The first international magazine for surface treatments
®
ipcm digital on In this issue :
SPECIAL ON ACE & OFF ROAD VEHICLES
& INTERNATIONAL PAINT&COATING MAGAZINE
ISSN 2280-6083
INDUSTRIAL CLEANING TECHNOLOGIES
www.myipcm.com 2018
9th Year - Bimonthly N° 54 - NOVEMBER/DECEMBER
s.r.l.
CHAINS FOR CONVEYORS
News Chains with 100Cr6 ball bearings for operation at temperatures up to 250°C
Leader in Europe since 1962
M A D E
w
w
w .
o
I N
r
I T A L Y
b
i
t
a
.
i
t
© shutterstock
© ST Powder Coatings
CONTENTS NOVEMBER/DECEMBER 2018
FOCUS ON TECHNOLOGY
HIGHLIGHT OF THE MONTH
Mixing it Up: New 2K Coating System for ZIEHL-ABEGG
© Ferrari Costruzioni Meccaniche
32 © ipcm ®
12
Powder-on-Powder Application Without Any Intermediate Gelation Phase: The Technological Innovation That Opens up New Horizons for Powder Coatings
SP EC IA L O N AC E & O FF R O A D V EHIC L E S
SPE C IAL O N AC E & OFF ROAD VEH ICLES
FOCUS ON TECHNOLOGY
42 05 06
FOCUS ON TECHNOLOGY
Berti Macchine Agricole. An Innovative Industrial Solution for the Coating Process of Its New Production Site.
EDITOR’S LETTER ANALYSIS
36 39
58
Ferrari Costruzioni Meccaniche: A New Tunnel Shot Blasting System for Highly Customisable Agricultural Machinery
SUSTAINABILITY
66
Eisenmann, a Paint Shop 4.0 Pioneer, Debuts an Integrated, End-to-End Solution for the Paint Shop of the Future
ON THE ROAD TO ipcm® N. 54
Thin Organic Coatings (TOCs)
16 18 22 26
BRAND-NEW SUSTAINABILITY BRAND-NEW HIGHLIGHT OF THE MONTH Colours as an Iconic and Emotional Journey. PPG Presents Human Icon, Its Colour Proposal For 2019
41 52 54
SPE C IAL O N AC E & O F F RO AD VE HIC L E S
72
Under the Surface: Innovative Pretreatment for the ACE Industry
HIGHLIGHT OF THE MONTH UV curing systems: A Low-Consumption and Sustainable Technology for High Production Rates
BRAND-NEW INNOVATIONS: PRESENT&FUTURE
SUCCESS STORIES
76
FOCUS ON TECHNOLOGY The Single-Stage Cold Pre-Treatment Technology Improves Production Efficiency and Environmental Sustainability
TECHNOLOGY INNOVATION SERVICE PERFORMANCE
Specialty Powder Coatings In addition to the traditional products, we offer a variety of specialty powder coatings designed to offer a certain
RIPOL Series BT low temperature cure systems
RIPOL Series OGF outgassing-friendly
RIPOL Series BACTERI Ag antimicrobial systems
RIPOL Series ESD antistatic and conductive systems
RIPOL Series TF thin ďŹ lm powder coatings
look, feel or function.
RIPOL Series AG scratch-resistant powder coatings
RIPOL Series PF coil coating & post forming
RIPOL Series HR improved overbaking stability
RIPOL Series MED Marine Equipment
international@ripol.com www.ripol.com
© Frank Boston_Fotolia
© Venjakob Maschinenbau GmbH & Co. KG
CONTENTS NOVEMBER/DECEMBER 2018
HIGHLIGHT OF THE MONTH
Mixed Powder Today: More Scratch-Resistant Specialist Coatings with Great Flow Properties
Mihail©fotolia
90
INNOVATIONS: PRESENT&FUTURE
© ipcm ®
84
The New Dimension of the Spray Painting Solutions by Venjakob
136 94
ICT - CASE STUDY
Opting for a Modified Alcohol Cleaning Technology for Oil-Hydraulic Components in the Framework of a Smart Factory Project
FOCUS ON TECHNOLOGY Steelpaint: The Industrialisation of a Nanotechnology Pre-Treatment Process for Large-Sized Workpieces Treated in a Static Coating Plant
100 102
112
In the Portuguese Bike Valley, a Cutting-Edge Coating Plant Brings Automotive Technology and Quality to the Service of the Bicycle Industry
INNOVATIONS: PRESENT&FUTURE Times and Methods in Production Processes
118 121 122
MicroCare Corporation Expands at the European Level: Inaugurated a New English Plant for the Mixing and Packaging of Industrial Cleaning Solutions
132 144 150
ICT - CASE STUDY
ICT - HIGHLIGHT OF THE MONTH MAFAC Cleaning Solutions: A New Dimension of Dynamic Cleaning
TRADE FAIRS & CONFERENCES ZOOM ON EVENTS
ICT - INDUSTRY NEWS
An Environmentally Friendly and Low Energy Consumption Cleaning Process for Tailor-Made Oil-Hydraulic Componentsy
SUCCESS STORIES Dürr Builds a Highly Automated Paint Shop with Integrated IIoT Solutions for VinFast
BRAND-NEW FOCUS ON TECHNOLOGY
142
ICT - CASE STUDY
154
ICT - ZOOM ON EVENTS
EDITOR’S LETTER It is time for “Humans 4.0”. Richiedi la versione in italiano a info@ipcm.it
T
he paradox of the fourth industrial revolution, the era of the Digital Factory, is that human capital will remain a crucial resource to seize its opportunities. With the advent of the concept of Industry 4.0, the dichotomy between man and robot
has been overcome and replaced by the centrality of human resources in the digitisation process. Already in 2017, the World Economic Forum had confirmed the importance of the human factor, highlighting that by 2020 one third of the skills required of employees would include competences that are not considered crucial today. Companies are no longer required only to invest in 4.0-oriented machines. It is imperative to find specialised personnel able to manage them, exploit their full potential, and above all analyse big data – skills without which the Industry 4.0 loses part of its appeal and purpose. The incentives that all European governments have given to companies willing to invest in machines and plants 4.0 have been widely used to renew production lines and create digital, interconnected factories that track production, predict errors, and perform necessary maintenance. Now it is time for these companies to invest in human resources. These include professionals able to solve complex problems and think critically to help organisations adapt quickly to changes; software programmers; data analytic experts and data scientist transforming the collected data into strategic suggestions; and IT security experts to protect networks and expertise. Extremely specialised technical skills will be needed, some of which perhaps do not exist, yet. Graduates in Science, Technology, Engineering, and Mathematic (STEM) subjects and super-experts are the most sought after by global companies, and they will be for many years to come. However, the question is if the current educational offer will be able to meet the demands of the world of work in the next five years. Indeed, after making huge investments in technology, several manufacturing companies are now facing a sense of disorientation among their employees. The older ones feel threatened by digital machines and struggle to adapt to the new production environment; the younger ones do not have the technical skills to manage the new digital factory, yet, and they struggle to find information and training resources. The human factor, therefore, must be enhanced even before technology. There are no technology and innovation, without adequate human resources. The technological changes call for a different education and culture for students and workers. Strengthening the school-work link, as many European countries are doing, is certainly one of the keys to preparing the new generations of engineers to the reality of the digital factory, which develops so quickly that knowledge becomes obsolete within a few years. Plug & play training and the development of professionals ready to enter specific work environments are the solutions to reduce the gap between students’ education and businesses’ needs. The ipcm Academy project, i.e. the professional training courses organised by the ipcm® magazine, is aimed precisely at this. The different modules make up a training course able to refine the professional skills of participants and offer immediate specialisation. ipcm Academy has very interesting development projects in store, in line with the demands of the manufacturing world for 2019 and 2020.
Alessia Venturi Editor-in-chief Direttore Responsabile
2019 will also be the year of ipcm®’s 10th anniversary. Therefore, we end this year full of energies and ready to work! Happy Holidays. We will see you all next year.
international PAINT&COATING magazine - NOVEMBER/DECEMBER 2018 - N. 54
05
Š CONDOROIL
Opening photo: Thin Organic Coating (TOC) formulations can have a rapid growth in the immediate future, especially in the treatment of hot galvanised coils.
ANALYSIS
Thin Organic Coatings (TOCs) Marco Zavattoni Condoroil Chemical S.r.l., Casale Litta (Varese) - Italy
T
marketing@condoroil.it
his article aims at explaining why
In order to let you understand what led us
What are TOCs?
we believe that the so-called Thin
to this prediction, we will start by explaining
As the name suggests, TOCs are formulations
Organic Coating (TOC) formulations
what TOCs are in terms of formulation,
that produce a low-thickness organic
can have a rapid growth in the immediate
where and how they are applied, what their
coating. They are commonly also called
future, especially in the treatment of hot
characteristics are, and what their current
permanent coatings, to differentiate them
galvanised coils (ref. Opening photo).
industrial uses are.
from temporary coatings, or anti-fingerprint
06
N. 54 - NOVEMBER/DECEMBER 2018 - international PAINT&COATING magazine
1
Figure 1: The thickness created by TOC is generally about 1 μ. This is the main characteristic that distinguishes them from other formulations, with generally higher thicknesses.
How and where are they applied?
Main features
TOC formulations are
ones are as follows:
employed in various
- corrosion resistance;
industrial sectors, although
- overcoatability;
they are mainly applied on
- foamability;
hot metallised (especially
- anti-fingerprint characteristic;
galvanised and zinc
- aesthetic effects;
aluminised) steel coils, i.e.
- lubrication;
galvalume, for which the
- chemical resistance;
precursors of this product
- temperature resistance;
category were developed
- UV resistance;
in the early 1980s.
- scratch resistance.
TOCs have a wide range of features. The main
Although this phase can be integrated on coil coating
© CONDOROIL
© CONDOROIL
ANALYSIS
lines, these formulations are generally applied at the exit of the galvanising line
coatings, due to one of their characteristics.
with a chemical coater (Fig. 2). Since they
Basically, these formulations contain as follows:
are no-rinse products, after the application
- one or more organic resins;
of the film, a drying phase is needed for
- various functional additives that can be
which hot air, IR, NIR, or induction ovens are used.
organic or inorganic.
The applied product layer can be The thickness of the coating they create is
measured inline through continuous
generally about 1 μ, or anyway within the 0.5-3
flow spot measurements performed
μ range. This is the main characteristic that
with an X-ray gun, by measuring the
distinguishes them from other formulations,
thickness of the wet film, or by dividing the
with generally higher thicknesses (Fig. 1).
instantaneous product consumption value
The selection of the resins is crucial, as they
by the treated area. Depending on the
must ensure perfect adhesion to metal even
resin used, the coating thickness, and the
when charged by the additives dispersed or
required characteristics, it is necessary to
solubilised in them. Such additives, on the
reach a certain PMT value, generally equal
other hand, give the coating the characteristics
to or greater than 70 °C. The temperature
that we will analyse in the following
at which the coil rewinding occurs, on the
paragraphs.
other hand, should not exceed 40 °C.
2 1
Figure 2: The TOC formulations are generally applied at the exit of the galvanising line with a chemical coater.
End-to-end solutions – from body shop to coating and final assembly. www.eisenmann.com
© CONDOROIL
The thickness of the coating they create is generally about 1 μ, or anyway within the 0.5-3 μ range. This is the main characteristic that distinguishes them from other formulations, with generally higher thicknesses. The selection of the resins is crucial, as they must ensure perfect adhesion to metal even when charged by the additives dispersed or solubilised in them.”
The products available on the market have most of the listed properties. Depending on their formulations, they can be more or less suitable to the intended use of a material. In order to quickly highlight the distribution of their various properties, these products are generally provided with a spider web diagram, like the one shown in the Figure 3.
Application examples Production of household 3 1
Figure 3: The distribution of the properties of a product used on home appliances and sandwich panels: 1 - corrosion resistance; 2 - overcoatability; 3 - foamability; 4 - anti-fingerprint characteristic; 5 - lubrication; 6 - chemical resistance; 7 - temperature resistance; 8 - UV resistance.
appliances and equipment in general The use of TOC coated coils enables the manufacturers of appliances, equipment, and structural components not
© CONDOROIL
subjected to strong deformations
4 1
Figure 4: The Condorboard series by CONDOROIL with a blackboard effect.
08
N. 54 - NOVEMBER/DECEMBER 2018 - international PAINT&COATING magazine
ANALYSIS
TOC formulations are employed in various industrial sectors, although they are mainly applied on hot metallised (especially galvanised and zinc aluminised) steel coils, i.e. galvalume, for which the precursors of this product category were developed in the early 1980s. Although this phase can be integrated on coil coating lines, these formulations are generally applied at the exit of the galvanising line with a chemical coater.�
to treat metal sheets without lubricants and, therefore, to coat them without any prior pre-treatment cycle. At the same time, TOC coated parts can also be used in hidden areas of household appliances (e.g. washing machine backside) because they have much higher corrosion resistance than traditional HDG coated parts and a much lower cost per unit compared to pre-painted components. Depending on the case, the coatings can be required to have particularly high lubrication, corrosion resistance, or overcoatability properties. Production of sandwich panels TOCs are a valid alternative to back coat paints in the production of sandwich panels. Also in this case, the lubrication and corrosion resistance properties are important, as well as the presence of a foamable deposit. Coil coating Although generally classified as passivating or pre-treatment products, the no-rinse paints applied with a chemical coater as a surface preparation phase prior to coating belong to the general TOC category. In this case, corrosion resistance and overcoatability are the most sought after features. Also the so-called pre-treatment primers, combining the characteristics of a pre-treatment product and a primer in one formulation, belong to the large TOC family. There are many ongoing research projects for the industrialisation of pre-treatment primers, and a few low productivity lines are already using them. Other minor uses Internal components of electronic equipment, profiles, shelves, ventilation channels, etc. are other examples of use of TOC coated sheet metal.
Why TOCs are promising Now that we have presented this technology, let us go back to the initial question: why do we expect a future development of TOC formulations? As is often the case, a simple question calls for a complex and articulate answer. Surely, the main driving force behind the search for new applications, and therefore new formulations, will be the possibility of increasing the profit Š CONDOROIL
margin of galvanised coils by applying a product that virtually does not affect production costs. This growth factor is further enhanced by a situation of production overcapacity that is limiting the processing margins of companies. This perfectly chimes with a product like TOC, whose potential has only been minimally expressed. Based on what has been illustrated so far, there are currently few formulations with a limited range of properties on the market. These characteristics can however be enhanced and expanded
5 1
with the use of different resins and additives. Close collaboration between sales representatives of metallic materials who know the users’ needs, line engineers, and chemists will certainly
Figure 5: Mogalvin is a TOC that gives a galvanised coil a gold-like appearance. It was born from the collaboration between CONDOROIL and the Saudi company Unicoil.
compounds, and the Condorboard series with a blackboard effect (Fig. 4). Condoroil is also proud to present
enable the industry to grow through the
Mogalvin, a special product born from
following actions: - development of increasingly high
with tactile finishes recalling natural
- self-cleaning coatings through the addition
the exclusive collaboration with the Saudi
performance formulations towards specific
of nanoparticles with UV degradation
company Unicoil. This TOC gives the
needs (lubrication, corrosion resistance,
properties;
galvanised coil a gold-like appearance by
aesthetics, etc.); - development of formulations with new specific characteristics; - opening to other sectors than coil (there are already a few applications on wires, bars, and tubes).
- anti-scratch coatings through the addition of ceramic nanoparticles; - conductive coatings through the addition
exploiting the brilliance of the metal itself (Fig. 5). This material is now being used in an important advertising campaign
of graphene or an alternative conductive
launched by Unicoil throughout the
molecule;
Middle East area.
- coatings with particular aesthetic effects.
Conclusions
Here below, you will find some examples of
CONDOROIL has worked a lot on the latter
TOCs have a strong potential for
products with special properties:
in the last few years, developing particularly
development on the market, which
- fluorescent coatings for escape routes;
pleasant products in terms of colours and
has just begun to appreciate some of
- antiseptic coatings through the addition of
finishes. Some examples are the Condorcoat
their features. This article presents the
PC 800 series with wrinkled finishes, the
characteristics of these formulations and
Condorcoat PC 900 series with metallic
highlights the reasons and the markets
effects, the Condorcoat PC 600 series
where their future growth is expected.
bacteriostatic agents; - trackable coatings as a support in the event of disputes;
10
N. 54 - NOVEMBER/DECEMBER 2018 - international PAINT&COATING magazine
New 2018
One App to manage all the big data of your coating plant
You know the figures of your coating plant. But can you manage them? Experience the total control and secure storage of your big data to get fundamental information in order to improve your plant efficiency and performance. In real time, for each single unit of your production line, through any device. We can upgrade your plant, control and train your staff to obtain the maximum results from i4paintshop. Start your 4.0 future now.
Secure Cloud
Your plant Data
Global and detail consumption report Analysis by functional area Alarm and process parameters control Rapid access through QR code Lot tracking and traceability OEE report Maintenance calendar Realized by IMEL Fully integrated with your plant control SW Secure storage in cloud Modular and customizable platform Real time control Multi device access Easy deployment
IMEL SpA - Via Divisione Julia 10 - 33033 Codroipo, UD - Italy - T +39 0432 908578 - info@imelspa.com - www.imelspa.com
Š ST Powder Coatings
Opening photo: Metal sheets coated with the Powder on Powder technology.
HIGHLIGHT OF THE MONTH
Powder-on-Powder Application Without Any Intermediate Gelation Phase: The Technological Innovation That Opens up New Horizons for Powder Coatings Alessio Carlotto ST Powder Coatings, Montecchio Maggiore (Vicenza) - Italy
T
info@stpowdercoatings.com
he coating industry is certainly
trends, but it also concerns the application
That is why ST Powder Coatings
among the most dynamic and
methods, with the aim of combining
(Montecchio Maggiore, Vicenza, Italy -
ever-evolving sectors. Innovation
quality and advanced technologies with a
Fig. 1), a company specialising in the
does not only involve colours and finishes,
more efficient process in terms of costs
production of powder coatings, has
which go hand in hand with market
and times.
started an intensive R&D program to
12
N. 54 - NOVEMBER/DECEMBER 2018 - international PAINT&COATING magazine
HIGHLIGHT OF THE MONTH
meet a new market requirement that was
To guarantee maximum performance in the
first imposed in Germany (Fig. 2).
subsequent finishing phase, three hybrid primers
The result was the development of a
have been developed, in three different colours:
powder-on-powder technology enabling to
white (to be used with light-coloured finishes), black
apply a topcoat immediately after primer, without
(for dark-coloured finishes), and grey (for all other
any intermediate gelation stage and with standard
tints). The choice to develop three primers with
application methods. ST Powder Coatings
the same chemical nature but in different colours
presented its Powder on Powder technology
was dictated by the will to minimise all problems Š ST Powder Coatings
for the first time in May 2018, on the occasion of the XVI Wagner
related to the risk of mixing primers and topcoats,
Symposium
which can
held in Poland
compromise
(ref. Opening
the final
photo). This is
quality level
a revolutionary
(especially for
system, among
light colours):
the first in Italy,
should this
which guarantees
happen, the
a considerable
result would
reduction in the
be however
coating time
guaranteed
and process
by the colour
optimisation.
matching of
One of the main
the primer
issues of powder-
and the
on-powder
topcoat.
systems without
Another factor
an intermediate
that played
gelation stage
a crucial
has always been the application of a finish with the same electrostatic charge of the
role in the
1
development
Figure 1: ST Powder Coatings’ headquarters is located in Montecchio Maggiore (Vicenza, Italy).
of these primers was the environment:
primer, which entails the risk of mixing and distension
they are eco-friendly, since they do not contain zinc
problems. In order to overcome these
or other harmful substances.
problems, it is necessary to reconsider the
The development of specific primers allows to use
application technology used, opting for
finishes that are already present in the ST range,
triboelectric application systems, not widely
without having to resort to specially designed
used, or hybrid systems, i.e. triboelectric and
products. The tests performed did not find any
Corona. ST Powder Coatings has developed
problems of distension of the coatings, which present
a technology that can be applied with the
the same properties of a one-layer system. Currently,
widespread Corona system without any
the finishes suitable for this process can be smooth,
qualitative problems, although without a
glossy, semi glossy, and matte.
primer gelation phase before the topcoat
The Powder on Powder product range has excellent
application.
anti-corrosion qualities: It was subjected to a salt
© ST Powder Coatings
2 1
Figure 2: A bird’s eye view of the inside of the factory.
spray test for a cycle of 5000 hours
This system also guarantees greater
for a double application process
on sheets pre-treated with zinc
elasticity, which depends on how the
in the available booth. The final
phosphates. This paves the way
primer is applied. ST Powder Coatings’
polymerisation temperature
for the use of powder coatings
engineers recommend to apply
depends on the selected ST topcoat.
in many sectors, even those that
not too high thicknesses to achieve
The powder coatings of the Powder
have always preferred liquid paints,
both greater film elasticity and
on Powder range feature excellent
such as the heavy industry and
improved finish application. Usually,
corrosion resistance and they
corrosion protection ones. For
the recommended total thickness of
contribute to significant savings
optimal results, it is necessary to
the coating is between 100 and 150
in terms of plant management
respect some parameters and
microns.
costs and an increase in hourly
follow the application suggestions,
In terms of application equipment,
productivity. The possibility of using
also with regard to the guns’ voltage.
no system changes are required: it
these products without any special
Generally, the primers can be
is sufficient to adjust the application
arrangements and with commonly
applied under standard voltage
process depending on the system
used technologies makes them
conditions, whereas the topcoats
installed. If there are not two booths
versatile and easy to use in most
require a slightly lower voltage.
on the line, it is possible to provide
industrial sectors.
