the trigger of the gun and by touching the gun’s keypad, without having to reach the operator panel.
Why choose the J Series “All the components of Zeus’ J Series are made within the European Union to guarantee reliability and customer assistance,” explains Massimo Ricci. “The J Series is 4.0-oriented, user friendly, efficient, robust, reliable, and, above all, a safe investment,
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.
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.
because we ensure continuity through constant updates and timely interventions in case of malfunction or breakage.” However, the R&D activity of Zeus does not stop here: the next step will be augmented reality glasses for operators and the maintenance departments of the customers.
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.
“The future of modern industry goes hand in hand
Non avrai più blocchi di produzione
with the consolidation of the relationships with the
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.
suppliers, a sort of trusted partnership which is reinforced thanks to the ability to jointly solve our customers’ problems. This is the perspective with which we have managed our investments in the last few years”, concludes Ricci.
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
The Smart Coat function facilitates the coating process by reducing the rebound effect: as the electrode moves close to the inside of a cavity, the gun automatically reduces the amount of air used and the powder flow rate to avoid over-accumulation; as the nozzle moves away from the cavity, the pre-set values are restored.”
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”
REPORT IIN N RE REGALO! REGALO EGALO! LO
© ipcm ®
Opening photo: Some workpieces hanging during the powder coating process.
FOCUS ON TECHNOLOGY
A Last-Generation Booth Can Make the Difference Ilaria Paolomelo ipcm®
D
ue to the economic recession of
of Sentiljan Nerhati, who in 2013 decided to
The firm specialises in powder coating
the last few years, many businesses
take over the company where he had been
processes and it is now managed by
from the surface treatment industry
employed as a worker for over fifteen years
Sentiljan Nerhati with the collaboration
have closed. However, someone’s misfortune
and to establish Nerhati Color in Lunano,
of four family members: his two brothers,
canbbe someone else’s gain. That is the case
in the beautiful province of Pesaro-Urbino.
wife, and father (Fig. 1).
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N. 52 - JULY/AUGUST 2018 - international PAINT&COATING magazine
FOCUS ON TECHNOLOGY
Due to the economic recession of the last few years, many businesses from the surface treatment industry have closed. However, someone’s misfortune can be someone else’s gain. That is the case of Sentiljan Nerhati, who in 2013 decided to take over the company where he had been employed as a worker for over fifteen years and to establish Nerhati Color in Lunano, in the beautiful province of Pesaro-Urbino. The firm specialises in powder coating processes and it is now managed by Sentiljan Nerhati with the collaboration of four family members: his two brothers, wife, and father.” In Nerhati Color’s DNA, there are entrepreneurial vision, dedication to work, passion for coating, courage, and family bonds. All this has led to success: over five years and thanks to repeated investments in technology, which have ensured the achievement of a rather high quality standard, the company has become the partner of choice for many firms located in the province of Pesaro-Urbino, especially manufacturers of furnishing accessories and woodworking machines. “Taking over the coating business of the person who had been my employer for fifteen years required an economic effort for my family and me,” says Sentiljan Nerhati, “but that was just the beginning. In order to develop the company that I envisioned, investments in technology were needed. I must thank all the suppliers that have supported me also economically along this journey, and especially those that advised me well for my most recent investment, my new automatic coating booth (Fig. 2).” Six months ago, Nerhati Color replaced its old spray paint booth with a fully automated machine produced by GRT Srl (Modena, Italy), a company specialising in the design, production, and installation of automatic booths and systems for powder coating. The booth’s automation degree, its transfer and overspray recovery efficiency, and its colour change and cleaning speed enabled Nerhati to achieve three almost unhoped-for results: lower paint consumption, increased coated surface following the acquisition of new orders thanks to the improvement in the coating quality level, and less working hours needed. “Both the company and all of us
© ipcm ®
The coating cycle Previous investments included the installation of a new automatic cleaning tunnel, which the old production structure lacked. “In the past, the workpieces were washed manually by the operators,” explains Nerhati. “With this new automatic system, the parts are now treated with a multi-metal phosphodegreasing process using a solution at 50 °C, which ensures excellent results on both aluminium and steel. In future, we plan to lengthen the tunnel by 6 metres to add more rinses and active stages and further improve our surface preparation degree.” After drying, the workpieces reach the automatic powder coating booth, with
1
a pre-retouch station, and then the Figure 1: From left to right: Edmir Nerhati, Damjan Nerhati, Mirsela Nerhati, Sentiljan Nerhati, owner of Nerhati Color and Andrea Grazi from GRT.
94
about 20 minutes at 190 °C.
latter,” says Sentiljan. “We had reached an
Coating application: the new GRT booth
unsustainable work pace: this booth has
“About six months ago, we decided
also simplified our work and improved our
to install a new coating booth that
quality of life.”
could adapt to the new production
© ipcm ®
personally have greatly benefited from the
Six months ago, Nerhati Color replaced its old spray paint booth with a fully automated machine produced by GRT Srl (Modena, Italy), a company specialising in the design, production, and installation of automatic booths and systems for powder coating. The booth’s automation degree, its transfer and overspray recovery efficiency, and its colour change and cleaning speed enabled Nerhati to achieve three almost unhopedfor results: lower paint consumption, increased coated surface following the acquisition of new orders thanks to the improvement in the coating quality level, and less working hours needed.”
bell curing oven, where they stay for
2 1
Figure 2: The new automatic coating booth produced by GRT.
N. 52 - JULY/AUGUST 2018 - international PAINT&COATING magazine
© ipcm ®
FOCUS ON TECHNOLOGY
© ipcm ®
3 1
4 1
Figs. 3 and 4: The PLC-controlled automatic powder management unit.
pass through, iin a completely automatic
quantity,” says Sentiljan Nerhati. “The
way (ref. Opening photo). Nerhati also
powder saving guaranteed by the new
requested a manual pre-retouch station
booth will be enough to obtain a return
just to be sure, although the automatic
on investment very soon. The booth is
guns ensure optimal coverage.”
also equipped with a few devices that I did
The booth ensures as follows:
not know but that make our work easier,
• colour change operations in a
such as the powder weighing scale: giving
guaranteed time of 8 minutes to switch
estimates is now much easier and faster!
from white to black;
We are very pleased with this system,
• automatic cleaning of the booth, the
which is also proving robust and reliable
application equipment, and the supply
since we have never needed technical
circuits;
assistance during these six months of use.