14
N. 54 - NOVEMBER/DECEMBER 2018 - international PAINT&COATING magazine
BRAND-NEW
F
inishing Group has manufactured and
© ipcm ®
The New Headquarters of Finishing Group for the Production of Euromask® Masking Products distributed its Euromask® -branded masking products all over the world for over twenty
years. Created in 1994, this brand includes professional masking systems for any type of surface treatment: powder and liquid coating, electrostatic coating, liquid immersion coating, platinising, galvanic treatments, anodising, oxidation, nickel-plating, galvanising, and so on. Over the years, a production department has been created and gradually expanded. The possibility to manufacture its products in-house has given the firm total flexibility in terms of both products and ability to meet the most diverse customer needs. Finishing Group carries out the whole production process of its hook range and all processing operations on its masks, i.e. cutting, die cutting, rewinding, and so on. The success on the market of these products has led the company to an exponential growth not only at the European level, but also internationally. Finishing Group is now a multinational company with activities
1
Figure 1: A moment of the inauguration of the new Finishing Group’s headquarters in Lainate (Milan).
world, from Europe to the Americas, from Asia to Africa. Exports account for over 40% of its turnover.
© ipcm ®
in over 50 of the most important countries in the
Recently, the company has further expanded: on 5 October, it inaugurated its new headquarters in Lainate (Milan): this is the main production site of the whole Euromask® range (Figs. 1 and 2). From here and from three other factories located in Northern Europe, Eastern Europe, and Central America, the masking products of this Italian company are shipped all over the world. Its key to success are speed, flexibility, and professionalism. Here below, you will find a few significant figures: • 85% of orders processed in 24/48 hours; • 60,000,000 ready-for-delivery components; • 3 days for the sampling of out-of-standard masks; • 3-5 days for the sampling of special moulded products. For further information: www.euromask-shop.com
16
N. 54 - NOVEMBER/DECEMBER 2018 - international PAINT&COATING magazine
2 1
Figure 2: The whole staff of Finishing Group.
BRAND-NEW
Gema Wins BESSER LACKIEREN Supplier Award 2019
G
ema is the winner of the BESSER LACKIEREN Supplier Award 2019 for the product area “Powder Application Equipment”. This is the result of a survey conducted by the “IMK Institut
für angewandte Marketing- und Kommunikationsforschung GmbH” on behalf of the magazine BESSER LACKIEREN. Participants of the survey were owners/managing directors and paint shop managers of customers based in Switzerland, Germany and Austria. The survey participants assessed their suppliers on the basis of seven criteria: • Product quality; • Price-performance ratio; • Delivery performance; • Support during installation and commissioning; • Partnership strength; • Understanding of current and future market requirements;
Based on the positive scores in all
© GEMA
• Innovation competence.
these categories, Gema was able to prevail over its competitors and was elected best supplier for 2019. Gema achieved particularly positive scores in ‘Product quality’, ‘Delivery performance’ and ‘Support during installation and commissioning’. “Gema’s strategy is largely focused on innovation, quality and customer service, therefore we are particularly proud of this award that is entirely based on customers’ satisfaction indicators. It is an important recognition for our past performance and a great incentive for all our team to continue growing our business with dedication and enthusiasm”, says Claudio Merengo, Gema President Worldwide. For further information: www.gemapowdercoating.com
SUSTAINABILITY
A Second Look at Paint Recycling Mr. Radhakrishnan Regent Paints Inc., New York - USA
huzaifa@regentpaintsusa.com
© pngtree.com
18
N. 54 - NOVEMBER/DECEMBER 2018 - international PAINT&COATING magazine
SUSTAINABILITY
P
aint recycling is an excellent
since passed similar laws, and more states
coatings; two-component coatings; roof
mechanism for preventing the
are expected to do so in the coming year.
patch and repair materials; and asphalt, tar
land-filling and incineration of
In these states, architectural paints carry an
and bitumen-based products are not part of
unwanted paints that have residual value
additional fee that covers the costs of the
the program. As with architectural coatings,
as paint products, but not in their intended
program. Unused architectural paints are
there are significant environmental benefits
applications. The American Coatings
returned to the more than 1,750 drop-off
to be gained by recycling and/or reusing
Association (ACA) established PaintCare
sites across the nine PaintCare states for
these materials, many of which are
Inc., a non-profit 501(c)(3) organization
free. The paint is sorted and managed for
solvent-based products.
representing paint manufacturers that
reuse, recycling, energy recovery, or safe
One company is taking on the challenge of
operates paint stewardship programs
disposal. In California alone, from July 1,
recycling solvent-based industrial coatings
for architectural paints in U.S. states and
2016-June 30, 2017, PaintCare collected
and paint raw materials that would otherwise
jurisdictions that pass paint stewardship
and processed 3.4M gallons of paint.
end up in waste streams. Regent Paints Inc.
laws. The first paint stewardship law was
PaintCare focuses on architectural paints
is a US-based Division of Matawala Paint
passed in Oregon in 2009 as a three-year
(house paint and primers, stains, sealers,
Industries UAE and the Matawala Group
pilot initiative, with the PaintCare program
and clear coatings), and does not collect or
of Industries, which has manufacturing
in that state made permanent through
process products intended for industrial or
locations in the United Arab Emirates.
legislation in 2013. California, Colorado,
non-architectural use. Paint thinners and
The company accepts materials (both
Connecticut, the District of Columbia, Maine,
solvents; automotive, marine, industrial
solvent- and water-based) from paint/
Minnesota, Rhode Island, and Vermont have
maintenance, and traffic/road marking
coating, resin, and solvent manufacturers
Aluminium Wheel Painting
Excellence in surface finishing For the painting of aluminum wheels, DĂźrr 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. DĂźrr 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
international intern inte rnat ationa ionall PAINT&COATING PA NT& PAINT &CO COATIN COAT ING NG magazine NG maga mag aga gazine zzine ine i - NOVE NOVEMBER/DECEMBER V MBER M /DECCEMBE /DECEMBE MBE BER R 2018 2018 - N. N 54 54
1199
SUSTAINABILITY
across the US and in Canada, Europe,
entire batch. If a mineral spirit paint
primers that can then be provided
and the Middle East and ships them
batch based on a long-oil resin gets
to Regent for sale to its customers.
to its plant in the UAE for reworking.
mixed with methanol, toluene, or any
“When we share our proprietary and
These materials are typically products
other very fast drying solvent, Matawala
unique process for converting waste
generated during production that are
notes that the paint will lose its
into useful products, we are opening
unusable for some reason, whether due
viscosity. Mixing of automotive paints
an avenue and a product line with that
to a major batch failure or because they
with medium oil resins can lead to the
company. In order to be protected,
are even slightly off-spec.
formation of undesirable precipitates.
however, the supplier must agree
“Although these materials are no longer
Depending on their properties, the
to only use the process to produce
fit for sale by the manufacturer, they still
materials end up in bitumen primer
products for Regent Paint and its
have value that we can leverage through
or bitumen emulsion products sold
affiliates and to not share any details
recycling/reworking. The manufacturer
under the brand names TOLOKOTE
of process,” Matawala observes.
benefits because they receive payment
and REGENT. Both are basic,
Matawala Group of Industries is a
for materials that previously they had to
economic products that are marketed
third-generation paint manufacturer
pay to dispose of. Reduction of waste
for infrastructure applications in
that began recycling its own paints
streams benefits the environment,
developing nations, according to
and raw materials as a way to reclaim
and we are able to provide economical
Matawala. TOLOKOTE is produced
the value of off-spec materials. “We
products that offer good performance to
from solvent-based resins, pulp,
have found that recycling oil-based
markets in need of such basic protective
and off-spec paints and is intended
paint is cheaper than fuel blending
coatings,” says Huzaifa Matawala, CEO of
for use on walls and underground
because the value of the ingredients
the Matawala Group of Industries and
concrete as a protective coating to
is better captured, and at the same
Regent Paints Inc.
prevent damage to substrates in hot,
time no power is needed and natural
Water-based paints are sorted by color,
humid, salty climates. It is also used
resource consumption and CO2
combined and filtered, then subjected
for road construction applications.
generation are reduced or avoided.
to further blending and finally packaged.
These products are often formed
In addition, the performance of
For solvent-based products, the
from gelled resin batches that are the
recycled paints in most cases is the
paints are first sorted by the end-use
result of production errors during resin
same or even better than freshly
application: decorative enamels, epoxies,
manufacturing. In the warmer climate
produced batches,” Matawala asserts.
polyurethanes, and other industrial
of the UAE, they often flow more easily
After developing its recycling process,
primers and coatings. The materials are
and can be removed from barrels
the company soon realized that other
then sorted based on the type of resin
naturally. If not, they are gently heated
paint, coating, and resin producers
and solvent used in the formulation.
to reduce the viscosity and then mixed
had similar issues, and that its
Most of the items are mineral spirits-
with other resins/paints and blended
process could be applied to the
based, while most of the resins are
with additives and thinners to obtain
recycling of material from external
soya-based, long/medium oils, according
a homogenous product. All of the
sources as well. “We now offer in
to Matawala. The matt/gloss properties
bitumen coatings are formulated as
addition to the recycled paints, a
of the materials are also determined
black coatings by adding black pigment
virgin line of white and base paints,
using a glossmeter. Density is checked to
in the appropriate dosage levels.
pigments, and specialty ingredients
ascertain the resin content, which varies
For some materials that are not
that can be mixed with the recycled
with every barrel received. Determining
shippable in their current form, Regent
products to improve their properties,”
the compatibility of different inputs is
Paints provides suppliers, under non-
Matawala says. He also notes that
essential prior to blending, as mixing
disclosure agreements, with details
the company hopes to expand its
of incompatible ingredients can lead
of its process for producing reworked
recycling business in the US and all of
to undesired gelling or hardening. For
coating products. Regent shares
North America.
instance, mixing a hardener by mistake
information on segregation, bulking,
with a batch of epoxy or polyurethane
and the use of additives to convert
For further information:
coatings can lead to solidification of the
unusable material into alkyd stains or
www.regentpaintsusa.com
20
N. 54 - NOVEMBER/DECEMBER 2018 - international PAINT&COATING magazine
Italian Excellence since 1917
Italian colour technology at the service of all industries.
www.arsonsisi.com
100% made in Italy
Arsonsisi provides complete solutions to meet the requirements of the entire painting cycle for any type of product, with its industrial liquid paints, powder coatings and electrocoating paints. Everything is strictly designed and made in Italy.
we
l UV you
UV coatings In how many ways can the love for beauty and colour be expressed? Arsonsisi does it through a line of state-of-the-art UVcuring coatings, thanks also to the experience and know-how of Tecnocolor, a specialized company that is part of our group. Arsonsisi UVcolor range includes solvent-based, water-based or 100% dry residue coatings, suitable for various types of applications among which high vacuum metallization, Sputtering or PVD, and hybrid “Dual Cure� coatings with mixed heat/UV curing for complex 3D objects. Italian colour technology at the service of all industries.
www.arsonsisi.com
100% made in Italy
BRAND-NEW
BASF Introduces AUROOM™, a Platform for the Digital Visualization of Automotive Exterior Colours
W
ith AUROOM, BASF’s Coatings
Working together with almost every
reproductions. For our customers, it
division introduces a digital
car manufacturer on the market, BASF
means the colour decision process will
platform which enables OEM
currently produces over 600 colours
become easier, faster and much more
designers to access a database of
in Europe with new colours constantly
effective. They can also use the data for
photo-realistic virtual car colours (Fig. 1).
being designed. This massive portfolio will
their own brand-specific car configurators
BASF’s virtual colours capture all facets
now be scanned by cameras. The huge
so that car buyers can experience
of automotive coatings including
amount of appearance data generated
automotive colours in their entire variety
lightness flop, colour flop and sparkling.
during the scan is processed using a
which supports their buying decision,”
By mapping these colours on car
sophisticated mathematic model while
said Krzysztof Patryk Stolarzewicz, head
models, OEM designers can virtually
BASF’s colorimetric know-how contributes
of Global Strategic Marketing at BASF’s
paint every colour proposal and gain
to ensure its authenticity. OEMs can then
Coatings division.
realistic impressions of colours and
In the start-up phase, BASF’s virtual colour
effects on a complete car already
solution will first be introduced
in an early design phase.
to OEMs in EMEA. In
AUROOM will be a
addition to the
valuable tool for OEM
digital platform, © BASF
designers to speed up and perfect the overall colour design process as
the customers will have the chance to
1
experience
they are no longer
the technology
solely dependent on
at AUROOM’s
physical samples that need to
“analog twin” – a specially
be painted and shipped. AUROOM provides further innovative features like real-time side by side comparison of different colour shades of the same colour group to make the right colour
designed showroom at the Figure 1: AUROOM is a digital platform which enables OEM designers to access a database of photo-realistic virtual car colours.
decision easier.
Color Design Studio Europe in Münster, Germany. To demonstrate the colours and effects in the most authentic way possible, BASF also developed special virtual 3-D car shapes. Like BASF’s iconic
“Automotive coatings are highly
access the comprehensive colour data
dome shape, the virtual shapes simulate
complex colours with texture, colour
at the AUROOM platform and render it
various forms of a car body.
position and surface defining the overall
on different 3D shapes provided by the
In order to assess compatibility of colour
impression. To easily understand the
platform or CAD shapes of their own
with the overall design concept, OEM
impact of these colour parameters
models.
designers can choose shapes of different
on a 3-D shape, the digitized colours
“Digitalization is an important topic,
vehicle segments in AUROOM for colour
enable the user to see this on their
especially in the automotive industry. We
visualization.
individual models” said Mark Gutjahr,
have a lot of experience creating colours
head of Automotive Color Design
in our labs and now we are able to digitize
For further information:
EMEA at BASF’s Coatings division.
them and create photo-realistic digital
www.basf-coatings.com
22
N. 54 - NOVEMBER/DECEMBER 2018 - international PAINT&COATING magazine
* patent pending
BRAND-NEW
TEGO® Dispers 687 – Wetting and Dispersing Additive for Matting Agents in Solventborne Coatings
T
Light on rejects Light on waste Bright on application
EGO® Dispers 687 is a new dispersant specially developed for the wetting and dispersing of matting agents in solventborne coatings.
TEGO® Dispers 687 helps achieve coating characteristics
such as excellent anti-sedimentation and consistent matte values. Highly recommended for semi-gloss and matte wood coatings, TEGO® Dispers 687 extends the application
The must-have accessory for the Encore manual spray gun range
window by greatly reducing the sedimentation tendency of
The Encore® nLighten™ LED Kit*
matting agents, even when the paint is diluted over a period of time.
Reduce or eliminate rejects or rework
TEGO® Dispers 687 is especially suitable for untreated matting agents that have good transparency but high
Effectively highlight and fix light powder areas on surfaces,
sedimentation tendency. Because of its excellent
deep recesses and cavities – on the fly.
anti-sedimentation property, it allows users to lessen or
Reduce material waste
eliminate the use of anti-sedimentation additives in their formulation – which is advantageous to the development of
Optimum light levels enable precisely targeted powder
highly transparent matte coatings.
application, to reduce waste and save on material costs. Increase efficiency
For further information:
This all-in-one application and inspection tool gives © Evonik
www.coating-additives.com
every operator the power to both spray and inspect at the same time. Improve safety Rated for use in all powder coating environments. For more information please visit www.nordsoncoating.com/nlighten
1
ics.eu@nordson.com | www.nordson.com/powder Figure 1: TEGO® Dispers 687 is a new dispersant specially developed by Evonik for the wetting and dispersing of matting agents in solventborne coatings.
Performance by design
BRAND-NEW
PHASCOPE® PAINT: The Pen That Measures Coating Thickness
T
During measurement, a red LED
the PHASCOPE PAINT is equipped with a
Fischer PHASCOPE® family is the new
indicates if tolerance limits are exceeded.
conductivity compensation feature, which
pen-probe. PHASCOPE PAINT reliably
That makes it easy to recognize defects in
ensures accurate measurement results.
measures the thickness of paint layers on
the coating, even for non-technical users.
In addition to spot checks, the
various substrates – quickly and easily.
To simplify analysing the readings,
PHASCOPE PAINT also has a continuous
Small and pen-shaped,
PHASCOPE PAINT uses an intuitive app.
mode for testing large areas, with up to 70
it slips neatly into
The measurements can be visualized
measurements per minute.
your pocket, and it’s
on a smartphone without having to
designed to be simple
first transfer them to a computer. And
Features
to use.
reports can also be created directly on
• Automatically recognizes the substrate
The handy, pen-like
the smartphone. Special feature: the
PHASCOPE® PAINT is
user can quickly insert photos of the
• Broad measurement range (0 – 2500 μm).
test site into the measurement report
• Modes for single-point and continuous
ideal for fast and easy
© Fischer
he latest member of the
thickness measurement
to document potentially damaged
of paint layers on
areas. Then the app does the statistical
ferrous and non-ferrous
evaluation.
metals. Thanks to its
The versatile PHASCOPE PAINT is ideal
broad measuring range
for measuring all thicker paint coatings
material.
(free-running) testing with up to 70 measurements per minute. • An LED on the probe indicates when tolerance limits are breached. • Data analysis with the Fischer app for smartphone or tablet.
up to 2500 μm, it is
• Potentially damaged areas can be
particularly well-suited for very thick coatings.
documented with photos in the reports.
Statistical evaluation of
• Bluetooth connection to mobile devices.
the readings is carried
• Due to its robust housing, even under
out on a smartphone
harsh environmental conditions the gauge
using the intuitive Fischer
remains extremely reliable.
app. Reports can then be sent quickly and easily as
Applications
1
PDFs.
• Quick and easy coating thickness
Because field testing often involves checking many different kinds of coatings, a flexible instrument is needed. PHASCOPE PAINT relies on the versatile eddy current method.
measurements, equivalent to DIN EN ISO Figure 1: PHASCOPE PAINT developed by Fischer is ideal for fast and easy thickness measurement of paint layers on ferrous and non-ferrous metals.
For example, it can measure paint coatings
2360, ASTM D7091, DIN EN ISO2178 and DIN EN ISO 21968. • Measurement of paints and lacquers on ferrous and non-ferrous metals and analysis of anodized surfaces.
on magnetizable substrates such as steel
• Automotive industry and car-body paint
or iron, as well as on non-magnetic metals
and applicable in industries ranging from
like aluminium, without having to change
automotive to corrosion protection.
• Corrosion protection.
the device or the probe. PHASCOPE PAINT
When handling workpieces of various
• Facade engineering.
can also automatically detect the kind
aluminium alloys, their different
of substrate at hand and selecting the
conductivities can influence the coating
For further information:
appropriate mode.
thickness measurements. This is why
www.fischer-technology.com
24
N. 54 - NOVEMBER/DECEMBER 2018 - international PAINT&COATING magazine
shops.
BRAND-NEW
Dürr Designs Highly Flexible Assembly Layout for the New Lamborghini Urus
T
he Urus super SUV from
but also the overall capacity to 7,000
another in a linear conveyor system as it
Lamborghini is manufactured under
vehicles annually. For this strategically
has been the case up to now. They also run
the most modern conditions.
important project for the future of the
without rails, are freely programmable like
The plant at the headquarters of the Italian
brand, Lamborghini entrusted Dürr with
robots, and can be controlled flexibly. This
sports car manufacturer in Sant’Agata
developing new production lines for
means that future model series can also be
Bolognese, which was rebuilt in record
complete vehicle assembly (Fig. 1).
manufactured on existing lines, since they
time, is characterized by highly flexible
This is based on a forward-looking layout in
can be changed over quickly in order to be
assembly lines with newly developed AGVs
which each area can be used flexibly. That
appropriate to new market scenarios and
(Automated Guided Vehicles) and especially
allows the line configuration to be modified
varied production requirements. The AGVs
ergonomic workstations. As the general
at any time following installation, in other
at Lamborghini come in three different
contractor, Dürr was responsible for the
words it remains adaptable to changing
sizes and are suitable for line feeding tasks,
installation of the assembly lines as well
requirements.
the processes in the main line, and for
as for the integration and optimization of
subassembly and powertrain operations.
innovative technologies and processes.
AGV fleet in various sizes
With a view to the market launch of the new
The conveying system with AGVs,
Urus super SUV, Lamborghini modernized
specifically developed by Dürr for the
Ergonomically optimized workstations
its long-established plant within just 18
Urus, guarantees a high degree of
In addition to the AGVs, Dürr installed
months during ongoing production.
flexibility.
further technologies that also meet the
Not only was the production space
The AGVs move individual components
most demanding standards for ergonomics
and bodies separately instead of one after
in the workplace. These include loading
doubled from 80,000 m to 160,000 m , 2
2
carriers (body on AGV), unloading devices © Dürr Systems AG
(car from AGV), rotating and vertical adjustable carriers for body transport and lifting, as well as slat conveyors with a lifting table for moving the vehicle into an ergonomic position. Overall control of the project on behalf of the Dürr Group rested with CPM, its Italian subsidiary specializing in final assembly. CPM and Lamborghini were already working hand in hand on layout design for conveyor technology, assembly lines, marriage stations, trim lines, and the end-of-line area. CPM was supported by its German colleagues from Dürr Assembly Products, which among other things supplied the x-road roll/brake test stand and adjusted it 1
Figure 1: As the general contractor, Dürr was responsible for the installation of the assembly lines as well as for the integration and optimization of innovative technologies and processes.
precisely to the Urus. For further information: www.durr.com
international PAINT&COATING magazine - NOVEMBER/DECEMBER 2018 - N. 54
25
© ipcm ®
Opening photo: PPG Colorshow 2018 was held on 12 October in the Intesa Sanpaolo skyscraper in Turin to present PPG’s new colour ranges for next year. Human Icon is the new colour project that will certainly have an impact on the colour trends for 2019.
HIGHLIGHT OF THE MONTH
Colours as an Iconic and Emotional Journey. PPG Presents Human Icon, Its Colour Proposal For 2019 Barbara Pennati ipcm®
26
N. 54 - NOVEMBER/DECEMBER 2018 - international PAINT&COATING magazine
HIGHLIGHT OF THE MONTH
C
physically; Diversity, referring to creativity
use last generation metallic pigments and
creative process behind the choice
as a means to stand out; and Experience,
very fine synthetic micas to create a “liquid”,
of each shade. PPG Colorshow 2018
referring to the core concept of Human
almost mirror-like appearance. The red,
was held on 12 October in the Intesa
Icon: in a world where everything is
blue, purple, yellow, and orange shades,
Sanpaolo skyscraper in Turin, which, with
readily available, the emotional journey
finally, convey vividness and irony through
its suggestive 360-degree view of the city,
continues to be of primary importance.
tints made more saturated and deeper by
olorshow is a biennial event
Durability, referring to the ability to
shades for sobriety and elegance to the
organised by PPG to present
survive over time, both in memory and
lightest ones for refinement. The “fluid” tints
its new colour ranges and the
© PPG
perfectly fitted Human Icon, a new tint range that will certainly
a coloured transparent layer containing patented nano
have an impact on the colour
pigments called Andaro® –
trends for 2019 (ref. Opening
ipcm® has already dealt with
photo).
them in its Ferrari report1. The colours created are
Human Icon was developed with
the result of a creative but
the aim of giving its new colours
also technical process. “All
an emotional and sympathetic
128 colours are classified
aspect as well as a unique and
according to their application
iconic appearance. “We live in an
properties, innovation degree,
interconnected world, in highly
formulation, and pigments
technological environments. That
used (Fig. 5). This results in
is why PPG created these new factor in order to stand out and focus back on awareness, quality, and emotional
the most suitable process for
1
colours, inspired by the human
industrialising our products
Figure 1: PPG Style Centre Manager Daniela Nicolelli during the presentation of the new colour range Human Icon.
experience through tints that
with the utmost confidence. Our technical department, therefore, works jointly with our Style Centre to offer our
can communicate,” explains PPG Style
For PPG, colors are an emotional journey.
customers innovative tints, able to convey
Centre Manager Daniela Nicolelli during
These four themes have helped develop
emotions and at the same time ensure ever
the presentation of the new colour range
seven colour palettes (Techno Attitude,
higher performance levels,” says Rodolfo
(Fig. 1).
Native Soul, Think Pink, Deep Authority,
Saporiti, the Automotive Market Manager
Analysing our environment, PPG
Enchanting Spirit, Nordic Dimension,
and CEO of PPG (Fig. 6).
identified four main themes for its
and Hop Art – Figs. 2, 3 and 4). PPG
creative project: Engagement, referring
experimented with different nuances
to attentive and aware actions;
and effects, ranging from the darkest
The global leader in fine spray atomisation.
Four Brands that lead the finishing world... ...One family World Class Manufacturers of: Process Controls | Curing & Conveying | Electrostatics Fluid Handling | Powder Coating | Atomisation Carlisle Fluid Technologies UK Ltd Ringwood Road, Bournemouth, Dorset, England BH11 9LH Tél: +44 (0)1202 596257 Tél: +33 (0)7 84 37 97 03 Email: marketing-fr@CarlisleFT.eu
The inventor and global leader in electrostatic painting technology.
Specialists in advanced powder coating equipment and systems.
The single source solution for spray finishing and fluid handling.
1 “Ferrari: The Italian Automaker Revolutionises the Car Painting Process with a Low Cure Clear Coat System”, ipcm®_International Paint&Coating Magazine no. 51, Vol. IX, 2018, pages 34-48.
© ipcm ®
© ipcm ®
© ipcm ®
2 1
3 1
4 1
Figures 2, 3, and 4: Some of the seven palettes that gather the 128 Human Icon colours.
The Colorshow event was organised by PPG
FCA Head of the Colour & Materials Style
brands of the Group. Our task is to grasp
for FCA - FIAT Chrysler Automobiles, in order
Centre Rossella Guasco (Fig. 7), who attended
and anticipate trends, reinterpreting them
to renew the long-standing collaboration
the event, explained the process behind the
for each brand and car model. That is why
with the automotive Group and pursue PPG’s
creation of the automotive colours designed
we highly value our collaboration with our
mission to support the automotive industry in
for the FCA Group: “Colour is one of the main
suppliers, such as PPG, our exclusive coating
the use of colour as a strategic business lever
protagonists of the work we carry out at the
partner: for years, they have supported
to stand out on the market. “PPG has always
FCA Style Centre, which deals with all the
us in identifying the right colours, effects,
believed in the ability of colour to transform beautiful. That is why we invest in innovation
© PPG
the world, protect it, and make it more and talent, developing high quality and sustainable solutions helping our automotive customers to maximise performance, enhance the uniqueness of their products, and minimise their environmental impact. With our six manufacturing sites throughout Italy, two of which are dedicated to the production of coatings for the car sector, we develop the creativity of this industry and innovate it, launching new trends and leading the change. Our commitment on the territory is proved, for instance, by our long-standing collaboration with the FCA Group. We have worked with them in Italy and abroad for many years now, through a mutual collaboration aimed at developing new highly impacting and effective colours, such as those presented at PPG Colorshow 2018,” states Rodolfo Saporiti.
28
5 1
Figure 5: The 128 shades were also analysed at the technical level and they are classified according to their application properties, innovation degree, formulation, and pigments used.
N. 54 - NOVEMBER/DECEMBER 2018 - international PAINT&COATING magazine
© PPG
HIGHLIGHT OF THE MONTH
6 1
Figure 6: From left to right: PPG Style Centre Manager Daniela Nicolelli, PPG Automotive Vice President Roald Johannsen, and PPG Automotive Market Manager Rodolfo Saporiti.
© PPG
The colours created are the result of a creative but also technical process. All 128 colours are classified according to their application properties, innovation degree, formulation, and pigments used. This results in the most suitable process for industrialising PPG products with the utmost confidence. PPG’s technical department, therefore, works jointly with the Style Centre to offer customers innovative tints, able to convey emotions and at the same time ensure ever higher performance levels.”
7 1
Figure 7: Rossella Guasco, the Head of the Colour & Materials Style Centre of FCA (left), with Daniela Nicolelli.
When a new car model is developed, the first colour proposals are submitted twenty-four months before the launch in order to select about fifteen shades. Then, a small-scale silhouette of the car is presented, in order to have a more precise idea of how these colours will “dress” the shapes and assess any changes or alternatives. When the first bodies are manufactured, a colour test is performed on them to assess the effect on a life-size car as well as the application process in the coating plant.” © ipcm ®
pigments, and technologies for our requirements, which in turn are based
The creation and selection process is long and complex. When a new car model is
on an initial analysis of trends and
developed, the first colour proposals are
scenarios.” The Style Centre may choose a
submitted twenty-four months before
particular tint based on various sources of
the launch in order to select about fifteen
inspiration: images, objects, fashion, or the
shades. Then, a small-scale silhouette of
nature. Also for FCA, the creative process
the car is presented, in order to have a
goes hand in hand with technical analyses
more precise idea of how these colours
to check the applicability of the selected
will “dress” the shapes and assess any
colours.
changes or alternatives. When the first
“Our Style Centre works for seven brands,
bodies are manufactured, a colour test
each with several car models. In general,
is performed on them to assess the
each year we develop about 30 standard
effect on a life-size car as well as the
colours and about 10 tints for special
application process in the coating plant.
series. PPG always selects its colour
For its colour assessment, FCA also uses
proposals based on the products for which
virtual tools and new technologies, such
the coatings are intended and also taking
as panel lights that artificially reproduce
into consideration any potential application
the various times of the day, each with
problems,” says Rossella Guasco.
a different light diffusion pattern. The advanced tools available guarantee an
“The model on which we have experimented and dared the most in
8 1
non-artificial environments with natural
terms of colour is Fiat 500, a timeless car that lends itself to any chromatic interpretation. In addition to experimenting with colours such as candy pink, coral, and
Figures 8 and 9: The exclusive location of PPG Colorshow 2018, overlooking the winter garden and the light artwork created by Migliore+Servetto Architects for the Intesa Sanpaolo skyscraper.
milk-mint green, this car was also among effect. However, whereas
light are also performed. The FCA Style Centre also controls the images used by the configurators available online, in order to offer to the customers a representation that is as close as possible to
© PPG
the first to offer a matte
accurate analysis, but assessments in
reality.
with brands like this it is important to keep up
After finding out how the
with trends and anticipate
Human Icon project was
them, other brands,
developed, the guests were
such as Maserati, call for
able to actually see the 128
sophisticated colours
selected shades, divided into
with a focus on depth
the seven colour palettes,
and on the final effect.
while tasting an aperitif on an
This proves that the
exclusive terrace overlooking
development and choice
the winter garden and the
of colours is not a trivial
light artwork created by
process, but it requires
Migliore+Servetto Architects
in-depth thought and research.”
30
9 1
N. 54 - NOVEMBER/DECEMBER 2018 - international PAINT&COATING magazine
for the Intesa Sanpaolo skyscraper (Figs. 8 and 9).
Meet the world’s most experienced rookie.
Say hello to a remarkable business partner: We combine decades of expertise with the enthusiasm and dedication of a start-up. With the united powers of Silica products, TEGO® additives, and specialty additives of former Air Products, we offer innovative and tailor-made solutions that deliver real value for your coating formulations.
Coating Additives of Evonik. Home of ACEMATT®, AEROSIL®, SURFYNOL®, and TEGO®. And much more.
ur Join o ars: ebin free w oating c . s r a webin ives.com addit
www.coating-additives.com
© shutterstock
Opening photo: The increasing global demand for energy-saving fans and rising quality standards have prompted the fan and motor manufacturer to expand its production capacity.
FOCUS ON TECHNOLOGY
Mixing it Up: New 2K Coating System for ZIEHL-ABEGG Mark Dekreon, Sprimag, Kirchheim-Teck – Germany
mark.dekreon@sprimag.de
S
primag’s new coating system for fan rotor
Fans have an extensive range of
When it comes to these and many other
bodies provides a breath of fresh
application, including in everyday
areas of application, ZIEHL-ABEGG is
air to fan and motor manufacturer
ventilation, automotive engineering and
widely regarded as one of the leading
ZIEHL-ABEGG, because its chain system is
even in machine and system technology,
manufacturers of fans and ventilation
capable of handling even complex requirements.
such as that produced by Sprimag.
systems. The increasing global demand for
32
N. 54 - NOVEMBER/DECEMBER 2018 - international PAINT&COATING magazine
FOCUS ON TECHNOLOGY
system that was in every way a perfect fit for the
Sprimag’s new coating system for fan rotor bodies provides a breath of fresh air to fan and motor manufacturer ZIEHL-ABEGG, because its chain system is capable of handling even complex requirements.”
new ZIEHL-ABEGG production hall. As requested by the customer, the coating system’s dry spray station was deliberately positioned facing outwards for the added benefit of easy access for maintenance staff when changing the dry extraction filters for the coating, for instance. A large viewing window at the start of the evaporation zone gives the operator a clear view of the rotor once coated, meaning the quality of
energy-saving fans and rising quality standards have
the coating on the parts can always be inspected
prompted the fan and motor manufacturer to expand
before the parts move on to the two-stage drying
its production capacity by means of a new building
process.
and additional production facilities.
Another requirement of the coating system was
Among the new equipment installed is a Sprimag coating system, which
that it needed to be able to process a wide range of parts that vary greatly in terms of the
has been coating rotor bodies
size and dimensions
of energy-saving fans (EC
bodies. As well
start of 2018 (Fig. 1).
as large rotors
Sprimag rose to
measuring
through close
275 mm in
collaboration with
diameter, the
ZIEHL-ABEGG and
system should
© Sprimag
the challenge and,
a series of trials
be capable of coating
in the applications
compact ECblue
center, succeeded in
rotors with a
meeting even the most
diameter of just
complex requirements
146 mm. The system is
of the new facility. “The foundations were laid for
1
a trusting working relationship from
required to coat a total of 23 different types of part. A number of trial
the very beginning of through an extensive
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
of the rotor
technology1) since the
the project, particularly
Spare Parts for Industrial Plants
Figure 1: A detail of rotor body of energy-saving fans.
series, conducted in Sprimag’s
series of initial trials. It was important to us
in-house applications center, ascertained whether
that the system operated a fully dependable
the SpriMix II 2K paint supply would be suitable
coating method that guarantees us maximum
for ZIEHL-ABEGG’s purposes (Fig. 2). During these
process reliability,” explains Jürgen Rehrauer, Head of Process Planning for EC Fans at ZIEHL-ABEGG. The first challenge to overcome was the spatial requirements, because space was at a premium on this project, especially in terms of height. This gave rise to a compact chain on edge coating
1 EC stands for “electronically commutated”. This type of motor needs less electricity to operate.
The increasing global demand for energy-saving fans and rising quality standards have prompted the fan and motor manufacturer to expand its production capacity by means of a new building and additional production facilities.”
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
coating are coated with precision. Because the
trials in the technical center it was initially established that the existing SpriMixII 2K paint supply had found its limits: The technology was currently set up for significantly higher flow rates, and so needed to be honed into a new solution. Sprimag rose to the challenge and was ultimately able to adjust the mixing technology to also accommodate low flow rates with ease. The coating system is integrated in a
The technology was currently set up for significantly higher flow rates, and so needed to be honed into a new solution. Sprimag rose to the challenge and was ultimately able to adjust the mixing technology to also accommodate low flow rates with ease.”
industry-wide rise in quality standards leaves no room for compromise in this area, we drew on our extensive experience and were able to meet the customer’s exacting requirements for precision coating of rotor bodies. The overall ventilation technology was created in consultation with ZIEHL-ABEGG’s technical plans for the building design. The objective was to ensure that the air needed for the system is not taken from the hall. To achieve this, fresh air is taken from outside and the exhaust air
work stations. Once the shafts have been
from spray booths, paint rooms, evaporation
pressed, the operator places the rotor
zones, dryers and cooling zones is fed into an
© Sprimag
working environment with two other
body on the coating machine’s transport
air collection system. The requisite fans and
system. Once the coating process is
automatic throttle valves ensure a smooth
complete, an operator conveys the
connection to the exhaust air system.
parts to the pick-up station, ready for
Sprimag was on hand offering in-depth advice
magnetization. The Sprimag chain on
throughout the entire collaboration. As a result,
edge coating system features a transport
in the space of just two weeks all 22 coating
system that is ideal for conveying heavy
programs were set up and the operating staff
parts weighing over 5 kg. To avoid the need
were trained on coating processes and using
for time-consuming retrofits, a universal
the SpriMix II. This was possible thanks to the
retaining chuck is used here, which is
trials conducted in the applications center at
suitable for the full range of different parts.
the very start of the project, which enabled
The parts are rotated in the spray station
us to adapt our SpriMix II to the customer’s
and coated by a coating robot. The
requirements and gain experience with the
transport cart is connected to the spray
coating system at an early stage in the project.
station by the chain system in operation,
“Thanks to the excellent partnership with
ensuring that parts that require only partial
Sprimag, from the trials to the system design and construction and all the way through to commissioning, we are now in a position to meet ever-growing demand and our own
The first challenge to overcome was the spatial requirements, because space was at a premium on this project, especially in terms of height. As requested by the customer, the coating system’s dry spray station was deliberately positioned facing outwards for the added benefit of easy access for maintenance staff when changing the dry extraction filters for the coating, for instance.”
34
integral quality standards,” reports Jürgen Rehrauer, who is looking forward to further opportunities to work together.
2 1
Figure 2: The SpriMix II 2K paint supply.
N. 54 - NOVEMBER/DECEMBER 2018 - international PAINT&COATING magazine
Sprimag was on hand offering in-depth advice throughout the entire collaboration. As a result, in the space of just two weeks all 22 coating programs were set up and the operating staff were trained on coating processes and using the SpriMix II.”
SUSTAINABILITY
A sustainable alternative to CrVI: Manifest of the Alliance of PVD Providers APP - Alliance of PVD Providers’ official notice
T
he Alliance of PVD Providers (the
process on the pending authorisations
APP) lead and managed by Fipra
The APP calls on the EU institutions to replace a hazardous chemical substance inclused in the REACH Regulation, the hexavalent chromium (CrVI), with the sustainable alternative of PVD, the physical vapor deposition technology. ”
International Ltd. includes IHI Hauzer
Techno Coating B.V., Ionbond Netherlands, B.V., Kolzer SRL, Oerlikon Balzers Coating Germany GmbH and Vergason Technology, Inc. The APP calls on the EU institutions to replace a hazardous chemical substance inclused in the REACH Regulation, the
of the CrVI applications, included the Gerhardi, Lanxess and Hapoc applications, by December 2018. - Reduce authorisation for Gerhardi application to maximum 7 years. This would be in line with the opinions of some ECHA - European Chemicals Agency’s members.
hexavalent chromium (CrVI), with the vapor deposition technology.