• powder recovery up to 95%;
We are also looking forward to installing
• paint saving of about 18%;
a new coating plant that will enable us to
• decrease in daily working hours, with
paint workpieces with a height of more
an improvement in the workers’ quality
than 2.20 metres and, therefore, to expand
of life.
our target market.”
“Like all GRT booths, this machine features
© ipcm ®
GRT offered to Nerhati a booth from its Superior series, built entirely in PVC and with a capacity of 16,000 m³, featuring a PLC-controlled automatic powder management unit, and a fast recovery cyclone with a filter system. Automation includes two reciprocators with motorised bases and three guns each and optical bars for shape recognition that control the positioning of the axes, the guns’ switching on and off as the workpieces pass through, in a completely automatic way. Nerhati also requested a manual pre-retouch station just to be sure, although the automatic guns ensure optimal coverage.”
an anti-explosion system dispensing CO2 into the cyclone
to prevent any
kind of fire, unlike conventional systems that no longer comply with the regulations, featuring a door that, in the event of an explosion inside the filtering group, would
and quality needs of our company,” states
be heaved meters
Nerhati. “This investment allowed us to
away, making it truly
obtain excellent quality results in a short
dangerous for those
time and, therefore, to accept more orders
present in the work
while reducing our working hours. In other
area (Fig. 5)”, explains
words, it revolutionised our coating cycle.”
Grazi. “Finally, this
“GRT offered to Nerhati a booth from its
type of booth can be
Superior series, built entirely in PVC and
integrated into a plant
with a capacity of 16,000 m³, featuring
4.0 at any time”.
a PLC-controlled automatic powder
says GRT owner Andrea Grazi. “Automation
Excellent results in a short time
includes two reciprocators with motorised
“I never thought
bases and three guns each and optical
I would get such
bars for shape recognition that control the
excellent results in a
positioning of the axes, the guns’
short time, in terms
switching on and off as the workpieces
of both quality and
management unit (Figs. 3 and 4), and a fast recovery cyclone with a filter system,”
96
N. 52 - JULY/AUGUST 2018 - international PAINT&COATING magazine
5 1
Figure 5: The filter of the booth.
8
ALUMINIUM 2018 12. Salone mondiale e Congresso
9 â&#x20AC;&#x201C; 11 Ottobre 2018 Fiera di DĂźsseldorf, Germania www.aluminium-messe.com
Organised by
Partners
BRAND-NEW
New Nozzles for More Efficient Coating with Metallic and Effect Powder
W
AGNER has expanded its
charge system. But they can also be
powder coating portfolio with
used just as effectively for all other
the special nozzles C4 F5 and
coatings,” explains Michael Topp,
X1 F5 for metallic and effect powders
Senior Global Product Manager © WAGNER
(Fig. 1). With the new nozzles, deposits on the inside of the nozzle are a thing of the past - and thus
for industrial powder coating systems at WAGNER. Customers also confirm the
powder deposits with
effectiveness of the new
sputter formation on the
special nozzles in long-
workpieces. The nozzles are available as a version
term tests. “The rework and scrap rate could
1
for the manual gun PEM-X1
be minimized by
(Fig. 2) and the automatic
using F5 nozzles for
gun PEA-C4 (Fig. 3). Especially for the coating of complex geometries, whether as manual coating for pre- or postprocessing or robot application, WAGNER also launches nozzles in X-design on the
coating with highly Figure 1: Nozzles in X-design for robot applications and manual recoating of complex workpiece geometries.
market.
pigmented metallic powder. In addition, the coating material could be applied in a higher dosage,” says Michael Topp. Coatings with metallic and effect
Coatings with metallic or effect powder are
powders are used in many areas.
in vogue. Manufacturers are responding
They counteract deposits through an
They are particularly common in the
to the increasing demands on special
adapted internal geometry and the
furniture and automotive industries,
coatings from industry and consumers
optimized positioning of the electrode in
for example, as well as in
with innovative formulations. At the same
the nozzle. This ensures highest coating
household and sports
time, it is becoming increasingly difficult
quality even with the most delicate metallic
equipment.
to achieve a high-quality coating result
powder coatings, reduces time-consuming
with such “high-tech powder coatings”.
reworking of the workpieces, which can add
The processing of metallic powder is
up to thousands of Euros per year in terms
demanding. The added metal particles
of the working time required for this,
create an eye-catching appearance on
and rejects. Fast color changes in
the one hand, but also promote adhesion
improved quality and short
to the electrode holder on the inside of
cycle times are also
the nozzle on the other. These deposits
supported.
now offers for the first time special
Less postprocessing with metallic powder coating
metallic flat-jet nozzles especially for
“The F5 nozzles produce a particularly
the application of metallic powder and
homogeneous spray cloud when coating
for coatings with difficult effects as an
with metallic powder and achieve a higher
extension for C4 and X1 guns.
application efficiency due to the optimized
processes and adhere to the workpiece. In response to these challenges, WAGNER
98
N. 52 - JULY/AUGUST 2018 - international PAINT&COATING magazine
Figure 2: The manual gun PEM-X1 with metallic nozzle.
© WAGNER
detach during subsequent spraying
2 1
© WAGNER
BRAND-NEW
3 1
Figure 3: The new metallic nozzle F5 (left) and F1-X (right) using the PEA-C4 automatic gun as an example.
Also new: X-nozzles for robot applications and manual recoating of complex workpiece shapes WAGNER has also expanded its product portfolio with X-design nozzles for use with robots and for more efficient coating of hard-to-reach areas by hand. These are available both for conventional powder coatings (X-nozzle) and especially for metallic applications (F5-X-nozzle). In contrast to the flat spray nozzles used by WAGNER as standard for coating guns, the X-design nozzle offered as an accessory has a cross-shaped opening on the spray head. “When machining edges and corners, flat-jet nozzles must be precisely aligned to prevent cut-outs during coating. A nozzle with cross opening, on the other hand, requires less precision, which is why our new product enables shorter cycle times for these applications - for example for the internal coating of housings,” says Michael Topp. In this area, the flexible X-nozzle also offers corresponding advantages for manual recoating.
Available individually and as a set F5-, F5-X- and X-nozzle are designed for the manual gun PEM-X1 and the automatic gun PEA-C4 from WAGNER and are supplied individually or as a set with suitable electrode holder and union nut. The conversion effort is minimal, as the guns can be converted to F5 nozzles for processing metallic or effect powder in seconds. In robot systems, the desired X-nozzles are also simply mounted on the guns. The flat jet nozzle X1 F5 can be used with the current CoronaStar. A special CoronaStar adapter is available as an accessory for the C4 F5 nozzle.
+49 89 13928723
© ABL-TECHNIC Entlackung GmbH
100
N. 52 - JULY/AUGUST 2018 - international PAINT&COATING magazine
HIGHLIGHT OF THE MONTH
Innovative Paint Stripping Solutions Sören Augart ABL-TECHNIC Entlackung GmbH, Leutkirch/Allgäu Germany
T
info@abl-technic.de
he creation of flexible,
For heavily coated painting aids and
responsible use of resources.
individual solutions determines
temperature-resistant products, thermal
Painting aids such as gratings, paint
our everyday business while
stripping is preferred.
skids and parts which cannot be
meeting the highest standards of
Depending on the material and
thermally or chemically stripped
quality, efficiency, economy and a fair
proportion of paint, the treatment is
because of their geometry and the
pricing policy.
carried out in pyrolysis ovens (385° C
material they are made of, are instead
For over 40 years, a team of
- 430° C). Innovative thermal recovery
stripped with water pressure – 1,400
technicians and production
techniques and emission control by
bar - 3,500 bar – in open blast cabinets
supervisors of ABL Technic has
post-combustion are used as standard
or continuous feed systems (Fig. 1).
been working continuously on
This method is quick and
the development of innovative
environmentally friendly, as
installations and the improvement of
the service water is prepared
existing paint stripping, waste disposal and recovery of valuable materials technologies (ref. Opening photo). The goal of the effort is to create improved paint stripping media and paint stripping methods that will be introduced in all ABL plants worldwide and to provide individual special solutions for all complex products and fixtures. Chemical stripping is, for instance, particularly suitable for temperature-
The creation of flexible, individual solutions determines our everyday business while meeting the highest standards of quality, efficiency, economy and a fair pricing policy. For over 40 years, a team of technicians and production supervisors of ABL Technic has been working continuously on the development of innovative installations and the improvement of existing paint stripping, waste disposal and recovery of valuable materials technologies.”
in ABL’s proprietary waste water plant and can be returned to the water cycle, conserving resources. For the paint stripping of plastic parts, e.g. PP, PPEPDM, PE, PA, PA-GF, Teflon etc., an innovative method is employed. Lasting 30-60 minutes, it uses environmentally friendly chemicals that have no
sensitive products and painting aids.
effect on the mechanical and
The parts to be stripped are immersed
chemical properties of the
in baths or processed in spraying
by ABL. As after-treatment, the parts are
plastic. The surfaces can be re-coated
systems at a temperature of 75° C -
blasted or treated chemically and then
and the entire process is far more cost
150° C. The paint residues are then
freed of rust and passivated.
effective than manufacturing new parts.
removed with high pressure water.
Thermal stripping and chemical
This and other methods can also
After-treatment to protect the parts
processes also allow the recovery of
be performed on the customer’s
(passivation, preserving, rust removal,
valuable materials such as precious
premises. Indeed, a paint stripping
ultrasonic cleaning) is carried out as
metals and metals from components or
facility specially tailored towards the
required for the specific products,
machinery, e.g. copper from motors and
stripped items can be installed onsite
using alkali, acid and solvent paint
generators, making for a sustainable
and paint stripping and post process
stripping methods.
and efficient contribution to the
treatment are carried out in special
Opening photo: For over 40 years, a team of technicians and production supervisors of ABL Technic has been working continuously on the development of innovative installations and the improvement of existing paint stripping, waste disposal and recovery of valuable materials technologies.
international PAINT&COATING magazine - JULY/AUGUST 2018 - N. 52
101
© ABL-TECHNIC Entlackung GmbH
A paint stripping facility specially tailored towards the stripped items can be installed onsite and paint stripping and post process treatment are carried out in special modules. This allows a seamless integration in the workflows and fast access to the stripped items, making it possible to achieve significant savings in cost and time.” 1
- Grease removal that, in chemical
Figure 1: Painting aids such as gratings, paint skids and parts which cannot be thermally or chemically stripped because of their geometry and the material they are made of, are instead stripped with water pressure – 1,400 bar - 3,500 bar – in open blast cabinets or continuous feed systems.
spraying systems, ensures trouble-free downstream processes such as painting. The solvents used are environmentally compatible and gentle on the parts. - Waste disposal, e.g. contaminated products, parts of systems or entire
modules. This allows a seamless integration
mixers, pipes, nozzles), it is possible
installations. As a “Specialized Waste
in the workflows and fast access to the
to employ the pyrolysis method, at
Management Company”, ABL meets all
stripped items, making it possible to achieve
temperatures up to 430 °C. In this
the legal requirements and ensures the
significant savings in cost and time.
process, the organic contamination is
best possible avoidance of environmental
In addition to conventionally deployed
carbonized and any residual deposits
pollution. Development and application
cleaning methods such as high pressure
are chemically or mechanically removed.
of innovative methods of waste disposal,
water, cleaning by chemical immersion
Then the parts undergo a corrosion-
e. g. the treatment of the process water
and rinsing processes, for the cleaning of
protection process, usually achieved by
in the company’s proprietary waste water
polymer polluted parts and assemblies
passivation.
plant, is part of its production process. - Laser cleaning for high quality
(such as extruder screws, filters, pumps, ABL also carries out:
applications in industry. A focused
- Cleaning of tube bundle and plate heat
laser beam vaporizes dirt and surface
exchangers - Rubber removal, for the efficient
For heavily coated painting aids and temperature-resistant products, thermal stripping is preferred. Depending on the material and proportion of paint, the treatment is carried out in pyrolysis ovens (385° C - 430° C).”