On the basis of the above considerations, the
© Kolzer
sustainable alternative of PVD, the physical
APP has written the Manifest intitled
CrVI is a carcinogenic substance: in the
“A sustainable alternative to CrVI”4, which
European market it has been banned since
has the aim to show that the current draft
2011. However, despite this and despite
decisions approving the CrVI‘s continued
the existence of sustainable alternative
use are not based on the latest available
technologies, it is still used on an industrial
information, but on the opinion submitted to
scale without providing a precise date for
the European Commission by the European
its final replacement. Indeed, the European
Chemicals Agency in 2005-2006 (RAC and
Commission is planning to extend various pending CrVI authorisations for a very long
SEAC). During this period the PVD technology was still in rapid development and has been
1
time (12 years). The Committee for Socio-economic Analysis (SEAC) and the Committee for Risk Assessment (RAC) within
greatly developed since then. Figure 1: The PVD technologies provide the same quality of the CrVI, they are cost-effective and available to meet the market demand and they were approved by the automotive industry.
ECHA - European Chemicals Agency have
other ones: • Lanxess: 4-year authorisation for functional plating with decorative character1, whilst maintaining a 7-year authorisation for other
2 Opinion of RAC and SEAC (16 September 2016) on an Application for Authorisation for Chromium trioxide use: Functional chrome plating.
36
quality, they are cost-effective and available approved by the automotive industry (Fig. 1).
• Gerhardi: 12-year authorisation3 although
The replacement with more environmentally
there were 2 minority positions in RAC and
friendly products must be the main aim of
SEAC in favour of a shorter review period;
REACH.
• Hapoc: RAC and SEAC have not yet issued a recommendation on this application.
The current status quo means the maintenance of a situation that represents a defeat for the
applications2;
1 Opinion of RAC and SEAC (16 September 2016) on an Application for Authorisation for Chromium trioxide use: Functional chrome plating with decorative character.
the PVD technologies, that provide the same to meet the market demand and they were
recommended the European Commission to grant the following authorisations, among
Nowadays the CrVI can be easily replaced with
The APP requests the EU institutions to:
society, since it is a missed opportunity for a
- Clarify and speed-up the decision-making
more sustainable Europe.
3 Opinion of RAC and SEAC (13 March 2017) on an Application for Authorisation for Chromium trioxide, use: Plating on Plastics for Automotive Applications (PoPAA). ECHA/RAC/SEAC: AFA-O0000006558-63-02/F.
4 The manifest can be downloaded from the website: https://fipra.com/wp-content/uploads/2018/10/Nonconfidential-APP-manifest-PVD-a-sustainable-alternative-toCrVI-14092018-final61.pdf
N. 54 - NOVEMBER/DECEMBER 2018 - international PAINT&COATING magazine
HAI UN IMPIANTO DI MOVIMENTAZIONE A CATENA?
SUSTAINABILITY
TRAS-MEC è la prima azienda che mette in sicurezza il tuo impianto e ti garantisce da contratto una produzione senza fermi improvvisi
The current status quo means the maintenance of a situation that represents a defeat for the society, since it is a missed opportunity for a more sustainable Europe. Indeed, both the companies and the NGOs know that the CrVI’s replacement with the PVD technology is the only possible solution.”
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.
Indeed, both the companies and the NGOs know that the CrVI’s replacement with the PVD technology is the only possible solution. Inspired by what Erin Brockovich achieved with the CrVI’s elimination
Non avrai più dubbi sulla produzione del tuo materiale
in the United States, the APP was created to achieve a better result.
Produzione: Costruiremo il tuo trasportatore secondo metodi standardizzati sviluppati nel tempo per farti avere un impianto performante.
The APP urges the EU institutions to say yes to the investments in a sustainable and recyclable product, that is suitable to the EU’s ambition to create a non-toxic environment; to say yes to a climate-friendly production process and in line with the Paris Conference’s objectives; lastly, to say yes to a competitive
Non dovrai più preoccuparti del montaggio del convogliatore
EU that has the know-how and the capacities to compete with technological giants in United States, China and elsewhere, rather
Installazione: Con quest’opzione, avrai il tuo convogliatore chiavi in mano montato da un team di tecnici montatori esperti.
than to leave room to other Countries in order to be the first continent to develop new greener technologies (Fig. 2). For any question, please contact Willem Vriesendorp (+32 2 613 2828), Fipra International’s partner on behalf of the Alliance
Non avrai più blocchi di produzione
of PVD Providers. The PVD technologies provide the same quality
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.
of the CrVI, they are cost-effective and available to meet the market
© Kolzer
demand and they were approved by the automotive industry.
TRAS-MEC è la prima azienda che ha integrato tutti i processi in un unico sistema industriale, per farti lavorare nel modo più performante senza più fermi di produzione che non sono stati programmati. Se vuoi avere più informazioni sul tuo trasportatore scrivi a customercare@tras-mec.it Riceverai in regalo il report “I 5 errori da evitare per mettere in sicurezza il tuo impianto nto ed eliminare per sempre il rischio dei fermi improvvisi” vvisi”
2 1
Figure 2: Europe has the chance to become the first continent to develop ecological solutions alternative to the CrVI: in the image one of the PVD chromium plating machine manufactured by the Italian company Kolzer.
REPORT IIN N RE REGALO! REGALO EGALO! LO
ON THE ROAD TO ipcm
®
n. 54
international PAINT&COATING magazine - NOVEMBER/DECEMBER 2018 - N. 54
39
SPECIAL ON ACE & OFF ROAD VEHICLES
42
FOCUS ON TECHNOLOGY
52
BRAND NEW
54
INNOVATIONS: PRESENT&FUTURE
58
FOCUS ON TECHNOLOGY
Berti Macchine Agricole. An Innovative Industrial Solution for the Coating Process of Its New Production Site.
Under the Surface: Innovative Pretreatment for the ACE Industry
zhao jian kang © fotolia
Ferrari Costruzioni Meccaniche: A New Tunnel Shot Blasting System for Highly Customisable Agricultural Machinery
© ipcm ®
Opening photo: In 1972, Berti Macchine Agricole (Caldiero, Verona, Italy) decided to specialise in the production of mulchers, whose range now includes 500 models.
FOCUS ON TECHNOLOGY
S P E C I A L O N AC E & O FF ROAD V EHICLES
Berti Macchine Agricole. An Innovative Industrial Solution for the Coating Process of Its New Production Site. Alessia Venturi ipcm®
T
he switch from manual-only
of a well-established Italian manufacturer
in all design and development phases,
operations to an automated,
of agricultural machinery for the redesign
they created one of the most advanced
robotised, and digitised process; total
of its coating process by a group of
finishing systems ever installed in the
traceability of the operating process; data
plant engineering firms. Some of the
agricultural machinery sector. This
collection; and diagnostics for preventive
main players in the sector accepted the
new coating plant started in 2018 by
maintenance: these were the requirements
challenge: by effectively collaborating
Berti Macchine Agricole and born from
42
N. 54 - NOVEMBER/DECEMBER 2018 - international PAINT&COATING magazine
FOCUS ON TECHNOLOGY
the collaboration among Savim, Futura
The production flow
reversed, our production is now steadier,
Convogliatori Aerei, Gaiotto Automation,
“Our machining and welding operations are
as is the workflow with our contractors.”
and Verind is compact, modern, extremely
entrusted to a few contractors that work
“We order all the productive material
functional, and Industry 4.0-oriented.
almost exclusively for Berti,” says Sales
according to our technical office’s
Manager Filippo Berti (Fig. 1). “Until a few
instructions and all workshops operate
years ago, our work was seasonal: production
with our know-how,” says Filippo Berti. “Our
The story of a company and a family
production flow is order-based: our main
Berti Macchine Agricole was established
issue are delivery times, because the fact
by Livio Berti in Caldiero (Verona) in the
that the European dealers operate with very little stock does not match well with
early 1920s, as an artisan company in the
the requests for 20-day deliveries now Berti Macchine Agricole typical of this market. Indeed, there is was established by Livio Berti in now a trend towards a just-in-time in the production of mulchers (ref. Caldiero (Verona) in the early 1920s, as an production. That is why in 2015 Opening photo), developing them at artisan company in the field of agricultural we decided to start a corporate the technological level for over thirty implements. In 1972, the Berti family decided restructuring project involving years. More than thirty years have to specialise in the production of mulchers, our productive structure, and passed since the creation of the first developing them at the technological level for especially our downstream vineyard and orchard mulcher. One over thirty years. More than thirty years have processes: assembly, coating, of the company’s main objectives passed since the creation of the first vineyard and storage. This investment has always been to build innovative and orchard mulcher. One of the company’s and restructuring plan was mainly machines specially designed for the main objectives has always been to build motivated by our will to switch from professional maintenance and reclaim innovative machines specially designed of urban, agricultural, and forest green for the professional maintenance and an order-based to a continuous-flow production. We currently have six spaces. reclaim of urban, agricultural, assembly lines, which will become nine in Berti now offers a range of 500 products and forest green spaces.” field of agricultural implements. In 1972, the Berti family decided to specialise
for all types of cultivation and ground
January and twelve at the end of 2019, of
conditions, applicable to any tractor or
which five will be devoted to continuous © ipcm ®
excavator. Its complete range of robust and high-
production and seven to special machines.”
performance equipment
“After assembly, we
is divided into two product
also focussed on our
lines intended for two
coating phase.
well-defined market
We already had a
segments. The “agricultural
recently bought plant
line” includes vineyard and
installed in a building
orchard mulchers, mowers,
specifically devoted
in-line mulchers, hedge
to this operation.
mowers, and forestry
However, it was a static
mulchers (with an installed power range from 15 to 300 HP). The “professional line”, on the other hand, includes different
system performing a
1
manual application
Figure 1: From left to right: Filippo Berti, Berti Macchine Agricole’s owner, Maria Grazia Signorini, Finance Manager and Francesco Attuati, Purchase Manager.
process and using solvent-based paints. Luckily, the corporate growth of
earthmoving devices intended for maintenance and forestation
peaks were concentrated from February to
the last few years enabled us to invest
operations, which are suitable for every
July, while the last months of the year were
in a new, technologically advanced
kind of excavator (with an operating
dedicated to the preparation of the new
automatic system and, at the same time,
weight between 1.5 and 35 tonnes) and
season. By differentiating our target markets
to switch to water-based coatings,”
skid steer.
and also working overseas where seasons are
explains Filippo Berti.
international PAINT&COATING magazine - NOVEMBER/DECEMBER 2018 - N. 54
43
© ipcm ®
© Berti Macchine Agricole
SP ECIAL ON ACE & OFF RO AD V EH ICLES
3 1
2 1
Figure 2: A bird’s eye view of the new coating plant supplied by Savim (Arbizzano, Verona).
Figure 3: A detail of the plant.
“Using two-component water-soluble coatings
with Savim (Arbizzano, Verona), which
and automation requirements,” says
was a business choice unrelated to any
then recommended all other technological
Attuati. “Inver, our supplier of water-based
regional regulation,” says Purchase Manager
partners for the handling, automation, and
coatings, also greatly supported us in the
Francesco Attuati. “We assessed that the
application aspects, i.e. Futura Convogliatori
design phase. Understanding our coating
market is gradually abandoning conventional
Aerei, Gaiotto Automation, and Verind.
requirements was crucial to design an
solvent-based products in favour of
Under the coordination of Savim, we created
optimal application system. In any case, the
water-based systems with the same
a relationship of mutual esteem with all of
starting point for us was our will to create
performance. Moreover, we are located in an
them.”
a new production structure that was a
urban environment: over the years, the town
“The plant designed by Savim was undoubtedly
linear, streamlined, efficient, automatic, and
of Caldiero has practically developed around
the most suitable to our production needs
completely traceable at all times.”
coatings seemed the most natural choice for us, although there remains a small part of our
© ipcm ®
our plant. Therefore, switching to water-based
production requiring solvent-based paints. Finally, in our new production area, we also added an automatic warehouse to favour the switch from an order-based to a continuousflow production.”
The origin of the new coating plant 4.0 Since it used to perform only a manual painting process, Berti did not have any knowledge of coating systems. “In order to design the new plant (Fig. 2 and 3) and, above all, understand how our automation, productivity, and surface quality needs could be met, we did some technical research and spoke with people who had already installed a coating system,” says Filippo Berti. “We thus came into contact
44
4 1
Figure 4: A component at the entrance of the pre-treatment booth.
N. 54 - NOVEMBER/DECEMBER 2018 - international PAINT&COATING magazine
FOCUS ON TECHNOLOGY
Characteristics of the coating line
“We opted for the use of a water-based liquid
The system installed by Savim is completely
system with an application and automation system
Industry 4.0-oriented. By interfacing with the
that would allow us to industrialise and automate
automation and application systems, the
a process that used to be completely manual, little
management software package collects and
controllable, and hardly standardisable,” states
checks all operating parameters, applied
Francesco Attuati. “The goal was to improve the
thicknesses, and consumption data. The project
process, increase quality, decrease consumption
also included a thorough study of ergonomics,
and waste, and above all digitise operations as
flexibility, and modularity, so that the new line
much as possible.”
meets every current and long-term future
The products applied by Berti are the © ipcm ®
production need. The maximum capacity of the plant is 4 m in length;
INVERPUR semi-matte two-component anti-corrosion primer
however, two manual booths
based on hydro-soluble
(primer and enamel) have
acrylic resins and the
been devoted to machines
INVERPUR/X SM 2K
with larger dimensions,
two-component
accounting for 15% of the
water-soluble enamel
total production. The plant
based on acrylic resins,
management is based on
both in the company’s
barcodes.
distinctive orange colour.
The chemical pre-treatment
They are supplied by
is performed with a 3-stage
Inver, a brand of the
process (Fig. 4 and 5)
Sherwin-Williams Group.
followed by an intermediate
The primer forms a film
blow off and masking station.
with good salt spray,
Berti coats fully assembled
chemical, and water
machines and, therefore, all
resistance characteristics.
delicate components must
It reduces the enamel
be protected. The coating application station features two dry booths with a floor filtration system, a robotised and a manual one, for both
GANCI | HOOKS
TELAI | RACKS
brilliance very little and
5 1
it is a suitable basecoat
Figure 5: The 3-stage chemical pre-treatment process.
MASCHERATURE | MASKING
for iron, aluminium, and cataphoresis products, as it has excellent adhesion
the primer and enamel application.
and good corrosion protection properties.
Savim chose to integrate these automatic booths
The two-component enamel forms a hard and
with two manual ones (Fig. 6) to coat oversized
elastic film with excellent weathering resistance
workpieces, but also to perform accurate
characteristics and it is suitable for high quality
post-retouching operations on parts where
finishes on metal surfaces of various kinds, such
particular masks may hinder uniform coverage by
as agricultural and earth movement machinery,
the robots and to treat the components that still
machine tools, and industrial vehicles. It is applied
require a solvent-based coating, accounting for
with a viscosity (D4/25 °C) of 50-70” and with a final
15% of production. The robots are equipped with
dry thickness lower than 50-60 μm.
electrostatic guns, whereas the manual booths
“For the design of the paint application and feeding
perform a conventional application operation.
system, we chose to rely on Verind, belonging to
The application process includes a flash-off phase
the Dürr Group, because its equipment range was
between the primer and enamel application
the closest to our needs for 4.0-orientedness,”
stages and a final curing stage in a direct fired
states Filippo Berti. “In order to develop the best
furnace (Fig. 7).
application system, Verind had a preliminary
PER INFORMAZIONI E ORDINI VI INVITIAMO A CONTATTARE: PLEASE CONTACT:
Cecilia Ghizzi Gola ghizzi-gola@emptmeyer.it Fon: +39 02 947 58 58 2
www.emptmeyer.it
© ipcm ®
SP ECIAL ON ACE & OFF RO AD V EH ICLES
coatings through fibre-optic flow metres (Fig. 9). The coating management unit is equipped with three groups of lifts for the 200 kg-drums used for the storage of paints, level sensors, and Dürr circulation pumps for the primer and enamel. The remote coating management unit (Fig. 10) is located about 50 m of pipes away from the booths. Specific loading stations feed directly the process tanks of both the manual application stations and the insulated stations that contain the electrostatically charged pumping systems.” “The application equipment of the primer (Fig. 11) and enamel booths are symmetrical,” says Benevelli. “Each booth features an EcoDose 2K electronic dosing system. The automatic
6 1
stations’ systems are equipped with a remote station, fibre-optic volumetric
Figure 6: One of the two manual booths.
meeting with Inver to share a few
© ipcm ®
In 2015 Berti decided to start a corporate restructuring project involving the productive structure, and especially the downstream processes: assembly, coating, and storage. This investment and restructuring plan was mainly motivated by the will to switch from an order-based to a continuous-flow production. Berti currently has six assembly lines, which will become nine in January and twelve at the end of 2019, of which five will be devoted to continuous production and seven to special machines.”
technological choices. In fact, our two products could be applied with both the mixed air and low pressure technology: our coating quality depended on this choice.” “Our choice fell on an airless air assisted application for the primer, in order to achieve the right thicknesses and application speed, and for a low pressure application for the enamel, in order to ensure maximum aesthetic quality,” explains Verind Area Sales Manager Giovanni Benevelli (Fig. 8). “Therefore, we developed a flexible and modular system that combines an electrostatic application process with an automatic system for the dosing and mixing of 2K
46
7 1
Figure 7: The curing stage in the direct fired furnace.
N. 54 - NOVEMBER/DECEMBER 2018 - international PAINT&COATING magazine
© ipcm ®
© ipcm ®
SP ECIAL ON ACE & OFF RO AD V EH ICLES
9 1
8 1
Figure 8: Left to right: Manuel Pesamosca, the Technical Sales Manager of Gaiotto Automation, Francesco Attuati, the Purchase Manager of Berti Spa, Alessandro Soba and Giovanni Benevelli, the Verind Area Sales Managers.
Figure 9: Verind’s EcoDose 2K automatic system for the dosing and mixing of 2K coatings.
Future-ready automation
friendly and offers one point of command
high and low pressure pumps, whereas
Berti’s new industrial coating line includes
through which the operator can easily control
the manual retouching stations feature
four GA25-P six-axis spraying robots provided
the overall state of the machines and the
standard EcoDose 2K systems with high
by Gaiotto (Fig. 12 and 13), installed on a
exchange of data with the other systems
and low pressure pumps. A PLC manages
linear translation axis and complying with
operating within the plant.
an EcoDose 2K for the automatic
current safety regulations, especially the ATEX
“The four robots installed for Berti Macchine
application process of each robot and an
standard for explosive atmospheres. This
Agricole feature all three programming
EcoDose 2K for each manual station.”
robot was specifically designed and developed
logics available: point-to-point, self-learning,
EcoDose is an advanced electronic
for paint spraying applications, with all the
and off-line, which is the main challenge
system for the stoichiometric dosage and
advantages of a system intended for a given
in the field of industrial robotics of the last
mixing of two or more water-based or
type of automation and, above all, with high
decade. In fact, the off-line programming
solvent-based coating products. Its main
mechanical reliability. Its Human-Machine
method enables to create coating programs
technical features are as follows:
Interface (HMI) makes the machine user-
without stopping the line thus reducing
• direct dosing technology with two channels (A and B)
© ipcm ®
counters, and insulated devices with
• view of actual flow rates, partial consumption for each program, alarms, diagnostics, VOC quantities, and consumption related to each model/colour for every application station • connection to the line master for the automatic management of the style queue and the colour change operations • management of the pot-life and pot-time parameters • information to the operator for predictive maintenance on all application components, in order to avert downtimes.