102
treatments without damaging the base material. This cleaning method provides
recovery of metals from metal-rubber
a real alternative to traditional cleaning
compounds, e. g. vibration dampers,
methods (rust removal, grease removal,
drive bearings and engine and
removal of chemical residues, paint
ship couplings. In thermal systems, this solution is suitable both for
stripping, etc.). - Chemical pre-treatment, suitable for
environmentally friendly waste disposal,
steel, galvanized material, stainless steel
and for rejected parts which can then
and aluminium. This thin-coat technology
be quickly returned to the production
includes a number of pre-treatment
process.
processes based on zirconium and
N. 52 - JULY/AUGUST 2018 - international PAINT&COATING magazine
HIGHLIGHT OF THE MONTH
ABL Technic’s range of services is committed to a very responsible approach to the environment, validating each product in a test environment before selection and release of the final cleaning production flow and process parameters. This enables to secure a higher level of quality, while fulfilling national and international requirements on the environmental.”
grease removal process, the nano-layer
product in a test environment before
during passivation.
selection and release of the final cleaning
- Filter management for painting, body
production flow and process parameters.
construction, assembly, storage areas,
This enables to secure a higher level
offices, changing rooms, showers, kitchen
of quality, while fulfilling national and
facilities and much more.
international requirements on the
- Design, manufacturing and repair for
environmental.
painting aids damaged in the painting
In the development of new,
process such as frames, gratings or
environmentally friendly process,
paint skids. The parts are checked for
the company avoids the use of
functionality, and repaired or replaced if
polychlorinated solvents (CHCs) because
necessary.
their environmentally safe disposal cannot
Environmental Management
be guaranteed, deploying instead specially developed formulas from high-boiling
Companies are also increasingly affected
organic compounds which can be recycled
by environmental and energy issues: the
without leaving any residue.
titanium. Used together with a thick iron
requirement to deal responsibly with the
Heat recovery from the pyrolysis
phosphate layer, this nano-multi-metal
environment is increasing.
ovens and wastewater treatment
system achieved the same test results as
ABL Technic’s range of services is
through purification are also significant
those obtained with zinc phosphate.
committed to a very responsible approach
contributors to sustainability and
The phosphate layer is built up during the
to the environment, validating each
environmental awareness.
Our solutions
for construction machinery
& cranes !
2K Smart mixing & dosing unit • Consistent mixing ratios • Homogeneous coating results • High process reliability
www.wagner-group.com
Coating, bonding and sealing. Efficiency and highest quality.
BRAND-NEW
The Spanish Company Spray S.A. Turns 50 and Launches a New Series of Powder Coating Equipment
F
Figure 1: In June 2018, Spray S.A., a Spanish company based in Barcelona and specialized in the production of industrial electrostatic systems in the application and surface finishing sectors, has celebrated 50 years of activity.
ounded in 1968 and with almost 30 years of experience in international markets, Spray S.A.,
based in Barcelona, has become the only Spanish manufacturer of industrial electrostatic systems in the application and surface finishing sectors, with an international penchant that expands 1
globally, day after day (Fig. 1).
“The true essence of Spray S.A. can be found in these 50 years of commitment to offer a flawless service to its customers. It is with pleasure and gratitude to those who have always supported and appreciated us that we will continue to pursue future projects, to keep alive the family spirit with which the company was founded and to
In June 2018, the family business
cross new frontiers and
celebrated 50 years of activity
countries – which will be
and there is no better way to
added to the thirty nations
honour such a milestone,
where close partnerships
than launching a new
and alliances have already
technically advanced powder coating
been established”, continues
system (Fig. 2).
Laura García, Export Director of
“The results achieved
Spray S.A.
seven months
“I reiterate my words of gratitude to
after the start of the
the companies that over the past 50
promotion of the new
years have believed in our business
Series 600 of electrostatic powder
and products, in technological
coating systems exceeded our
innovation, in our future, in the quality and service provided and in the
expectations”, says Oscar García,
respect of others who, at the
the company’s CEO. “We have improved the global technological
same time, have contributed
component and designed a new
to improve, day by day, our
mode of ‘TCC’ crown charging
commitment to offer an
mechanism, making this
impeccable service to them
technology unique in today’s
and to companies that, if
market. The new S-600 system
they wish so, can rely on us unreservedly”.
offers incredible economic benefits to any production process, since its advanced
For further
electronic and electrostatic
information:
digital technology makes it the
www.spray-sa.com
most efficient, user friendly and reliable coating system in the world.”
104
2 1
Figure 2: To celebrate the milestone, the company launched the new technically advanced S-600 electrostatic powder coating systems.
N. 52 - JULY/AUGUST 2018 - international PAINT&COATING magazine
BRAND-NEW
All Eyes on Record-Breaking Attraction Coated by AkzoNobel
V
isitors to the Middle East will soon
Ain Dubai is a proud addition to our global
important to specify a system which
be able to experience the largest
portfolio.”
provides both corrosion and UV
and highest Ferris wheel in the
The high performance system of
resistance,” added Andrea Meconcelli,
world – Ain Dubai (the Dubai Eye)–,
International products being applied to
AkzoNobel’s Performance Coatings
which is being protected by coatings
the structure includes Interzinc 52 primer,
Director for the Middle East. “The
from AkzoNobel (Fig. 1).
Intergard 475HS (a high build epoxy
specification is designed to deliver © AkzoNobel
A dizzying 210 meters high, the spectacular attraction features more than 9,000
maximum protection, as well as offering outstanding colour and
tons of steel (almost 25%
gloss retention.”
more than the Eiffel Tower in
Modelled after the
Paris). AkzoNobel is the sole
London Eye, Ain Dubai
supplier of protective coatings
will provide 360-degree
for the massive structure,
views of the city and the
which is expected to be
Arabian Gulf. Featuring
completed later this year.
48 passenger capsules,
Located on the man-made
it has a maximum
Bluewaters Island, adrenaline
capacity of 1,400
junkies will be thrilled to hear
people. A full rotation
that one of its legs is also
will take 48 minutes.
being fitted with the highest
AkzoNobel has a
rope climbing platform
growing presence
in the world (topping out
in the UAE, with the
at 150 meters). It means
company having
AkzoNobel has now coated
established itself in
four of the world’s most
Dubai in 2011.
iconic observation wheels, the
An advanced
others being the London Eye,
application training
Melbourne Star Observation
centre was also
Wheel and Singapore Flyer. “It’s an honour to be associated with such a landmark project, which will welcome tourists from around
opened in Dubai
1
Figure 1: The largest and highest Ferris wheel in the world – Ain Dubai (the Dubai Eye) – has been coated with the high performance system of International products, including Interzinc 52 primer, Intergard 475HS, Interthane 990 and Interfine 979 polysiloxane topcoat.
the world,” said Rajiv Rajgopal,
last year. Other high profile projects in the UAE to have featured AkzoNobel’s products in recent years include
the company’s Regional Director for
providing protection against corrosion),
the Yas Viceroy Hotel, Aldar HQ and
Performance Coatings in the Middle
Interthane 990 (a high build epoxy finish
Sheikh Zayed Bridge, all located in
East and Africa. “We have a proven
coating) and Interfine 979 polysiloxane
Abu Dhabi.
track record of supporting large-scale
topcoat.
ventures that require superior technical
“Given the harsh local climate and Ain
For further information:
expertise, products and technology;
Dubai’s proximity to the water, it was
www.akzonobel.com
international PAINT&COATING magazine - JULY/AUGUST 2018 - N. 52
105
BRAND-NEW
Walther Trowal: Efficient Coating of O-Rings
T
he new Rotamat system for small batches allows the efficient coating of work piece volumes © Walther Trowal
from 2 to 15 litres (Fig. 1). At the DKT exhibition Walther Trowal presented the newly designed Rotamat R 60 for coating of mass-produced small parts like, for example, O-rings. This system was specifically developed for users who are increasingly switching to smaller batches and, generally, lower batch volumes. However, the R 60 offers all the features found in its larger “siblings”! The new Rotamat R 60 is the first coating system on the market that allows efficient processing of work piece volumes between 2 and 15 litres. With a diameter of only 600 mm the drum is ideally suited for small batch volumes. The inclination of the drum is adjustable within a wide angle allowing its adjustment to different work piece geometries. It allows the intensive mixing of the parts in the drum and guarantees complete, optimum coverage by the
1
spray nozzles (Fig. 2). With the new machine Walther Trowal takes into account that in connection
Figure 1: The new Rotamat system for small batches by Walther Trowal.
with just-in-time requirements many companies generally place purchase
and R 90C. With the newly developed
Details of the innovative features:
orders in smaller work piece quantities.
R 60 they can now efficiently coat small
- Precise control of the inlet air
Frank Siegel, sales manager “coating
batches without having to invest in a larger
temperature: the measuring point for
technology” at Walther Trowal is now able
machine.”
the inlet air temperature is immediately
to offer the right machine for practically
For the Rotamat R 60 the Trowal engineers
at the drum entry. Compared to
every conceivable application: “Many
have utilized the proven components of the
measuring the temperature with a
of our customers want to coat small
larger machines: For example, the inlet and
sensor behind the air heating unit the
part batches but do not want to give
exhaust air system, the explosion protected
measurement is now much more direct
up the high technical standard we have
LED lighting inside the drum and the
allowing extremely precise temperature
implemented in our larger units R 60
mounting of the drum.
readings.
106
N. 52 - JULY/AUGUST 2018 - international PAINT&COATING magazine
© Walther Trowal
BRAND-NEW
2 1
Figure 2: With a diameter of only 600 mm the drum is adjustable to different work piece geometries and allows the complete, optimum coverage by the spray nozzles.
- Eco-friendly operation: for typical applications – today 90% of all customers are using water-based paint – Walther Trowal supplies a specially adapted filtering system. For coating tasks with solventbased paints the new R 60 – like with the bigger Rotamat units – can be equipped with a four stage exhaust air filtering system with a Papp filter, a filter mat and two pocket filters. - Low energy requirements: the capacity of the heating unit was adapted to the smaller drum diameter, resulting in considerably lower overall energy requirements. Depending on the technical characteristics of the work pieces and/or paint Walther Trowal can equip the machine with PID or pulse control for the heating unit. The result: Customers can also use paint types that do not allow going over or below certain operating temperatures. For further information: www.walther-trowal.com
SUSTAINABILITY
Arsonsisi is Colore Sicuro: Not Only Colour But Also Value
A
rsonsisi has adhered to “Colore
PRODUCT QUALITY – Absolute priority in
Sicuro” (Safe Colour), the project
declaring product performance certified
of Assovernici created to promote
by tests carried out in laboratories in
the excellent member manufacturers, who
compliance with national and international
share and support mutual values inspired
regulations.
by respect for their customers, for their
HEALTH AND SAFETY – Acting responsibly
products, society and the environment.
to protect the health and safety of workers
Assovernici is the official competent
at production sites, of users and their
association for Italian manufacturers of
customers.
coatings.
ENVIRONMENT – Favouring the cleanest
As one of its aims, the association
technologies and eco-sustainable products
promotes the use of high-quality coatings
with a special focus on energy saving.
by consumers in order to encourage
TRANSPARENCY – Easy access to all
excellence in a particularly crowded and
information on the member companies,
fragmented market.
their products and services. © Assovernici
Assovernici believes that users are entitled to obtain clear and objective information about the products
SOCIETY – Contributing to technological progress by operating as players involved in
they buy. In promoting this aim, its
a social, economic and cultural
members decided to share a mutual
context.
path, inspired but the association’s
INFORMATION – Spreading
Code of Ethics.
knowledge of products by
They created a comprehensive
helping consumers to choose the
classification of the characteristics
most suitable products for their
of coatings in full compliance
needs, using clear and authentic
with national and international
communication.
regulations governing the
Arsonsisi has joined Assovernici’s
industry, assuring all consumers,
“Colore Sicuro” project with its
professionals, retailers and
complete range of industrial
companies that come in contact
coatings.
with paints that the products supplied by its members offer
For further information:
specific and reliable performance,
www.en.arsonsisi.com/the-
represented by the “Colore Sicuro”
colore-sicuro-project-not-
symbol.
only-colour-but-also-value
The fundamental principle of the “Colore Sicuro” project is represented by the “Charter of Values” which describes the commitments undertaken by the member companies (Fig. 1).
108
1
N. 52 - JULY/AUGUST 2018 - international PAINT&COATING magazine
Figure 1: The Charter of Values of “Colore Sicuro”.
SUSTAINABILITY
© Ultrimax Coatings
Two Industry Leaders Join Forces to Tackle One Big Environmental Challenge
1
Figure 1: Select Plant Hire is one of the UK’s largest suppliers of equipment to the construction and building services industry. They were able to cut VOC emissions by 80% thanks to the innovations supplied by Ultrimax Coatings, who manufacture a new primer finish with considerable cuts in the environmentally harmful solvents.
O
ne of the UK’s largest suppliers to the
reducing their emissions so as to have less
the trial: “Ultrimax loves solving problems for
construction industry has drastically
impact on the environment.
its clients and once again we have been able
cut their solvent usage after
Ultrimax Coatings, who have manufactured
to demonstrate our ability to help customers
consultation with experts Ultrimax Coatings.
industrial paints and coatings for over
improve, not only their paint system but also
Select Plant Hire, an industry leader for
40 years, were able to suggest a new
the application method used for applying it”.
over 30 years, were able to cut their Volatile
application method, manufacture a new
The use of the of the new applicator combined
Organic Compound (VOC) emissions by 80%
primer finish product and set up a paint trial
with Ultrimax’s Aquimax 1 product also proved
and their overall paint reduction by 50%
to tackle the issue.
to be safer for the paint sprayer and required
thanks to the new innovations.