48
10 1
N. 54 - NOVEMBER/DECEMBER 2018 - international PAINT&COATING magazine
Figure 10: The coating management unit for manual station with Dürr pump.
productivity. In the last few years, Gaiotto
© ipcm ®
FOCUS ON TECHNOLOGY
has focussed a lot on this method, which allows the operators to design the painting programs only based on the geometry of the workpieces, without physically operating on them,” says Manuel Pesamosca, the Technical Sales Manager of Gaiotto Automation. “During commissioning, we realised that the off-line programming method was best suited to Berti’s needs, also because the company has the great advantage of having available all the 3D models of the machines produced. The integrated software package offers a process parameter control system, which makes it ideal for the industrial coating sector since it enables to check and modify the flow rate, the atomisation process, and the spraying fan. These parameters can all be defined directly during off-line programming, complete with simulations aimed at reducing time and waste.”
www.cieeng.com info@cieeng.com
11 1
Figure 11: The feeding system of the primer application booth for manual station with Dürr pump.
www.mstchemicals.com info@mstchemicals.com
© Berti Macchine Agricole
© Berti Macchine Agricole
SP ECIAL ON ACE & OFF RO AD V EH ICLES
12 1
13 1
Figures 12 and 13: Gaiotto’s GA25-P six-axis spraying robots.
“Gaiotto’s robots, with all their technological
Manager Alessandro Soba. Berti’s main
any deviations from the standard, and make
systems, operate at the core of the coating
objectives for its new Smart Factory were as
them available through a specific line interface
process, interfacing with both Verind’s
follows:
for corrective actions.
application systems and Savim’s plant systems,”
• Implementing a digitised application/
• Integrating the EcoDose 2K electronic system
says Pesamosca. “Together with Verind, we
coating system, managed with integrated
in its remote version with fibre-optic flow
developed an operating interface between the
control and automation systems and
metres, suitable for handling two-component
robots and the spraying equipment to enable
interfaced with robot and manual retouch
water-based epoxy and polyurethane coatings
continuous collection of operational data, error
stations.
applied with an electrostatic process (Fig. 14).
reporting, operating status updating, predictive
• Obtaining the best application and surface
• Remote service, predictive maintenance, and remote assistance.
maintenance, and control over the quantities
finish results with specific integrated
of coating consumed for each program or part
automation, application, and robot
“Berti’s coating process is very complex, with
type. In short, Verind’s system sends all paint
systems for the management of the
a significant number of variables. By focussing
consumption data to the robots and the robots
various 2K products and of the process in
on innovation, we were able to ensure that this
transfer them to Savim’s management software
its entirety.
application management workflow contributes
package, which collects all the data from the
• Monitoring all productivity information and
to reduce production costs per unit while increasing efficiency,” says Giovanni
“We could build a highly
Benevelli.
© ipcm ®
automation systems.” functional and compact smart
partners involved, which operated
A challenge won and an important industrial result achieved
in synergy since the design phase,”
“The joint and coordinated
says Pesamosca.
work of Savim, Gaiotto, and
architecture only thanks to the close collaboration of all the three
Verind has enabled the
Industry 4.0 principles and proven experience in the ACE sector
development of innovative and industrially sustainable solutions, oriented towards
“Its ability to combine system
eco-friendliness, workplace
engineering, know-how, and
safety, processing cost
innovation was crucial for Verind to meet Berti Macchine Agricole’s industrialisation requirements,” says Verind Industry Sector Sales
50
14 1
Figure 14: The pumping and recirculation unit of the coating products created by Verind/Dürr.
N. 54 - NOVEMBER/DECEMBER 2018 - international PAINT&COATING magazine
reduction, high surface quality, and industrial digitisation, with which we are very pleased,” says Filippo Berti.
Oops...
FASTRIP, for the easy, effective and rapid paint stripping of metals.
ALIT Technologies, the chemical paint stripping specialist. Products, machines, processes and consultancy.
www.alit-tech.com San Bonifacio – Verona - ITALY
BRAND-NEW
S P E C I A L O N AC E & O FF RO AD V EHICLES
R
oyal DSM, a global science-based
of up to 48% compared to standard
company in Nutrition, Health and
alternatives (Fig. 2).
Sustainable Living, has announced
In addition, because of the faster drying
the launch of a new Hybrane™ product. This
possibilities, our resin shortens the spray
product, Hybrane CY235, will drive standards
booth cycle time by 20%. Under typical
in the ACE, General Industrial and Car
workshop conditions, for example, car
Refinish metal coating industries by enabling
refinishers can paint two extra jobs every
enhanced coatings performance, higher
day, driving throughput. Crucially, these
throughput and reduced energy consumption
operational benefits in no way compromise
(Fig. 1).
the performance of Hybrane CY235, which
Based on DSM’s proprietary technology,
delivers excellent hardness, a high-quality
the new Hybrane CY235 product leverages
appearance with distinctiveness of image,
the high functionality of the Hybrane
and high reactivity without compromising on
molecular structure to deliver unprecedented
pot life.
performance standards. Unlike other high
Ap Heijenk, Industry Manager Industrial
solid acrylic resins, which typically require
Metal & Plastic DSM: “After many months
forced drying conditions at 60°C for 30
of careful experimentation and testing,
minutes, Hybrane CY235 only requires a
involving a cross-functional and cross-site
curing temperature of 40°C. In this way,
collaboration, we’re very proud to launch
Hybrane CY235 can deliver energy savings
Hybrane CY235. This product enables
© DSM Coating Resins
DSM Drives Performance of Metal Coatings by Expanding Hybrane™ Resins Family
2 1
Figure 2: Unlike other high solid acrylic resins, Hybrane CY235 only requires a curing temperature of 40°C. In this way, it can deliver energy savings of up to 48% compared to standard alternatives.
better coating performance at a lower © DSM Coating Resins
environmental cost. As such, it is clearly aligned with our wider organizational aims of using bright science to enable brighter living.” “Moving forward, we will continue to develop our Hybrane proposition in line with market demands. In particular, we will channel our development efforts to deliver Hybrane products for an even wider range of industries and also extending the application to different substrates like plastic and wood. We’re confident that our Hybrane technology will open up new coating horizons – in terms of sustainability and
1
processability.”
Figure 1: Hybrane™ CY235, will drive standards in the ACE, General Industrial and Car Refinish metal coating industries by enabling enhanced coatings performance, higher throughput and reduced energy consumption.
52
N. 54 - NOVEMBER/DECEMBER 2018 - international PAINT&COATING magazine
For further information: www.dsm.com/paint
BRAND-NEW
S P E C I A L O N AC E & O FF RO AD V EHICLES
O
ptiStar® 4.0 ensures excellent
© GEMA
The New Electrostatic App and OptiStar® 4.0: The Benchmark for Efficient Gun Control finishing results and measurable system optimisation actions.
New features, such as the E-App, make
the control module even smarter and allow access to the Smart Factory Automation (Fig. 1).
Smart and flexible The Electrostatic App is an innovative function that enables to control the coating process while improving its flexibility and efficiency. This makes the new command module of OptiStar® 4.0 a pioneer of the Smart Factory Automation on powder coating plants. The app can be used to monitor the application parameters on one or more control modules.
Greater efficiency with the Electrostatic App The Electrostatic App offers a completely
1
Figure 1: The new E-App makes the control module even smarter and allows access to the Smart Factory Automation.
• Services: direct access to the use and
• Application: all the main coating
new range of process control options,
parameters are clearly visible on the
maintenance manuals and to Gema’s
ranging from line management to
device and they can be controlled and
website.
equipment maintenance data. Process
regulated directly from there.
data and relevant application parameters
With the Electrostatic App, the most
• Line management: process productivity
can be seen on a mobile device and they
data can be recovered at any time.
relevant application data and the
can be adjusted and controlled directly
The most important statistics and
most crucial coating parameters are
through it. Calculations and statistics are
calculations of production costs are
immediately available on a mobile
automatically available at any time. This
generated automatically. The maintenance
device. The operator can easily access
saves time and improves the efficiency of
programs can be easily controlled with a
process evaluations and statistics.
the powder application process.
simple “Tap”.
This saves time and makes the coating
The Electrostatic App’s functions
• Settings: this function enables to configure
process even more efficient.
the control module. OptiStar 4.0 can be ®
controlled as a single device or within a
For further information:
With this app’s 4 functions, the coating
group of control units. System information
www.gemapowdercoating.com and
process can be monitored and controlled
and diagnostic data can be easily retrieved
www.youtube.com/watch?time_
though a mobile device:
and sent by e-mail.
continue=12&v=TSFRm5j6Mm4
international PAINT&COATING magazine - NOVEMBER/DECEMBER 2018 - N. 54
53
© Chemetall
Opening photo: Maintenance of the functional efficiency and the permanent corrosion protection of the vehicle surfaces therefore play an integral role in their longevity.
INNOVATIONS: PRESENT&FUTURE
S P E C I A L O N AC E & O FF ROAD V EHICLES
Under the Surface: Innovative Pretreatment for the ACE Industry Thomas Willumeit Chemetall GmbH, Frankfurt am Main - Germany
A
thomas.willumeit@basf.com
gricultural, construction, and
programs increases the long-term value
infrastructure, construction industry and
earthmoving vehicles operate in the
of the vehicles in terms of quality and
farming. The general trend towards global
most extreme of environments around
sustainability.
urbanization, ever faster growing cities,
the world and must remain functional for the
and increasing demands on infrastructure
entire life of the asset. To achieve operational
Manufacturers of agricultural,
expansion are some of the key drivers for the
longevity the quality of the surface finish of the
construction and earthmoving
global ACE companies.
vehicles plays a key role. Utilizing Chemetall’s
(ACE) machinery make an important
The requirements for corrosion
innovative pretreatment processes and
contribution when it comes to
protection and the appearance of
54
N. 54 - NOVEMBER/DECEMBER 2018 - international PAINT&COATING magazine
INNOVATIONS: PRESENT&FUTURE
ACE manufacturers and suppliers
ACE vehicles have increased. ACE machinery manufacturers put the
Agricultural, construction, and earthmoving vehicles operate in the most extreme of environments around the world and must remain functional for the entire life of the asset. To achieve operational longevity the quality of the surface finish of the vehicles plays a key role. Utilizing Chemetall’s innovative pretreatment processes and programs increases the long-term value of the vehicles in terms of quality and sustainability.”
quality of their design and surface finishes to the test on a daily basis: Off-road vehicles, construction machinery, industrial machinery, and agricultural equipment must withstand adverse conditions and yet remain functional for years. Maintenance of the functional efficiency and the permanent corrosion protection of the vehicle surfaces therefore play an integral
benefit from Chemetall’s decades long experience in the ACE industry sector and market. As a recent example of the sustainability initiatives, Chemetall collaborated with a large construction equipment manufacturer to provide a tailored pretreatment for their paint system. An audit, Chemetall’s initial step in any process recommendation, identified several areas of potential improvement. One area
photo). Pretreatment technologies
identified was the high number of
therefore must deliver consistently high-quality results on hot-rolled steel,
© Chemetall
role in their longevity (ref. Opening
heat exchanger plates that were replaced several times per year in
cold-rolled steel, cast iron, and
a process stage. The use of a CIP-
non-ferrous substrates such
system (Clean-In-Place)
as aluminium- all used in the
for the heat exchangers was
manufacture of these vehicles.
recommended, the aim being to
The pre-treatment of substrates
eliminate the need to replace three
processed into construction
to four heat exchanger plates per
materials plays a key role in corrosion
year. Each exchanger replacement
protection, thus extending substrate
represented a 3,5 – 4 K € cost
life and providing an aesthetic
for the construction equipment
appearance (Fig. 1). Chemetall, the
manufacturer. In addition, the
global Surface Treatment business
CIP-system allows temperature to
unit of BASF’s Coatings division,
be monitored and maintained very
offers tailor-made pre-treatments
closely improving the quality level of
which fulfil all the ACE manufacturer
the pretreated parts. Moreover, the
requirements. As a premium global
Clean-In-Place-program has virtually
supplier, Chemetall assumes the role
eliminated the need for the removal
of a solution-oriented partner for
of the exchangers manually, thereby
customers’ projects who desire to enhance their processes, quality, and safety standards in a sustainable way. For ACE machinery, a high-quality surface finish that meets or even exceeds OEM specifications, is
reducing employee exposure to
1
very aggressive acidic chemicals
Figure 1: The pre-treatment of substrates processed into construction materials plays a key role in corrosion protection, thus extending substrate life and providing an aesthetic appearance.
(Fig. 3). “The key to successful sustainability analysis is to look beyond the product to the entire process. By looking at a process holistically, far more improvements
becoming more and more important. At the same time, widely differing
In addition to achieving a high-quality surface
can be identified”, says Ron Sattler,
substrates place high demands on
finish, the cost-effectiveness and sustainability
Executive Director of Strategic Accounts at
production processes.
of the pretreatment technologies play an
Chemetall.
To meet the requirements of each
increasingly important role, as the processes
Furthermore, Chemetall also implemented
customer, we must first analyze the
used must not only be more conscious of
automated control and data acquisition
individual customer process and related
environmental concerns, but also more
which allowed the identification of a stage
needs to develop ideal and efficient
economically sustainable to meet future market
that had a serious water leak. Prior to the
technical solutions.
requirements (Fig. 2).
implementation of the system, the leak
international PAINT&COATING magazine - NOVEMBER/DECEMBER 2018 - N. 54
55
© Chemetall
SP ECIAL ON ACE & OFF RO AD V EH ICLES
had gone unnoticed resulting in excessive
increase safety and reduce costs.
chemical usage and
These technology
heat loss. Chemetall
requirements,
was able to pinpoint
products, and
the root cause area,
operating
allowing a quick and
procedures allow
targeted repair. The
companies to
result was water savings of over 1.900 m3. While the overall financial savings was significant, the true benefit was the
actively contribute
2 1
to a better global
Figure 2: The pre-treatment processes must not only be more conscious of environmental concerns, but also more economically sustainable.
environmental performance. Chemetall’s technologies
conservation of one of
fulfill national regulations and
the world’s most precious resources – water.
Chemetall also implemented automated control and data acquisition which allowed the identification of a stage that had a serious water leak.”
“Our process experts assist customers to improve the reliability of their control and monitoring to insure quality
requirements: The ISO 9001:2008 certified company offers a wide spectrum of tailored products and systems that follow global quality guidelines. Additionally, the
time minimizing waste,” adds Ron
production sites comply with the
Sattler. “We look beyond the chemistry, collaborating closely with our customers
© Chemetall
standards are met while at the same
quality standards ISO 14001:2015 certificate. This international
to identify unique opportunities for
standard sets out requirements
improvement to deliver on the promise
for an environmental management
of sustainability.”
system with which an organization
“A deep commitment to innovation
can improve its environmental
and sustainability, together with the
performance, fulfil legal and
customer as partner is the basis for
other obligations, and achieve
continuous improvement and to deliver
environmental goals.
the highest quality and mutual value
Based on customer requirements,
creation,” says Korneel Demeyere,
substrate throughput and existing
Key Account Manager at Chemetall.
plant technology, Chemetall can
With a strong global network and local
recommend to ACE manufacturer
technical representation, tailored and
suppliers coordinated technologies
sustainable solutions can be provided
such as the Oxsilan technology,
which are close to each customer. From
which fits perfectly in a multitude of
a regulation perspective, increasingly
applications. The modular structure
stringent environmental legislation
of this pre-treatment technology
as well as the ever more varied metal
makes it possible to increase
combinations now used create the
process efficiency quality and
need for companies to look beyond
production output in a wide variety
traditional phosphating processes.
of pretreatment systems. Oxsilan
Chemetall has been able to replace zinc
technology offers advantages versus
phosphate process in powder lines with
3 1
lower sludge formation, a major
eco-friendly processes. One goal is the elimination of Nickel salts by introducing globally applicable, environmentally-sound processes to
56
zinc phosphate including significantly
Figure 3: The Clean-In-Place-program has virtually eliminated the need for the removal of the exchangers manually, thereby reducing employee exposure to very aggressive acidic chemicals.
N. 54 - NOVEMBER/DECEMBER 2018 - international PAINT&COATING magazine
improvement considering the time and effort needed for the manual removal of zinc sludge in traditional
INNOVATIONS: PRESENT&FUTURE
Based on customer requirements, substrate throughput and existing plant technology, Chemetall can recommend to ACE manufacturer suppliers coordinated technologies such as the Oxsilan technology, which fits perfectly in a multitude of applications. The modular structure of this pretreatment technology makes it possible to increase process efficiency quality and production output in a wide variety of pretreatment systems.� zinc phosphating systems. Due to the absence of Nickel, the environmental impact of a pretreatment line will be decreased. The result is lower use of chemical as well as tremendous savings in water and energy (30 to 65 percent reductions). The sustainability benefit is not always apparent at first as the next example will show. A large global engine manufacturer decided to focus on reducing motorized vehicle traffic around the site to increase personnel safety. Traffic and chemical treatment are not often thought of as being linked, but by understanding sustainability and how all the processes within a facility are tied together even seemingly non-associated goals can be impacted. By making improvements to the effectiveness of a cleaning process Chemetall was able to reduce the amount of chemical required and as such reduced the need for the restocking of the chemical. This lower restocking was so significant it created a reduction in motorized vehicle traffic in the area by 19%. Without an understanding of sustainability and how a process, and not just a product can impact results, a true sustainability solution may have been missed. As global competition increases, and resources become scarcer, it is important to focus on comprehensive sustainable programs. Thus, for BASF, Chemetall and their customers, sustainability is not just a word but rather a mindset that is implemented to customer interactions. It’s a commitment to improve overall process performance by reducing environment impact, lowering manufacturing cost, and improving the human element associated with the process. For the ACE industry, Chemetall’s pretreatment technologies offer a multitude of benefits: multi-metal treatment, enhanced quality, significant process cost savings, and world class global support that is aligned with their customers business goals. This is what creates real quality and what Chemetall stands for expect more.
© Ferrari Costruzioni Meccaniche
Opening photo: Ferrari Costruzioni Meccaniche was established by Luigi Ferrari as a repairer of agricultural machinery in Guidizzolo (Mantua, Italy), in 1961. The company is now managed by his sons Francesco and Dario and it has specialised in the production of transplanting machines.
FOCUS ON TECHNOLOGY
S P E C I A L O N AC E & O FF ROAD V EHICLES
Ferrari Costruzioni Meccaniche: A New Tunnel Shot Blasting System for Highly Customisable Agricultural Machinery Barbara Pennati ipcm®
I
n our modern globalised world, we
possible and what process lies behind the
agriculture has always been the basis of
are used to having any product at our
salad head that we effortlessly put in our
our livelihood and, precisely for this reason,
disposal at any time. This is especially
shopping cart. If talking about agriculture,
it has evolved hand in hand with man and
true for food: supermarkets always offer
we are more likely to initially recall concepts
his habits – not just in terms of crops,
a huge selection of products, vegetables,
learned from our history and geography
which now do not know borders, but also
and fruits from all over the world. Although
books rather than thinking of it as an
of technology.
awareness and interest in this subject
integral part of the industrialised societies
Ferrari Costruzioni Meccaniche has
are exponentially increasing, we are often
of the first world. And yet, however far
been one of the players of this evolution
too busy to stop and wonder how this is
apart from the everyday life of most people,
since 1961. Established as a repairer
58
N. 54 - NOVEMBER/DECEMBER 2018 - international PAINT&COATING magazine
FOCUS ON TECHNOLOGY
of agricultural machinery in Guidizzolo
technology, which is our core business,
methods are selected depending on the type
(Mantua, Italy) by Luigi Ferrari, the company
makes sure that plants grow before
of plant: the sod system is more expensive,
is now managed by his sons Francesco,
weeds; however, despite the agronomic
but it brings significant benefits with short
and Dario and it has specialised in the
advantages, there was initially no machine
cycle crops, such as salads, whereas seeding
production of transplanting machines
to automate this process, which had to be
boxes are more suitable for longer cycle
(ref. Opening photo). “Ferrari Costruzioni
performed manually,” says Dario Ferrari.
crops, such as tomatoes, which take three to
Meccaniche is located in one of the most
“The systems developed and produced
four months.”
important agricultural areas of Italy: 40% of
by Ferrari Costruzioni Meccaniche can
With the advent of organic agriculture in
lettuce is produced in Guidizzolo,” explains
handle the semi-automatic and automatic
1995-96 and its success on world markets, a
technical director and partner Dario Ferrari
transplantation of plants placed in seed
new need arose: the reduction of chemical
(Fig. 1). “The company has followed the
boxes (Fig. 2) or on sods. These two
impact. Therefore, Ferrari Costruzioni
metamorphoses of the agricultural sector,
Meccaniche started offering a transplanting© ipcm ®
adapting its machinery to the needs arising over the
mulching machine able to lay a polyethylene or
years.”
biodegradable film, fix
With the advent of new
it to the ground, and
agronomic needs and
transplant the plants
the development of
(Fig. 3). By covering the
new technologies, the
soil adjacent to the plant,
quality level required for
this film prevents the
agricultural machinery has
growth of weeds without
increased. That is why,
the use of chemicals. An
in order to offer robust
electronic weeder was
and durable products
also developed: through
to its customers, Ferrari
a viewer, it carries out
Costruzioni Meccaniche
a mechanical weeding
has made some changes
operation at a speed
to its coating plant. One of them involved the mechanical pre-treatment phase, now performed with a tunnel shot blasting
of 4 km/h and without
1
damaging the plant – a
Figure 1: Technical director Dario Ferrari manages the company established by his father Luigi together with his brother Francesco.
has specialised in the design and production of shot blasting, sand blasting, and shot peening systems for over fifty-five years.