The trial produced encouraging results for
no solvent for cleaning, resulting in an even
Cutting VOC emissions is one of the biggest
both manufacturers with considerable cuts
bigger cut in VOC levels.
environmental challenge facing the paints
in the environmentally harmful solvents.
industry today.bbMany local authorities insist
Giles Hoare, Managing Director of Ultrimax
For further information:
that large paint users must look for ways of
Coatings, is delighted with the results of
www.ultrimaxstore.com
international PAINT&COATING magazine - JULY/AUGUST 2018 - N. 52
109
STANDARD & LEGISLATION - UCIF Informs
The Importance of Design Marcello Zinno
A
t first glance, surface treatments and design do not seem to have much in common. Actually,
however, finishing processes are
info@ucif.net
Andrei Merkulov © Fotolia
UCIF – Italian Surface Treatment Equipment Manufacturers’ Association, Milan
precisely aimed at treating the surfaces of products that more and more often, for design or mere aesthetic reasons, feature very peculiar shapes, thus calling for sophisticated industrial solutions to achieve a high level treatment. The aesthetic design of a structure cannot overlook the future treatment needs of its surface, but it is equally true that it is often the treatment process (e.g. coating) to have to adapt to the requirements imposed by the designer. Yet, on the “philosophical” level, we who develop solutions for processing
1
aesthetics-focussed objects see a very strong connection with the design field. Indeed, in our daily life, we are all aware
Figure 1: UCIF has decided to involve some experts in the field to organise a workshop on design with a focus on plant aspects, in the second half of 2018.
that the value of the consumer products we use is not only linked to their function but also to their aesthetics.
activities geared towards the ultimate
2018. Does it make sense to build a
This is characterised by two main
purpose for which they have been
plant or a machine with a different
elements: shape (design) and material
designed. And, last but not least, they
and fascinating design? What are the
and colour (finish).
must be sold. Therefore, like any other
trends of the future that a plant should
product, they cannot be built only based
follow to be immediately recognised as
At UCIF, we are so convinced of this
on rational engineering constraints,
an innovative technological solution?
that, in agreement with our members,
but they must also have some charm
Can design itself be a factor to gain
we have started focussing on design
in terms of shapes and aesthetics.
a competitive advantage over other
as a crucial issue not only in terms of
However, the subject is so vast that it
products on the market? Could it lead
manufactured products, but also of
involves the most diverse skills, up to
to replace some old plants with new
finishing plants. Indeed, if the value of
the analysis of colour evolutions and of
ones that are more efficient and also
an object is the function (also) of its
industrial trends in terms of ergonomic
more aesthetically pleasing? These
design and finish, the same applies to
science.
are the questions that we have asked
plants, too. We all know that machines
ourselves and then shared with the
are often locked in factories and cannot
That is why UCIF has decided to involve
experts who will explain to us what is
be admired by a wide audience, but
some experts in the field to organise
the point of view of the sector and how
they actually occupy a space, have
a workshop on design with a focus on
manufacturers can take these factors
some functions, and perform a series of
plant aspects, in the second half of
into consideration.
110
N. 52 - JULY/AUGUST 2018 - international PAINT&COATING magazine
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Paints, Varnishes and
/feitintasbrasil
Related Products Industry Fair
The world is made of colors
Join the 11th Feitintas
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ASIA PACIFIC COATINGS SHOW
São Paulo, Brazil September 03-05, 2018 www.expoaluminio.com.br/en/Home/
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Chicago, USA September 10-15, 2018 www.imts.com
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Frankfurt/Main, Germany September 11-15, 2018 automechanika.messefrankfurt.com
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FEITINTAS
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N. 52 - JULY/AUGUST 2018 - international PAINT&COATING magazine
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Birmingham, UK September 19-20, 2018 www.surfaceworld.com/surface-world-live
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ZOOM ON EVENTS
ExpoCoating Moscow 2018: the 16th International Exhibition of Technologies, Equipment and Materials for Surface Treatment and Coatings Application is Just around the Corner
E
xpoCoating Moscow is the only in Russia international specialised exhibition of technologies,
equipment and materials for surface
• 1.701 visitors plan to purchase
• Over 9 500 specialists visited hall where
participants’ products after the exhibition
ExpoCoating Moscow exhibition was held
• 1.470 visitors do not attend other exhibitions on similar subject
treatment and coatings application. At
Russian represents participants of ExpoCoating Moscow and foreign
the exhibition, companies will receive the
ExpoCoating Moscow is held alongside
developers, manufacturers and suppliers
opportunity of face-to-face transactions
with the international industrial
of technologies, equipment and materials
with Russian quality buyers who are
exhibitions: Industrial Robotics, NDT
for surface treatment and application of
sourcing in such services and products
Russia, Testin&Control, PowerElectronics,
coatings.
as:
PCVExpo, Heat&Power, Fasttec:
• Preparation and surface treatment
• 15.778 visitors attended all 8 exhibitions
• Electroplating coatings
in 2017
For further information: www.expocoating-moscow.ru
• Paintwork materials © Expo Coating Moscow
• Protective coatings • Coatings with special properties • Services for coatings application • Control and measuring, laboratory equipment Participation in ExpoCoating Moscow is profitable: • 100% of exhibitors consider participation in the exhibition to be important for their businesses • 78% of exhibitors are satisfied with the quantity of visitors • 71% of exhibitors are satisfied with the professionalism of visitors • 71% of exhibitors plan to take part in the exhibition in 2018 Visitors from 60 regions of Russia and 21 countries of the world visited the exhibition in 2017: • 1.995 visitors make or influence purchasing decisions in the company
1
Figure 1: Expo Coating Moscow will take place from October 23 to October 25, 2018 at Crocus Expo, Moscow, Russia.
international PAINT&COATING magazine - JULY/AUGUST 2018 - N. 52
113
ZOOM ON EVENTS
Lightweight Construction Will Continue to Pose the Greatest Challenge for the Automotive Industry in Future
L
ow-weight vehicles score points
By collaborating even more closely in future,
Process and material innovations
with CO2 reduction, vehicle
aluminium producers, processors and
are drivers for lightweight
dynamics and with comfort. This
vehicle manufacturers can unlock further
construction solutions
benefits aluminium as being one of the
potential for the use of aluminium here.