A global presence for every production requirement “Over the years, agricultural production has undergone many changes that have made it necessary to adapt the machinery to ever-new needs. For example, for what concerns sowing, the transplantation
“In 1985, the agricultural business established by
OMSG-Officine Meccaniche a well-established company that
people to perform. machinery repairing
machine supplied by San Giorgio SpA (Villa Cortese, Milan),
job that would require ten
Ferrari Costruzioni Meccaniche covers three buildings on a 15,000 m2 area and it has 102 employees, who manage the entire production process in-house. The production flow starts in the technical office, which designs the machines according to customer specifications. Once the work order has been generated, the various production departments are activated: turning (with 6 turning centres and 2 machining centres), laser cutting, welding (with both robotised and manual welding stations), coating, and assembly (where different specialised teams operate depending on the machine type).”
our father started to convert into a manufacturing company. We have developed different types of machines, but we have specialised in transplanting machines for different crops, especially tomato, brassicaceae, and salads, but also coffee, sugar cane, tobacco, and pineapple,” says Dario Ferrari. “By attending various trade fairs, we have managed to open up to the global market and we now have customers in fifty countries around the world, including USA, Latin America, Canada, South Africa, and China.”
international PAINT&COATING magazine - NOVEMBER/DECEMBER 2018 - N. 54
59
© Ferrari Costruzioni Meccaniche
© Ferrari Costruzioni Meccaniche
SP ECIAL ON ACE & OFF RO AD V EH ICLES
2 1
3 1
Figure 2: An automatic transplanting machine developed for vegetable plants placed in seed boxes.
Figure 3: With the advent of organic agriculture, Ferrari Costruzioni Meccaniche has added to its range a transplanting-mulching machine able to lay a polyethylene or biodegradable film that prevents the growth of weeds without the use of chemicals.
Productive flexibility in the name of quality
stations), coating, and assembly (where
The will to offer tailor-made solutions calls for
different specialised teams operate depending
extreme production flexibility. This has led
Ferrari Costruzioni Meccaniche covers three
on the machine type),” explains Dario Ferrari.
Ferrari Costruzioni Meccaniche to insource
buildings on a 15,000 m area and it has 102
“The process is automated, but not intensively,
most processes, including coating, to which
employees, who manage the entire production
as our key to success is a high customisation
it has devoted an entire building. “The
process in-house. “The production flow starts
level that requires significant artisanal skills.
components we buy are already coated. On
in our technical office, which designs the
We produce about 1,000 machines a year,
the other hand, all products coming out of
machines according to customer specifications.
belonging to different price ranges and very
our turning department can be subjected,
Once the work order has been generated, the
different from each other. This is precisely
depending on the type of workpiece, to a
various production departments are activated
due to the high level of customisation that we
galvanic treatment, carried out by a contractor,
(Figs. 4 and 5): turning (with 6 turning centres
make available to our customers, which have
or to a liquid or powder coating process,
and 2 machining centres), laser cutting, welding
the opportunity to build a system that is truly
performed with the system we have installed at
(with both robotised and manual welding
tailored to their needs.”
our premises,” says Dario Ferrari.
© ipcm ®
© ipcm ®
2
4 1
60
5 1
N. 54 - NOVEMBER/DECEMBER 2018 - international PAINT&COATING magazine
Figures 4 and 5: Ferrari Costruzioni Meccaniche manages its entire production process in-house. Its production departments include turning, laser cutting, welding, coating, and assembly.
© ipcm ®
FOCUS ON TECHNOLOGY
“The hydraulic motor cylinders are liquid painted in an offline manual booth, which requires a chemical pre-treatment process; the carpentry parts are powder coated in an inline system, which requires a mechanical pre-treatment operation.” The in-line coating plant, equipped with a one-rail conveyor, dates back to 1998, the year in which the painting process was insourced. Its booth and polymerisation oven have been revamped over the years. Originally, also this plant performed chemical pre-treatment (phospho-pickling, degreasing, rinsing with mains water, and rinsing with demineralised water). However, this did not guarantee the requested quality, resistance, and consistency performance levels. “Our powder coating line treats different types of parts and materials, including white and black sheet metal and tubes. We constantly had significant yield problems in terms of both quality and corrosion resistance. In short, the previously
The paint performs even under high pressure. Surface coating expertise on many levels – that‘s where Rippert has been making a name for itself for over five decades. We conceived surface coating plants for PILATUS for the finishing individual components and complete aircraft. We are delighted to accompany a successful company with our ideas and technologies. We make brands shine. Find out more at www.rippert.de
6 1
Figure 6: The TUNNELBLAST 1525/12 tunnel shot blasting system installed in December 2017 by OMSG (Villa Cortese, Milan).
© ipcm ®
S P E C I A L ON AC E & OF F ROA D V E HI C L E S
Figures 7 and 8: In order to perform a continuous flow process, the tunnel shot blasting system has no closing doors, but it is equipped with vestibules featuring rubber curtains at both the entrance and exit: this reduces the spillage of media and dust from the shot blasting chamber.
© ipcm ®
7 1
8 1
used pre-treatment cycle guaranteed neither high salt spray resistance values nor result repeatability, which fluctuated depending on the material treated,” says Dario Ferrari. “In order to solve these problems, we would have had to carry out a major tunnel updating and completely reformulate the active baths’ chemicals. That is why we decided to look for a different solution: a technology that could be installed inline and that was able to treat both small and large workpieces without affecting logistics and ensuring a high quality level in terms of both aesthetics and corrosion resistance. We thus came into contact with OMSG, which took us to the factory of one of their customers, a manufacturer of corn heads, to enable us to see its technology applied to a machine in our industry, and then developed the best suited plant for our needs.” The machine installed in December 2017 at the premises of Ferrari Costruzioni Meccaniche is a TUNNELBLAST 1525/12 tunnel shot blasting system (Fig. 6), able to treat workpieces up to 1500 mm in width and 2500 mm in height and equipped with 12 OMSG-patented single-disc turbines, each with a 7,5 Kw power, to guarantee an SA 2½ finishing degree. “The parts to be treated move continuously at a speed of 0.5 metres per minute. This limited speed allows us to obtain the required
FOCUS ON TECHNOLOGY
quality level without using larger media, which could damage the workpieces with their intense action,” explains Ferrari. “One of the requirements of Ferrari Costruzioni Meccaniche was that the shot blasting system could perfectly integrate into the coating plant and work inline and with a continuous flow. We opted for a tunnel shot blasting machine, not hermetic but with vestibules featuring rubber curtains at both the entrance and exit: this reduces the spillage of media and dust from the shot blasting chamber (Figs. 7 and 8),” states Giorgio Pozzi from the technical sales department of OMSG. “The rotation speed of the turbines is adjustable through an inverter. Special valves dose the abrasive, which is then recovered and reconditioned: through a blowing nozzle, the media left on the component are removed by the operator and collected in hoppers placed in the exit area (Fig. 9).” “As well as consistency and salt spray resistance, another problem that we solved thanks to this machine is related to the coating quality of laser cut workpieces,” says Ferrari. “Indeed, laser cutting creates a sharp edge that often causes a ‘tear’ in the paint. In the past, we rounded these edges with a brushing machine combined with an abrasive; now, thanks to our shot blasting plant, this is not necessary anymore.” After pre-treatment (chemical in the case of engine cylinders, mechanical for carpentry components), the workpieces reach the coating process. “The carpentry parts are coated in the inline plant, equipped with a booth featuring 4 reciprocators and 2 guns for manual retouching,
© ipcm ®
supplied by Wagner (Fig. 10). A one-layer system is applied that employs Sherwin-Williams polyester powders, which are then recovered during spraying through cartridge filters. The subsequent polymerisation phase takes place at 200 °C for 20 minutes (Fig. 11),” says Dario Ferrari. “On the other hand, for the liquid coating of our engine cylinders, we use an offline manual booth applying water-based two-component paints, 9 1
Figure 9: The abrasive can be recovered and reconditioned: through a blowing nozzle, the media left on the component are removed by the operator and collected in hoppers placed in the exit area.
also provided by Sherwin-Williams. The colours used are those typical of the Ferrari Costruzioni Meccaniche brand, i.e. RAL 2002 red and blue.”
HIGH
PERFORMANCE POWDER COATINGS
© ipcm ®
SP ECIAL ON ACE & OFF RO AD V EH ICLES
© ipcm ®
The OMSG Group (OMSG + Carlo Banfi), has always committed to offer constant and efficient after-sales assistance. Its customers are categorised according to the machines they have installed, and this allows OMSG to intervene promptly and effectively even in the most remote locations. Moreover, the machines are Industry 4.0-oriented and always provided with a package of devices and services for the management of the process (and of any problems), such as a PLC, an integrated touchscreen, remote assistance, and safety devices.” Our customers are categorised according to the machines they have installed, and this allows us to intervene promptly and effectively even in the most remote locations,” explains Giorgio Pozzi. “Moreover, our machines are Industry
10 1
4.0-oriented and always provided with a package of devices and services for the
Figure 10: The powder coating booth is equipped with 4 reciprocators and 2 guns for manual retouching, supplied by Wagner; it applies Sherwin-Williams polyester powders.
management of the process (and of any problems), such as a PLC, an integrated touchscreen, remote assistance, and safety devices.” “The plant has now reached optimal
A historical business keeping up with the times
conditions, and we can now focus on future improvements. To obtain an even
“Ferrari Costruzioni Meccaniche has
higher salt spray resistance value, we are
operated in the agricultural sector for over
considering the implementation of a primer
fifty years. With time, we have witnessed
application phase. In this way, we will be
and taken part in the succession of different
able to offer our customers increasingly
trends and technologies, always trying to establish ourselves on the national and international markets as a solid and reliable company,” states Dario Ferrari. “Therefore,
11 1
Figure 11: Workpieces entering the polymerisation oven.
products, in terms of both technology and quality,” says Dario Ferrari.
© ipcm ®
it was extremely important to find the right
advanced and competitive services and
technological partner to obtain increasingly optimal results in line with market needs.” “With the adoption of this machine, we have solved the problems related to consistency and salt spray resistance, managing to guarantee much higher quality and corrosion resistance levels (Fig. 12). We are very pleased of this system, of the results achieved, and of OMSG’s professionalism and technical efficiency,” says Ferrari. “The OMSG Group (OMSG + Carlo Banfi), has always committed to offer constant and efficient after-sales assistance.
64
12 1
N. 54 - NOVEMBER/DECEMBER 2018 - international PAINT&COATING magazine
Figure 12: A finished product of Ferrari Costruzioni Meccaniche.
®
SUCCESS STORIES
© Eisenmann SE
Eisenmann, a Paint Shop 4.0 Pioneer, Debuts an Integrated, End-to-End Solution for the Paint Shop of the Future
1
Figure 1: Eisenmann pre-assembles paint shop components at its Technology Center in Holzgerlingen near Stuttgart. A prime example is a new paint shop, built for the expanded Mercedes-Benz plant in Kecskemét, Hungary.
P
lant engineering enterprise
Eisenmann pre-assembles paint shop
be implementing a skidless paint shop in
Eisenmann, headquartered in
components at its Technology Center in
Kecskemét that incorporates a number
southern Germany, has built and
Holzgerlingen near Stuttgart.
of our solutions. With our combination of
pre-installed equipment for a new paint
The approximately 15,000 m2 production
Industry 4.0 technologies, we are making the
shop. The solution is ultimately destined for
halls enable the enterprise to put
vision of a highly flexible and efficient smart
Kecskemét, Hungary, but made its debut in
customer-specific solutions to the test prior
paint shop a reality.”
Holzgerlingen. The event demonstrated the
to delivery – and to cooperate closely with
individual but interconnected production
customers to tailor new technologies to
Highly flexible skidless conveyor
steps based on Eisenmann technologies. For
their needs. A prime example is a new paint
At the heart of this fully integrated,
the first time, these have been implemented
shop, built for the expanded Mercedes-
end-to-end solution is Eisenmann’s VarioLoc
as an end-to-end, highly flexible, skidless
Benz plant in Kecskemét, Hungary (Fig. 1).
conveyors (Fig. 2). They enable skidless
paint shop – underscoring Eisenmann’s ability
As Jörg Robbin, Vice President of Product
movement of vehicle bodies through
to design and build one-stop, future-proof
Development, Automotive Systems at
the paint shop. As Robbin emphasizes,
solutions.
Eisenmann explains: “We are proud to
“Eliminating the need for heavy skids paves
66
N. 54 - NOVEMBER/DECEMBER 2018 - international PAINT&COATING magazine
© Eisenmann SE
SUCCESS STORIES
????????? ???????
Figure 2: At the heart of this fully integrated, end-to-end solution is Eisenmann’s VarioLoc conveyors. They enable skidless movement of vehicle bodies through the paint shop.
Smart, energy-efficient dryers State-of-the-art dryers play a pivotal role in ensuring high paint quality at OEMs and their suppliers. The corresponding processes require considerable energy input – meaning efficiency gains translate into huge savings. “Our Smart Oven represents a milestone in vehicle body drying (Fig. 4). This new solution evenly delivers heat to the chassis, yet requires significantly less energy. This, in turn, reduces resources consumed by the paint shop, and slashes harmful emissions. Users benefit in the long term from an improved ecological footprint and higher coating
2 1
quality,” Robbin states. The Smart Oven
the way for greater flexibility in terms of cycle times, throughput, resources, and
At the heart of this fully integrated, end-to-end solution is Eisenmann’s VarioLoc conveyors. They enable skidless movement of vehicle bodies through the paint shop. VarioLoc conveyors with the car bodies move along a rail installed in the floor. The drives are independent, and speed can be adjusted according to each process step. As a result, cycle times and throughput can be managed flexibly and optimized.”
vehicle architectures.” VarioLoc conveyors with the car bodies move along a rail installed in the floor (Fig. 3). The drives are independent, and speed can be adjusted according to each process step. As a result, cycle times and optimized. Moreover, the modular system can be relocated to a new site, and easily extended without major modifications – as all VarioLocs are of identical design,
© Eisenmann SE
throughput can be managed flexibly and
and comprise highly standardized components. This enables responsiveness to fluctuating workloads, and quick and simple changeovers between vehicle models during ongoing production, without specially trained staff. In conventional paint shops, by contrast, it would be necessary to purchase entirely new skids, or to make significant alterations to existing ones. Figure 3: VarioLoc conveyors with the car bodies move along a rail installed in the floor. Cycle times and throughput can be managed flexibly and optimized.
3 1
international PAINT&COATING magazine - NOVEMBER/DECEMBER 2018 - N. 54
67
© Eisenmann SE
SUCCESS STORIES
4 1
Figure 4: Smart, energy-efficient dryers: This new solution evenly delivers heat to the chassis, yet requires significantly less energy.
is among the solutions leveraged in the Kecskemét paint shop. The Smart Oven can make the most of its strengths when deployed in conjunction with VarioLoc skidless conveyors. In the past, the hefty skids carrying the vehicle bodies through the dryer had to be heated up and cooled down with each cycle. And for a skid that tips the scales at 200 kg that is a huge amount of energy. By taking the skids out of the picture, VarioLoc reduces energy consumption for drying alone by up to 13 percent – and that is just part of the potential 37 percent savings that can be achieved annually with the Smart Oven. This total includes efficiency gains through preheated combustion air and reduced pressure loss (16 percent) and through load-dependent operation (8 percent).
68
Mercedes-Benz applies a primerless top coat to its vehicle bodies. Eliminating the solventbased primer means greater eco-friendliness and lower operating costs. What’s more, Eisenmann’s application systems are a precise fit for the twolayer base coat. And for the Kecskemét paint shop, the company is providing the entire paint supply system and a top coat line, comprising six spray booths with 36 paint application and 24 handling robots.”
N. 54 - NOVEMBER/DECEMBER 2018 - international PAINT&COATING magazine
Intelligent conveyor solution for pretreatment The scope of supply for the Kecskemét paint shop includes a pretreatment and electrocoating line featuring the E-Shuttle 200 conveyor (Fig. 5). The VarioLocs transfer the car bodies to the individual shuttles, and these then move them through the electrodeposition (ED) tank. A variety of car models can be processed on a single line. An intelligent shuttle control unit, connected via bus with the PLC, enables each shuttle to respond autonomously to changes in the process. In addition, it is possible to capture and store data on the exact position of each vehicle body at any time. This ensures complete
Eisenmann’s modular E-Cube solution removes paint overspray mechanically, and is sustainable and energy-efficient. It offers diverse advantages over conventional wet scrubbers. E-Cube saves energy, and does not require water, chemicals or other additives. It boasts an exceptionally high removal rate, and is user-friendly.”
Figure 5: The VarioLocs transfer the car bodies to the individual shuttles of the E-Shuttle 200 system, and these then move them through the electrodeposition tank.
© Eisenmann SE
SUCCESS STORIES
5 1
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 international PAINT&COATING magazine - NOVEMBER/DECEMBER 2018 - N. 54
69
visibility, and can be used for subsequent analysis to improve production and
© Eisenmann SE
SUCCESS STORIES
In addition, Eisenmann’s modular E-Cube solution removes paint overspray
increase flexibility. The
mechanically, and is
result is better paint quality
sustainable and
and a higher first-run rate.
energy-efficient (Fig. 7).
As Jörg Robbin points out,
It offers diverse
“Bearing in mind the trend
advantages over
toward mass customization
conventional wet
in the automotive industry,
scrubbers. E-Cube saves
E-Shuttle 200 is a smart
energy, and does not
investment. The system’s
require water, chemicals
intelligent control unit
or other additives.
enables easy, seamless
It boasts an exceptionally
integration into connected
high removal rate,
manufacturing environments. And that underscores E-Shuttle 200’s future-proof design and suitability for the smart factory.”
and is user-friendly.
6 1
The filtration modules
Figure 6: Eisenmann is providing application systems, which are a precise fit for the primerless top coating process.
Paint application and overspray removal Mercedes-Benz applies a primerless top coat to its vehicle bodies. Eliminating the solventbased primer means greater ecofriendliness and lower operating costs. What’s more, Eisenmann’s application systems are a precise
(cubes) are controlled and monitored via a touch panel, and can be replaced while the spray booth is in operation.
The skidless paint shop for the Kecskemét plant highlights Eisenmann’s role as a Paint Shop 4.0 pioneer. The enterprise has combined multiple state-of-the-art technologies to enable flexible, sustainable and energy-efficient car production – independent of chassis or engine type, and capable of being modified in line with changing demand.”
Furthermore, disposal of the solid matter trapped in the filters is convenient and simple. Outstanding flexibility in automotive paint shops The skidless paint shop for the Kecskemét plant highlights Eisenmann’s role as a Paint Shop 4.0 pioneer.
And for the Kecskemét paint
The enterprise has combined
© Eisenmann SE
fit for the two-layer base coat. shop, the company is providing the entire paint supply system
multiple state-of-the-art technologies to enable flexible,
and a top coat line, comprising
sustainable and energy-efficient
six spray booths with 36 paint
car production – independent
application and 24 handling
of chassis or engine type, and
robots (Fig. 6). The latter open
capable of being modified in
the car doors and hoods, allowing
line with changing demand.
automated application of paint
The solution will be
to the interior. VarioBell v.2
pre-assembled in Holzgerlingen
high-speed rotary atomizers
by the end of the year, then
and the VarioCharger v.2 paint
transported to Kecskemét and
metering system minimize paint loss. Eisenmann is also supplying application equipment for sealing and damping materials.
70
7 1
Figure 7: Eisenmann’s modular E-Cube solution removes paint overspray mechanically, and is sustainable and energy-efficient.
N. 54 - NOVEMBER/DECEMBER 2018 - international PAINT&COATING magazine
installed. The first chassis are expected to roll off the line by the early 2020s.
we keep an eye on your AUTOMATION needs.
vertical & horizontal axis reciprocators | color centers dimensional detection systems | control panels | accessories
www.reind.it
© UV Ray
Opening photo: UV Ray’s UV curing systems are distinguished by the low amount of energy needed during the work cycle, resulting in lower consumption and greater safety for the environment.
HIGHLIGHT OF THE MONTH
UV curing systems: A Low-Consumption and Sustainable Technology for High Production Rates Stefano Maiano UV Ray, Cornaredo (MI) – Italy
72
s.maiano@uvray.it
N. 54 - NOVEMBER/DECEMBER 2018 - international PAINT&COATING magazine
HIGHLIGHT OF THE MONTH
G
2014 UV Ray has been active also in the
iven the growing demand from several industries for efficient but sustainable solutions, UV Ray’s
UV curing systems are currently one of the most innovative and concrete responses for the spray painting, printing, and coating markets. Compared with conventional systems, the UV Ray products are distinguished by the low amount of energy needed during the work cycle, resulting in lower consumption and greater safety for the environment (ref. Opening photo).
UV Ray has designed and manufactured UV curing systems for over twenty years. Based in Cornaredo (Milan), the company, established by Alberto Maiano and now managed by him and his son Stefano, has numerous distributors worldwide: in Europe, in the Americas, in South Africa, in China, and in India. Mainly specialising in the printing and coating sectors, since
UV Ray has designed and manufactured UV curing systems systems for over twenty years. Based in Cornaredo (Milan), the company, established by Alberto Maiano and now managed by him and his son Stefano, has numerous distributors worldwide: in Europe, in the Americas, in South Africa, in China, and in India. Mainly specialising in the printing and coating sectors, since 2014 UV Ray has been active also in the painting industry, now accounting for 20% of its core business. In particular, the firm is present in the plastic, metal, and wood painting field for different industries, especially automotive and cosmetics.”
painting industry, now accounting for 20% of its core business. In particular, the firm is present in the plastic, metal, and wood painting field for different industries, especially automotive and cosmetics (Figs. 1 and 2). UV Ray’s systems are patented for the curing of liquid paints and they stand out for their high curing efficiency, as well as significant energy savings for the hot air renewal in the chamber. With their lean but solid mechanical design, UV Ray’s products are particularly convenient with high volume productions, as they can operate without interruptions at high rates, and they show greater reliability in the long term. Thanks to the low operating temperatures required, the work environment is easily accessible, thus simplifying any maintenance and repair operations.
The next generation of powder coating! A revolutionary solution for your coating requirements.
IPS coating center • Color change at the push of a button • Maximum coating quality • High-performance & fully automated system
go.wagner-group.com/ips
© UV Ray
Figures 1 and 2: Spray painting of packages for cosmetics with UV Ray’s Magnum long-arc UV reflector.
© UV Ray
1
The units can be isolated to solve any problems without having to stop the entire line. Thanks to innovative design and engineering, also the cost of spare parts is lower. All UV Ray systems feature an interface and UV sensors in the booth to monitor the production process remotely and safely.
All UV Ray systems feature an interface and UV sensors in the booth to monitor the production process remotely and safely. They also integrate a UV reflector in borosilicate with a multilayer treatment, which ensures greater reflection of ultraviolet rays on the substrate thus preventing the infrared rays from reflecting on it.”
74
2 1
They also integrate a UV reflector in
life precisely thanks to the low operative
borosilicate with a multilayer treatment,
temperature needed.
which ensures greater reflection of
UV Ray’s next projects will focus on the
ultraviolet rays on the substrate thus
development and manufacture of a
preventing the infrared rays from reflecting
system for the treatment of extruded
on it. This results in low temperature
metal pipes and on cooperation with
printed materials, very high efficiency, and
various paint manufacturers to patent a
therefore savings in the cooling process of
system suitable for the powder coatings
the lamp, which in turn has a longer service
curing.
N. 54 - NOVEMBER/DECEMBER 2018 - international PAINT&COATING magazine
P O W E R F U L
I N
V E R T I C A L
I
M
I
T L E S S
I N
H O R I Z O N T A L
Powder coating lines since 1976. V E R O N A
I T A LY
B A R C E L O N A S A N T A
S P A I N
C A T A R I N A
F L O R I D A
U S A
B R A Z I L
© ipcm ®
Opening photo: Cavalca liquid and powder coats workpieces with any weight and size.
FOCUS ON TECHNOLOGY
The Single-Stage Cold Pre-Treatment Technology Improves Production Efficiency and Environmental Sustainability Monica Fumagalli ipcm®
76
N. 54 - NOVEMBER/DECEMBER 2018 - international PAINT&COATING magazine
FOCUS ON TECHNOLOGY
I
n any Italian industrial sector, it is not
industrial coating, proving that our operations
uncommon to meet small or medium-sized
are fully eco-friendly. The “secret” is to invest in
companies that manage their production
proven processes in terms of economic savings
Experience, flexibility, and delivery speed: Cavalca Verniciature’s cornerstones
activities by making eco-sustainable choices for
and lower energy consumption. For example,
As well as its forty-year experience in coating
ethical reasons, despite the limited resources
when we decided to automate our powder
transport vehicles, Cavalca Verniciature’s
for updating their plants and
strengths include a
although the sporadic careful
manufacturing flexibility
and effective environmental
Cavalca Verniciature has opted for Chemtec Toran 3® for the preliminary treatment to the application of powders. In order to speed up the production phases, especially the cleaning ones. Certain types of workpieces, especially the large-sized and complex-shaped ones, required long cleaning times and complicated handling operations, resulting in higher production costs. Chemtec has solved these two problems while making the cleaning of the most complex parts in a uniform and optimal, but also eco-friendly way.”
controls by the responsible bodies may be an incentive to act oppositely. At the centre of the Emilia Romagna region, in Bagnolo in Piano (Reggio Emilia - Italy), we have met a company that has turned its environmental strategy into a winning strategy: Cavalca Verniciature, Carrozzeria Cavalca, established
every type of workpiece, with any size and weight, with a fast and efficient service guaranteed by its speed in terms of both production and delivery. “Our main target market is the local one,” says Cavalca. “The speed of production flow management and product delivery is crucial to counteract competition. That is why we are equipped
© ipcm ®
the business evolution of
level such as that it can treat
to handle both large orders
in the 1960s for the repair of
and small quantities, and
motor vehicles.
especially large-sized objects:
In 2007, the firm converted into
at the moment, we have a
a powder and liquid coating
modern powder coating plant
contractor specialising in metal
that can process components
(especially steel and aluminium)
up to 13.20 meters in length,
components mainly intended
3.20 meters in height, and
for the ACE and machine tools
3.20 meters in width. The
sectors (ref. Opening photo).
versatility of our machines also
“We mainly treat medium
enables us to better manage
and large-sized carpentry
the most urgent work, in order
components and complementary
to deliver in a very short time.”
small parts using two coating one,” says Riccardo Cavalca,
Liquid and powder coating processes
the owner of the firm with his
Surface treatments are
lines, i.e. a liquid and a powder
son Gabriele (Fig. 1). “Despite the complexity of the treated materials, we have never stopped focussing on the quality of our production processes, on the
performed on the two
1
coating lines through manual
Figure 1: From right to left: Chemtec owner Carlo Guidetti, Gabriele Cavalca from Cavalca Verniciature, Alessia Venturi from ipcm®, and Chemtec Product Manager Tommaso Giovenzana.
safety of our employees and
operations (Fig. 2). “As for liquid coating, we do not have an actual continuous line: we have arranged the different
of the environment in which they operate,
coating line about one year ago, we opted for
stations in both our buildings in order to
and of course on our end products’ quality.
an innovative solution: a single-stage cold pre-
make the air drying phase, performed after
We have been ISO 9001 certified for several
treatment system called Toran 3 and supplied
application with heat exchangers, more
years. Cavalca Verniciature is also one of the
by Chemtec (Corbetta, Milan), which is an effective
flexible. If necessary and at the specific
very few Italian companies with the ISO 14001
eco-friendly alternative to phosphodegreasing or
request of the customers, the parts can be
environmental certification in the field of
to phosphating followed by passivation.”
subjected to an initial sand blasting treatment
®
international PAINT&COATING magazine - NOVEMBER/DECEMBER 2018 - N. 54
77
© ipcm ®
2 1
Figure 2: The manual application of powder coatings.
to remove oxidation and calamine residues remaining on their surfaces after machining, thus achieving a roughness degree equal to Sa 2 ½ - Sa 3 (Fig. 3). Sand blasting is generally the preliminary treatment for components requiring marine-level treatments (C5-MH): these are special workpieces intended for areas with high salinity, e.g. offshore, or regions characterised by very aggressive atmospheric phenomena. That is why the coating system includes several layers of both the base coat and the top coat, so as to apply an average paint thickness of at least 320 microns. Besides these systems, we also apply intumescent paints, high solid © ipcm ®
coatings for lower environmental impact, and polyurethane and epoxy paints.” “For our powder line, we use epoxy-polyester paint products applied in two layers, a zinc-based primer and a top coat, with an intermediate polymerisation phase (Fig. 4). Powder coating,” says Cavalca “ensures numerous advantages compared with the conventional one, including lower costs, because the process is faster, and lower disposal costs.
3 1
Figure 3: The automatic shot blasting system.
FOCUS ON TECHNOLOGY
Toran 3® is a degreasing process suitable for any type of material, which requires only one cold phase and can be integrated on already existing cleaning lines. In the low-pressure spray application tunnel, the contact time between the chemical product and the part surface ranges from 1 to 3 minutes, depending on the contamination level and the pre-set process time.” Moreover, in terms of eco-friendliness, powders greatly reduce pollution and avoid the use of solvents. With the modern technologies implemented, we have reached high quality levels even with powder coatings in terms of both aesthetics and corrosion protection. Indeed, we have achieved extraordinary results, with workpieces showing a salt spray resistance value of over 2000 hours.” The company has opted for Chemtec Toran 3® for the preliminary treatment to the application of powders. “About one year ago, we assessed that in order to be even more competitive we had to further speed up our production phases, especially the cleaning ones,” states Cavalca. “Certain types of workpieces, especially the large-sized and complex-shaped ones, required long cleaning times and complicated handling operations, resulting in higher production costs. Chemtec has solved these two problems while making sure that we clean even the most complex parts in a
© ipcm ®
uniform and optimal, but also eco-friendly way.”
4 1
Figure 4: A detail of the result of a powder application process.
© ipcm ®
© ipcm ®
5 1
6 1
Figure 5: The pre-treatment tunnel with Chemtec’s Toran 3®.
Figure 6: The inside of the pre-treatment tunnel.
Toran 3®: a single-stage multi-metal process
bars. These are mounted on a compressed
“At the end of the process, after drying,”
air piston-driven cart that performs an
says Guidetti, “the parts are clean and
“Toran 3® is a degreasing process
oscillating movement inside the cleaning
coated with an organic polymer with a
suitable for any type of material, which
chamber: on the one hand, this guarantees
thickness of about 300 nm, ensuring both
requires only one cold phase and
more homogeneous and uniform cleaning
temporary protection, as the surfaces do
can be integrated on already existing
results and, on the other, it reduces the
not oxidise if left inside the tunnel, and
cleaning lines,” says Chemtec owner
volume of the plant (Fig. 8).
excellent paint adhesion. At the same
spray application tunnel, the contact time between the chemical product
© ipcm ®
Carlo Guidetti. “In the low-pressure
and the part surface ranges from 1 to 3 minutes, depending on the contamination level and the pre-set process time (Fig. 5 and 6). This is followed by a 5-minute dripping and oven drying phase. The standard drying time is 10 minutes at 130-140 °C: for Cavalca, the temperature is 180 °C, due to the particular shape and size of the workpieces.” The dripping phase is one of the most problematic: if the part has a particularly complex shape, the product risks not to drain properly, so that a manual intervention is needed (Fig. 7). The pre-treatment tunnel features tilting nebulisation
80
7 1
Figure 7: An example of components with a complex shape.
N. 54 - NOVEMBER/DECEMBER 2018 - international PAINT&COATING magazine
© ipcm ®
FOCUS ON TECHNOLOGY
8 1
Figure 8: Workpieces entering the pre-treatment tunnel.
At the end of the process, after drying the parts are clean and coated with an organic polymer with a thickness of about 300 nm, ensuring both temporary protection, as the surfaces do not oxidise if left inside the tunnel, and excellent paint adhesion. At the same time, this polymer is able to absorb any oily contaminants, turning these pollutants into active components that do not have to be disposed of. This eliminates the rinsing phase, since the process does not require the use of water, but rather of non-hazardous and non-toxic organic fluids.” time, this polymer is able to absorb any oily
maintenance, limiting the operations to the
contaminants, turning these pollutants into
cleaning of the filter, which is sometimes
active components that do not have to be
clogged up by metal micro-particles removed
disposed of. This eliminates the rinsing phase,
in the cleaning phase. In one year, we have
since the process does not require the use of
never emptied the tank or cleaned the nozzles.
water, but rather of non-hazardous and
A further benefit is that the cleaning product
non-toxic organic fluids.”
always maintains excellent performance and
“In this way, the product has a substantially
consistent process quality levels, so that we do
unlimited service life,” says Cavalca. “We
not need to perform daily or monthly analyses:
do not need to replace the cleaning agent,
quarterly analyses, on the other hand, are
but only replenish it. This also minimises
carried out by Chemtec’s staff.”
© Chemtec
The consistency of the chemical’s characteristics, which remain unchanged over time, ensures good powder film adhesion and result repeatability while improving the corrosion resistance of the coating system. Before implementing Toran 3®, Cavalca Verniciature performed some tests: they achieved a 700-hour salt spray resistance value with the epoxy-polyester powders that they usually employ, which is an excellent result for products intended to be exposed in very harsh environments.” 9A 1
Figure 9A: The results of the SEM analysis: a Q-Panel degreased with a solvent.
usually employ, which is an excellent result for products intended to be exposed in very
“After the implementation of Toran 3 , ®
harsh environments (Fig. 9a, 9b,
© Chemtec
Toran 3®’s advantages
and 9c). “The last and the most important
we have found significant benefits in
advantages are the greater
several areas,” states Cavalca. “First of
healthiness of our working
all, we have achieved the goal that had
environment and the lower
led us to install a new pre-treatment
impact of our production activity
system: greater speed and ease of
on the environment. Indeed,
management of the production flow.
the product used is VOC-free
The single-stage cleaning process
and classified as non-hazardous
now ensures that we always achieve
for man and the environment according to current European
the delivery speed that is one of our strengths, enabling us to be competitive
9B 1
regulations. Moreover, there is
also and above all in terms of costs.
no waste presenting a high risk
The small footprint of the single-stage
of water contamination and our
chamber also allows us to save useful space for faster and easier handling of
Figure 9B: A Q-Panel treated with Toran 3®.
characteristics, which remain unchanged over time, ensures good powder film adhesion and result
© Chemtec
“The consistency of the chemical’s
82
reduced. Chemtec’s solution has fully met all our expectations.”
larger workpieces.
The cleaning agent has a substantially unlimited service life. It is no longer necessary to replace it, but only replenish it. This also minimises maintenance, limiting the operations to the cleaning of the filter, which is sometimes clogged up by metal micro-particles removed in the cleaning phase.”
energy consumption has been
repeatability while improving the corrosion resistance of the coating system. Before implementing Toran 3®, we performed some tests: we achieved a 700-hour salt spray resistance value with the epoxy-polyester powders that we
Figure 9C: A Q-Panel treated with Toran 3® and polluted with 2% of oil: micro-drops of oil trapped in the polymer can be clearly seen.
N. 54 - NOVEMBER/DECEMBER 2018 - international PAINT&COATING magazine
9C 1
ROBUST AESTHETICS Highly weather-resistant powder coating systems with increased scratch resistance for fewer usage marks and greater security. The IGP powder coating systems IGP-HWFclassic 59 for exceptionally weather-resistant architectural coatings with reduced dirt adhesion are now also supplied with enhanced scratch resistance. Perfect flow in matt and silk gloss.
C
RO
BU
ES
Find out more at: www.igp-powder.com
ST SU RF
A
IGP Pulvertechnik AG 9500 Wil, Switzerland Phone +41 71 9298111 www.igp-powder.com info@igp-powder.com A member of the DOLD GROUP
© Venjakob Maschinenbau GmbH & Co. KG
Opening photo: The Venjakob’s Technical Center.
HIGHLIGHT OF THE MONTH
The New Dimension of the Spray Painting Solutions by Venjakob From an interview with Christian Nüßer, CEO of Venjakob Maschinenbau GmbH & Co.
T
he evolution of a company from locksmith’s shop to international manufacturer of painting systems
specific for wood to global player in the field of surface treatments and finishes of wood, metal and plastic: this is the life’s course of Venjakob Maschinenbau, one of the German historical and still familyowned companies, which set the standards in efficient and reliable finishing technology (Fig. 1). We have interviewed Christian Nüβer (Fig. 2), the third generation of the family at the head of the company, to listen from his voice the past, present and especially the future of this global player.
84
ipcm®: Can you outline a short history
The evolution of a company from locksmith’s shop to international manufacturer of painting systems specific for wood to global player in the field of surface treatments and finishes of wood, metal and plastic: this is the life’s course of Venjakob Maschinenbau, one of the German historical and still family-owned companies, which set the standards in efficient and reliable finishing technology.”
N. 54 - NOVEMBER/DECEMBER 2018 - international PAINT&COATING magazine
of Venjakob since its foundation? Christian Nüßer: Venjakob was founded in 1963 by Heinrich and Anneliese Venjakob and started business as locksmith’s shop. In 1964 the small enterprise designed and manufactured its first staining machine. This machine was the entry into the market of surface technology. In 1976, when the founders’ daughter, Elisabeth and her husband Otto Nüßer joined the company, Venjakob became an internationally operating enterprise. The company expanded, submitted and registered patents and established sales representatives around the world. At the
beginning, Venjakob was focussing on the wood and furniture industry. This might be due to the location in East-Westphalia (Germany) where most of
© Venjakob Maschinenbau GmbH & Co. KG
HIGHLIGHT OF THE MONTH
With a Venjakob coating solution, you can apply various liquid media (paint, glue, sol-gel…) on various kinds of workpieces (Fig. 5). Nearly on all
the kitchen and furniture
materials and shapes.
manufacturers were
Furthermore, Venjakob
located, too.
offers the corresponding
In 1993 Venjakob entered
automation/handling
the non-wooden market.
technology to make the
Then, in 2004, the product
customers workflow as
portfolio was expanded Meckeler and renaming the manufacturer of
effective as possible.