As the competition amongst materials
most important lightweight construction
The figures offer an impressive reflection of
intensifies, car manufacturers and
materials in the automotive sector. New
this trend. The average aluminium content
aluminium suppliers have begun working
solutions and applications in aluminium-
of cars is steadily increasing. Whereas 60
together more closely. By investing
based materials are seeing increased
years ago an average vehicle contained 19
in application-oriented research and
demand. This is also shown by the trade
kilograms of aluminium, between 1990 and
development, the aluminium industry
fair ALUMINIUM 2018 held in DĂźsseldorf
2014 the aluminium content of an average
has succeeded in continually improving
from 9 to 11 October.
car nearly tripled, increasing from 50 kg to
the properties of its materials, developing
Aluminium has transformed the automotive
140 kg. This figure is projected to increase
new products and optimising production
industry, and it will continue to do so in
to between 160 and 180 kg by 2020 as
processes. Process and material
future. It offers a better cost-benefit ratio
small and mid-size cars follow the trend set
innovations drive the development of
than any of the substitute materials on offer.
by luxury cars in the use of aluminium.
efficient lightweight construction solutions Š Aluminium Messe
and their implementation in series production, as with energy-saving components for chassis, engines, transmissions and gearboxes. New joining techniques drive the use of aluminium The use of aluminium in automotive manufacturing is also being driven by new joining technologies. Improved soldering methods, for example, have resulted in a situation where nearly all heat exchangers for automotive air conditioning systems and radiators are now made of aluminium. Innovative
1
welding processes and
Figure 1: ALUMINIUM 2018 will be held in DĂźsseldorf from 9 to 11 October, 2018.
114
N. 52 - JULY/AUGUST 2018 - international PAINT&COATING magazine
bonding technologies make
ZOOM ON EVENTS
it possible to create complex structures
regulatory framework that are pushing
and OEMs have already made it clear that
that are not only better in a technical
these developments forward. Increasing
the use of aluminium will increase for
sense, but which are also more economical.
urbanisation, such as in Asia, is forcing
bonnets, fenders and doors in the next
Applications even extend to entire axle
carmakers to come up with new
generations of vehicles. Cast aluminium
systems.
concepts, while threshold values for the
also remains an important and dynamic
fuel consumption of each automotive
growth market. Aluminium founders
Aluminium conquers new
manufacturer’s range of vehicles are
have a wealth of materials expertise, and
application areas
also having an impact. As a result of all
complex cast parts with high machining
In recent years, aluminium producers
these factors, the demand for innovative
depth offer tremendous potential.
and processors have developed a series
lightweight construction solutions in
The utilisation of aluminium solutions
of new aluminium alloys (5xxx, 6xxx)
the vehicle manufacturing industry will
in crash-relevant areas of the chassis
with improved mechanical properties,
continue to increase.
also represents a field with outstanding
including better strength, formability and
Thanks to growing demand for ‘sharp-
potential for the future.
corrosion resistance, allowing them to
edged’ designs for automotive exteriors,
offer to ever lighter components with
6xxx materials with excellent formability
Automotive manufacturing at the
reduced wall thicknesses. Thanks to their
properties are urgently needed. As a
focus of ALUMINIUM 2018
good workability, high strength values and
result of lightweight construction and
The future prospects of this material
excellent weldability, innovative aluminium
the reductions in sheet thickness that
in automotive manufacturing will also
materials have made their way into new
this entails, materials must offer high
be centre stage at this year’s No. 1
areas of application. The development of
strength values. The specific requirements
ALUMINIUM World Trade Fair from 9 to
new roller surface geometries and lubricants
of automotive manufacturers vary. On
11 October in Düsseldorf – both for many
for the improvement of tribological
the one hand, high strength and good
exhibitors and with such supporting events
properties is also moving full speed ahead.
crash performance, such as with ductility,
as the lecture forum and the guided trade
Developments in the field of e-mobility
are required, whereas only the highest
fair tours.
are also propelling use of this material, as
stiffness levels can satisfy the rigidity
This year’s Aluminium Conference
power electronics, e-motors and especially
requirements of the chassis. Depending
– organised by GDA, the German
batteries and the battery housings that
on the use to which a component is
Association of the Aluminium Industry
protect them against external influences
to be put and expansion possibilities,
(Gesamtverband der Aluminiumindustrie)
are creating further potential for the use
good formability related to strength
– will also pick up on this theme. Here the
of lightweight construction in vehicles. As a
and geometry is expected in the various
topics in focus include aluminium solutions
result of electronic vehicles’ different design
strength classes.
for sustainable transport concepts, alloys,
requirements, there are many new products
cooperation between aluminium and
and applications for which aluminium
Aluminium industry looks to the
automotive producers, new developments
profiles are the only sensible option, due to
future with optimism
in joining technology as well as additive
the possibilities for functional integration or
Overall, the automotive sector offers
manufacturing, to name but a few.
cooling, for instance. Light metal solutions
the prospect of exponential growth for
A total of 1,000 exhibitors and 27,000
are winning out in battery housings,
the aluminium industry, with demand
visitors from 100 nations are expected to
structural components and drive systems.
and requirements for aluminium
attend the world’s biggest trade fair for
continuing to grow. Even if aluminium
the aluminium industry. In six exhibition
Automotive manufacturers
should lose market share in individual
halls ALUMINIUM will showcase the
define requirements for material
areas of application, it will find increasing
complete cross-section of the industry –
developments
employment in others, and its growth
from aluminium production and machines
The automotive industry is one of the
areas will remain larger than the areas in
and equipment for finishing and finished
biggest drivers of material and process
which substitutes are found.
products through to recycling.
development for aluminium, whereby it
In future, aluminium sheet will take the
is less the end customers themselves,
place of other materials, such as steel for
For further information:
but rather society as a whole and the
the vehicle’s exterior and hang-on parts,
www.aluminium-messe.com
international PAINT&COATING magazine - JULY/AUGUST 2018 - N. 52
115
ZOOM ON EVENTS
The IoT Solutions World Congress 2018 Announces its First Speakers
1
Figure 1: IoT Solutions World Congress will take place in Barcelona, Spain, from 16 to 18 October 2018.
T
he speaker schedule at the IoT
IoT and a partner of Microsoft; and Edy
Roger Bou, Director of IoTSWC,
Solutions World Congress (IoTSWC)
Lingosari, Global Managing Director of
highlights the work of the programme
is taking shape. From 16 to 18
Accenture.
committee: â&#x20AC;&#x153;working to bring together
October the industrial internet event,
Nine core themes have been established
innovative success stories to analyse
organized by Fira de Barcelona, will
for IoTSWC 2018 as cornerstones for
IoT deployment in multiple industries
bring together more than 250 global
the more than 125 scheduled seminars:
and identifying the trends to plot
experts to debate real applications of
product manufacturing, healthcare,
the convergence of technologies,
the IoT which are transforming different
energy and utilities, connected transport,
standards and new applications.â&#x20AC;?
industrial environments and creating new
construction and infrastructures,
The program committee is led by
business models. The initial confirmed
open industry, enabling technologies,
the Industrial Internet Consortium
speakers include Gloria Zaionz, emerging
blockchain and artificial intelligence, the
(IIC) and made up of almost thirty
technology and innovation guru; Bert Van
latter two feature their own subject-
representatives of leading firms and
Hoof, Group Program Manager at Azure
specific forums.
entities.
116
N. 52 - JULY/AUGUST 2018 - international PAINT&COATING magazine
ZOOM ON EVENTS Some featured topics
research manager at Deloitte;
developers, security companies,
The Congress will discuss topics such
Helena Lisachuk, IoT Global Initiative
service and telecommunications
as the IoT-driven transformation of
Lead at Deloitte; Hyleco Nauta,
providers, industrial automation
the labour environment, the impact of
Director of e-Health Innovation at
firms, consultancies, hardware
industrial automation on employment,
the University Medical Centre in
manufacturers, technological
the digital connection of the entire
Utrecht; John Denning, Director
and R&D centres, business
value chain of a product, the safety
of Wholesale Change; Michael
incubators, associations and
of autonomous vehicles and smart
Godoy, Director of Telemedicine
entities related to the IoT, as well as
infrastructures in cities.
and Scalable Therapeutics at the
international group participants and
The energy and utilities theme will
UCSF Medical Center; Eric Harper,
governments of various countries.
address issues related to improving
Senior Software Architect at ABB;
In addition, the testbeds area will
the efficiency of processes by means
Brad Klenz, IoT Analytics Architect at
once again showcase real-world IoT
of cognitive computing, and the
SAS; Martijn Siebrand, specialist in
applications.
implementation of the “digital twins”
Blockchain, Logistics and Finance at
IoTSWC forms part of Barcelona
model to predict behaviours and
TKI Dinalog; Andy Zondervan, CEO of
Industry Week, a brand which
prescribe actions in different sectors
Settled!, and Pascal Haider, CEO of
also encompasses two other
will be analysed.
GarfieldEATS.
trade shows, In(3D)ustry From © IoTS World Congress
Speakers will debate the new doctor-patient relationship introduced by the new technologies and the use of
Needs to Solutions, dedicated to additive manufacturing, and Healthio, specializing in
data for the personalization of
health and healthcare
healthcare, telemedicine via the
technologies. All
IoT and specific security systems
three events, which
for the new eHealth.
create synergies and
The dedicated Artificial Intelligence
provide a platform
Forum will discuss the ethics and
for commerce and
social responsibilities involved in
knowledge in a wide range of industrial
the implementation of AI solutions in the real world. The Blockchain
sectors, will take place from 16-18
highlighting the application of this
Participation of leading companies
technology in the logistics industry,
Five months before the event begins,
For further information:
catering franchises and the resolution
70 percent of the total number of
www.iotsworldcongress.com
of copyright-related issues in music.
expected companies have already
Other names in the first preview
confirmed their attendance, including
of the Congress schedule include:
leading firms in the IoT ecosystem
Sven Schreck, Chief Architect of
such as ABB, Deloitte, Huawei,
IoT Security at Intel; Said Tabet,
Google Cloud, Intel, Microsoft, Sas,
Senior Technology Strategist at Dell
Telit, Vodafone, Wipro, Dassault
Technologies; Leila Dillon, Vice-
Systèmes, Fiware, Kaspersky,
President of Global Marketing & NA
Libelium, Software AG, Orange,
Distribution at Bigbelly; Jonathan
Telefonica and Thingstream. It’s
Moulton, co-founder and managing
expected more than 300 companies
partner at Momenta Partners; Willem
will take part in the exhibition area,
Sundblad, CEO and founder of Oden
including information technology
Technologies Ltd; Mark Cotteleer,
companies, software platform
Forum will showcase success stories
October at Fira de Barcelona.
international PAINT&COATING magazine - JULY/AUGUST 2018 - N. 52
117
ZOOM ON EVENTS
Eastern Coatings Show Call for Technical Papers
T
© Easter Coatings Show
he largest coatings show on the East Coast is set for May 13-15, 2019 at
Harrah’s, Atlantic City. The Eastern
furthering the advancement of coatings technology. The presentation format should
Coatings Show (ECS) is seeking
be as close to a short course
submissions from academia,
as possible. Presentations
government, and industry,
providing educational
presenting novel research
insights about emerging than February 1, 2019.
results in all aspects of industrial
- Presentations: send the PowerPoint
coating technology for presentations
technology will be given priority. Although a company logo may appear
at its biennial conference which
presentation to Chuck Shearer on or
on the slides, it is not appropriate for a
will be held May 13-15 at Harrah’s
before March 1, 2019. Copies of the
presentation to be overly promotional
Resort in Atlantic City. The goal of
presentations will be distributed to
the Eastern Coatings Show is to
attendees, so each presenter should
further the advancement of coatings
include his or her permission or denial
less than 20 minutes and no longer
technology and offer educational
along with their presentation deck.
than 30 minutes.
or laden with trade names. - Length: presentations should be no
- Content: the ECS Technical Committee
and technical presentations to create a profound understanding of the
will review the presentations based on
For further information:
theory, science, manufacturing and
their technical content and contribution to
easterncoatingsshow.com
marketing of coatings to highlight the and functionality beyond traditional expectations. Technical papers will be presented during show hours May 13- 15, 2019.
© Caesars License Company
improvement of coatings performance
The ECS Technical Committee will be responsible for coordinating the agenda and logistics of all speakers.
Criteria for presentations - Abstract, Biography and Picture: provide an abstract for the presentation, biography and photograph of the speaker to Chuck Shearer (charles.shearer@dsm.com) no later than December 1, 2018. Incomplete submissions will not be considered for a speaker slot. Acceptance letters will be sent by January 1, 2019. The presentation schedule will be published no later
118
1
Figure 1: Easter Coatings Show is set for May 13-15, 2019 at Harrah’s, Atlantic City.
N. 52 - JULY/AUGUST 2018 - international PAINT&COATING magazine
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