1
by taking over Pflock &
ipcm®: Which are
Figure 1: The Venjakob’s headquarters.
the most important
exhaust-air purification
markets and main
plants into Venjakob Umwelttechnik GmbH & Co. KG. Another proof for Venjakobs’ international success are own sales offices in Canada, India, Spain and since 2008 the takeover of Nutro Inc. Nutro is a well-known US manufacturer for customized finishing solutions, located in Strongsville, Ohio. Over decades in cross-industrial branches, Venjakob sets standards in efficient and reliable finishing technology. Venjakob, still family owned, in third generation, takes care of its very experienced team. More than 300
target industries for the company? CN:
The company expanded, submitted and registered patents and established sales representatives around the world. At the beginning, Venjakob was focussing on the wood and furniture industry. This might be due to the location in East-Westphalia (Germany) where most of the kitchen and furniture manufacturers were located, too.”
- Wood and furniture industry; - Steel & Pipe industry; - Building components (fiber cement boards, façade panels, acoustic ceiling panels, insulating material). ipcm®: Can you describe for our readers Venjakob’s key values and vision? CN: Highest possible quality and maximum customer satisfaction - in order to achieve this goal, we rely on the well-founded © Venjakob Maschinenbau GmbH & Co. KG
employees are developing customized
- Automotive industry (interior/exterior);
solutions, offering a fast and reliable service or are making sure that Industry 4.0, IOT, Predictive Analytics and other key words for industrial automation are lived and not only empty slogans (Figs. 3 and 4).
expertise of our employees. Competent and technically specialized staff develop and implement on time individual problem solutions for our customers from the most different branches. Equally important to us is the use of natural resources, in accordance with our responsibility to present and future
ipcm : Which is Venjakob’s main focus
generations.
and core business?
The quality work of Venjakob is reflected in
CN: Spray coating technology is the core
extensive consultation talks and underpinned
business, but it is accompanied by the entire
in test series in our own technical center,
range of products, which are needed to set
completed by punctual assembly, and
®
up a complete finishing line.
commissioning (ref. Opening photo).
This includes cleaning devices, surface
Nevertheless, you will also receive quality
pre-treatment and activating units as well as various kinds of application technologies, drying systems also as industrial automation and exhaust air purification plants.
and competence through our extensive
2 1
stock of spare parts, our fast and
Figure 2: Christian Nüßer, CEO of Venjakob Maschinenbau GmbH & Co. KG.
experienced service staff and the qualified training for your staff.
international PAINT&COATING magazine - NOVEMBER/DECEMBER 2018 - N. 54
85
© Venjakob Maschinenbau GmbH & Co. KG
Spray coating technology is the core business but it is accompanied by the entire range of products, which are needed to set up a complete finishing line. This includes cleaning devices, surface pretreatment and activating units as well as various kinds of application technologies, drying systems also as industrial automation and exhaust air purification plants.”
3 1
Figure 3: The offices of the headquarters in Rheda (Germany).
The basis of our common actions in our company are satisfied customers. With the
the environmental aspects in the design
developments let our customer produce
and development of environmentally
energy-efficiently, environmentally friendly
friendly machines, but also in production
and economically. In addition, the modular
and infrastructure, for the protection of the
design of our systems makes your
environment and our employees.
investment future-proof. Secure these
Numerous, partly patented product
added values.
© Venjakob Maschinenbau GmbH & Co. KG
In 1993 Venjakob entered the non-wooden market. Then, in 2004, the product portfolio was expanded by taking over Pflock & Meckeler and renaming the manufacturer of exhaust-air purification plants into Venjakob Umwelttechnik GmbH & Co. KG. ”
supply of high-quality machines, we fulfill their requirements in every aspect. The original claim of ISO 9001 to deliver consistent quality is not enough for us alone. With the help of our consistently applied, continuous improvement process (CIP), we constantly increase the quality of our products and services for the benefit of our customers. Our products and processes are constantly evolving to conserve resources and further reduce negative impacts on the environment. Venjakob not only considers
86
4 1
Figure 4: The Venjakob’s lab.
N. 54 - NOVEMBER/DECEMBER 2018 - international PAINT&COATING magazine
© Venjakob Maschinenbau GmbH & Co. KG
HIGHLIGHT OF THE MONTH
5 1
Figure 5: Application onto a glass workpiece.
ipcm®: Which is Venjakob’s best technology? Can you describe its advantages and key strengths? CN: High-performance painting in a new dimension. Based on our decades of know-how in the realization of highperformance spray painting systems, the flexibility of this new generation is impressive (Fig. 6). Here is a summary of the plant benefits and features: - Investment security through modularity; - Paint compatibility; - Systematic paint recovery; - Low production idling; - Short paint change times; - Perfect painting result; - Resource-saving, economical and ecological. The modular system offers long-term consideration of all production requirements. At the time of acquisition, the machine concept realized all variants from “lot size 1” to “high volume series” in the high-end sector.
© Venjakob Maschinenbau GmbH & Co. KG
6 1
Figure 6: VEN SPRAY VARIO offers the flexibility of an industrial spray coating robot and the high output of an automatic surface spray coating machine.
Competent and technically specialized staff develop and implement on time individual problem solutions for the customers from the most different branches. Equally important is the use of natural resources, in accordance with the responsibility to present and future generations.”
With a glance to the future, Venjakob is working on self-learning machines as well as on some visualization projects (plant visualization, VR /AR). Together with well-known universities in Germany it is developing systems for descriptive, diagnostic, predictive and prescriptive analytic software.”
Several plants, operating with RFID technology
companies like Dürr, Festo or Homag, Venjakob
are successfully implemented in the market.
is involved in the further development of the
Furthermore, Venjakob is a tapio-partner.
project and the possibilities this platform offers.
Tapio is intended to help the wood industry to
With a glance to the future, Venjakob is working
evolve into the digital future itself. With tapio
on self-learning machines as well as on some
machinery manufacturers, toolmakers and
visualization projects (plant visualization, VR /
material producers use the same technology
AR). Together with well-known universities
platform. In that way, digital solutions for
in Germany we are developing systems
common customers of every size are being
for descriptive, diagnostic, predictive and
discovered. Tapio itself is neutral within this
prescriptive analytic software.
network and considers itself to be a supporter.
Right now, we are testing a new visual service
By being a partner of this platform from the
module which we are going to present at the
very beginning, among many other re-known
upcoming Ligna in May 2019.
At any time, the modular principle enables
ipcm®: Do you have any kind of
the implementation of changed framework
cooperation with foreign companies who
conditions by upgrading new modules, making your investment future-proof. ipcm : Today the keyword is Industry 4.0: ®
What is Venjakob’s strategy and approach? CN: Industry 4.0 is a living project at Venjakob for many years. With a huge team of programmers, Venjakob is able to face the future and its upcoming tasks.
88
Venjakob not only considers the environmental aspects in the design and development of environmentally friendly machines, but also in production and infrastructure, for the protection of the environment and employees.”
N. 54 - NOVEMBER/DECEMBER 2018 - international PAINT&COATING magazine
shares your values and technological strengths? CN: We have been developing cooperation’s globally with paint suppliers, manufactures of 2K mixing systems and painting equipment. Furthermore, we are in a very close contact with our global sales network, reflecting us their view on prospective customers’ needs and expectations.
© Frank Boston_Fotolia
Opening photo: Metal office furniture has long become more than mere functional products: filing cabinets, desks, lights and office chairs are increasingly becoming designer items.
INNOVATIONS: PRESENT&FUTURE
Mixed Powder Today: More Scratch-Resistant Specialist Coatings with Great Flow Properties Peter Christl IGP Pulvertechnik AG, Wil - Switzerland
A
peter.christl@igp-powder.com
fter the emergence and
blends of epoxy and polyester resins
colloquially also referred to as “mixed
establishment of duroplastic
would appear in the late 1960s, forming a
powder”, permitted the creation of
coating powders based on
new class of powder coatings called hybrid
powder coating formulations that would
epoxy resins at the beginning of the
powder coatings.
be more reactive and less prone to
1960s, it was not long until the first
For the first time, this coating system,
yellowing.
90
N. 54 - NOVEMBER/DECEMBER 2018 - international PAINT&COATING magazine
INNOVATIONS: PRESENT&FUTURE
These systems replace a hardener with
such as surface variety, resistance to
production of “white goods” to
a further resin component from the
mechanical and chemical influences
radiators, fences, lights, shelves, metal
polyester resin family in mixing ratios
and weather stability was well achieved
furniture and coatings for glass and
of epoxy to polyester resins from 50:50
with these polyester powders at an
ceramic flower pots.
to 30:70.
acceptable price.
This core positioning in mass markets
Reducing the usually rather yellowish
As a result of an amendment to the
with very high sales potentials
epoxy resins in the coating recipes also
labelling requirements for powder
consequently attracted a large
first enabled the creation of pure white
coatings containing TGIC, the situation
number of established and new
shades such as Signal White (RAL 9003)
changed slightly and successor products
powder coating manufacturers.
or Traffic White (RAL 9016).
with the same or at least similarly good
The competition characterised by
The Achilles’ heel of the epoxy systems,
properties could be found within a very
partly self-destructive price declines
i.e. their extremely poor resistance
short space of time.
that emerged after the saturation
to UV radiation from natural daylight,
phase both made these markets
could also be reduced by admixing
increasingly lose their attractiveness and gave hybrid powders the tainted
polyester resins. The only clear advantage of epoxy systems that remains in most cases is their higher resistance to chemicals such as acids and alkaline solutions and their barrier function for superior corrosion protection. However, the innovative class of hybrid powder coatings was soon overshadowed by another novelty, pure polyester powders, which could be interlinked with the newly developed hardener triglycidyl isocyanurate (TGIC).
After the emergence and establishment of duroplastic coating powders based on epoxy resins at the beginning of the 1960s, it was not long until the first blends of epoxy and polyester resins would appear in the late 1960s, forming a new class of powder coatings called hybrid powder coatings.”
reputation of being cheap products. Representatives of the powder coating industry could be accused of having created a pricing situation in which the large-scale production of these products serves the sole purpose of maximising the utilisation of their own production capacity and deterring competitors. From a business point of view, it seems that this field has reached the point of exhaustion, and from a technical point of view, no further
From the early 1970s onwards, such
innovative developments seem
systems enabled a breakthrough in segments such as façade applications,
Over time, hybrid powder coatings
to make sense in such a pricing
which by their very nature place high
thus positioned themselves in a very
environment.
demands on weather stability.
extensive range of applications across
But there was no reason to hide the
all areas of industrial production
Does this mean the end of “mixed
overall performance of these powder
of consumer and capital goods.
powders”? What options are there for
coatings either: the compromise
Applications extend from traditional
coating manufacturers to differentiate
between typical coating requirements
mechanical engineering and the mass
the performance of their products
© Lista Büromöbel
For the first time, this coating system, colloquially also referred to as “mixed powder”, permitted the creation of powder coating formulations that would be more reactive and less prone to yellowing.” from the competition? What package should manufacturers offer to place hybrid powder coatings in targeted applications where their performance has not been sufficient so far or where the needs of customers and users have not been met?
The flow properties of conventional powder coatings with a smooth finish are limited, resulting in characteristic powder coating surfaces which look like “orange peel skin”. A more scratchresistant variant of such surfaces has so far usually been associated with a visible deterioration of the already limited flow.”
There are several promising approaches addressing these issues, which have already been successfully
powder coatings with a smooth finish
implemented in products.
are limited, resulting in characteristic
These include the combination of
powder coating surfaces which look
surfaces with anti-graffiti properties,
like “orange peel skin”.
for instance, which permit the easy and
A more scratch-resistant variant
nearly residue-free removal of such
of such surfaces has so far usually
acts of vandalism.
been associated with a visible
Modern hybrid powder coatings
deterioration of the already limited
also offer exceptional resistance to
flow.
chemicals. Some of them even exceed
With the new silk matt product
the performance of pure epoxy
3902 from the proven
systems.
low-temperature series 39, IGP
Another additional benefit, namely the
now provides a solution which, with
functionalisation of powder coatings as antimicrobial surfaces, is primarily aimed at the medtech and ventilation technology market, but can also be implemented in the field of municipal
1
Figure 1: The highly resistant surface is recommended
for the high-quality furniture industry.
its unique combination of good flow characteristics and cross-linking temperatures of 10 minutes at 160°C combined with significantly improved scratch resistance, offers
furnishing or generally in areas where
a high degree of resistance to
there is a high level of public footfall.
scratching. Scratch resistance is assessed
At the peak of current research and development is the creation of highly scratch-resistant surfaces. The combination of hard-wearing and smooth surfaces in easy-to-process powder coatings perfects the close alliance between form and function. The flow properties of conventional
92
Representatives of the powder coating industry could be accused of having created a pricing situation in which the large-scale production of these products serves the sole purpose of maximising the utilisation of their own production capacity and deterring competitors.”
N. 54 - NOVEMBER/DECEMBER 2018 - international PAINT&COATING magazine
by means of the “Martindale” test method. During this test, an abrasive object with a defined weight is applied to the test surface and rubbed across the surface in cycles in accordance with standard DIN CEN/TS 16611 “Furniture
INNOVATIONS: PRESENT&FUTURE
Users of metal furniture expect them to be not just beautiful but also hard-wearing, a requirement which has so far seldom been met. With the new combination of flow and resistance, this need is now optimally met from a technical point of view, while at the same time processing is more efficient due to the low cross-linking temperatures.” – Assessment of the surface resistance to microscratching”. The impact is assessed both visually and especially by measuring the residual gloss, i.e. the difference between the level of gloss measured before and after the surface has been exposed to scratching. Compared to conventional powder coatings, but also compared to many liquid coatings, 3902 performs extraordinarily well in these tests. Residual gloss values after a stress test load of up to 70% attest that this surface is highly resistant and therefore of great utility to the consumer. With such a performance profile, this surface is recommended for the high-quality furniture industry (Fig. 1). Metal office furniture has long become more than mere functional products. Filing cabinets, desks, lights and office chairs are increasingly becoming designer items reflecting the style and taste of their users and adding to their well-being (ref. Opening photo). Users expect them to be not just beautiful but also hard-wearing, a requirement which has so far seldom been met. With the new combination of flow and resistance, this need is now optimally met from a technical point of view, while at the same time processing is more efficient due to the low cross-linking temperatures. This and other developments have the potential of taking “mixed powders” out of their dusty low-cost corners and actively sending them back into the ring to fight for high-quality coating systems.
+49 89 13928723
© ipcm ®
Opening photo: Steelpaint’s new extremely flexible coating line to powder paint large workpieces.
FOCUS ON TECHNOLOGY
Steelpaint: The Industrialisation of a Nanotechnology Pre-Treatment Process for Large-Sized Workpieces Treated in a Static Coating Plant Ilaria Paolomelo ipcm®
F
or almost twenty years now, we have
technical characteristics and advantages in
with an equipment that constantly
been reading articles and technical
terms of surface performance and above
provides the bars with fresh product, thus
reports about the application of
all corrosion resistance. We also know their
minimising consumption and maximising
nanotechnology-based surface conversion
best application methods: they are typically
the treatment quality and uniformity levels.
products for the pre-treatment of ferrous
sprayed, but they can also be applied by
However, we always read about applications
metal prior to coating. We know all their
immersion or, even better, by nebulisation
in continuous-flow plants and automatic
94
N. 54 - NOVEMBER/DECEMBER 2018 - international PAINT&COATING magazine
© ipcm ®
FOCUS ON TECHNOLOGY
Figure 1: Products intended for the building sector and treated by Steelpaint.
Thanks to the collaboration with DN Chemicals, the recently established company combining the experience of Dollmar and NoxorSokem in the pre-treatment sector, Steelpaint has industrialised a flexible pre-treatment cycle that includes a nanotechnology conversion phase, performed in a specially equipped static cleaning booth.”
tunnels in which the workpieces are hung
of the many coating contractors working for
“Thanks to my previous work experience,
onto equally automatic conveyors.
the building industry (Fig. 1). Steelpaint still
Steelpaint could design on its own a new
Nonetheless, in the last few months, we
focusses on the construction sector, but it
extremely flexible coating line to powder
have gotten to know Steelpaint Srl, a
decided to diversify its activity by opening
paint large workpieces weighing up to 4000
contractor specialising in the treatment of
up to other industrial sectors, especially
kg (ref. Opening photo),” states Steelpaint
heavy and large-sized carpentry parts with
heavy metal carpentry.
Technical Director Alessio Di Mattia.
1
a static plant. Thanks to its collaboration © ipcm ®
with DN Chemicals, the recently established company combining the experience of Dollmar and NoxorSokem in the pre-treatment sector, this firm has industrialised a flexible pre-treatment cycle that includes a nanotechnology conversion phase, performed in a specially equipped static cleaning booth. In the last two years, Steelpaint has established itself in the field of industrial coating and sand blasting of materials for the building and architecture sector. Located in Castellalto (TE), in Central Italy, it is a young company with nonetheless many years of experience in the field of contracting coating and sand blasting. Indeed, it inherited the know-how of a well-known company in the Abruzzo region, closed after the period of recession that hit the construction sector in particular, but also had an impact on some
2 1
Figure 2: The manual one-rail overhead conveyor enables to handle the workpieces through the four treatment booths composing the plant.
international PAINT&COATING magazine - NOVEMBER/DECEMBER 2018 - N. 54
95
© ipcm ®
The pre-treatment phase “Depending on the surface contamination degree, we assess if a workpiece can be sent directly to the chemical pre-treatment station or if it must undergo a mechanical pre-treatment phase in the sand blasting booth. After sand blasting, the part undergoes the chemical pre-treatment cycle, divided into two stages: spray degreasing, performed with a pressure washer, and an innovative surface conversion process, with the nebulisation of active chemicals on the component’s surface inside the dedicated booth (Fig. 3). A few years ago, in fact, we automated this phase by installing a 500-cubic metre industrial nebulisation booth, on whose
3 1
roof we have mounted a few nebulisation
“The plant consists of four opposing
pre-treatment phase and the oxidation
treatment booths devoted to sand
process developed by Steelpaint itself,
blasting, chemical pre-treatment,
allowing to obtain a particular COR-TEN
powder application, and
effect on steel without applying any
drying/polymerisation. The parts are
powder coating,” explains DN Chemicals
handled through a manual one-rail
Sales Manager André Bernasconi.
© ipcm ®
Figure 3: The chemical pre-treatment booth.
overhead conveyor: the operator moves the load bars in each of the treatment booths, depending on the finishing cycle required (Fig. 2).” “One of the cornerstones of our corporate philosophy is precisely production flexibility. A flexible and versatile production, in fact, enables us to perfectly meet the demands of a constantly changing market and the needs of our customers,” says Di Mattia. In order to offer high quality products and increasingly innovative services, the firm has always cooperated with reliable and forward-looking partners, including DN Chemicals. “We supply Steelpaint with the products needed for the different chemical treatments to which they subject their coated structural steel. These include, in particular, the
96
Steelpaint now has a complex but flexible pre-treatment process that includes numerous stages: manual alkaline degreasing and spray rinse, phospho-pickling product application, second rinse, and nebulisation of the nanotechnological product that doubles the corrosion resistance of our products. The cycle ends with a drying phase in a static oven that also acts as a powder polymerisation oven.”
N. 54 - NOVEMBER/DECEMBER 2018 - international PAINT&COATING magazine
4 1
Figure 4: Nebulisation bars have been mounted on the roof of the pre-treatment booth to apply Dollcoat SA 115 after the use of DOLLACID ZN 539.
© ipcm ®
FOCUS ON TECHNOLOGY
bars that apply the Dollcoat SA 115 product after the use of DOLLACID ZN 539 (Fig. 4),” says Di Mattia. DOLLACID ZN 539 is a specific phospho-pickling product for galvanised steel, with a detergent and deoxidising power. Dollcoat SA 115, on the other hand, is a nanotechnological chemical with excellent performance levels, which has obtained several quality certifications from important national institutes. If applied on steel, it guarantees as follows: • improved passivation of metal; • better adhesion of powder coatings; • excellent pre-treatment flexibility; • excellent thermal resistance; • excellent barrier effect against water and oxygen; • no drop effect on the treated workpiece; • high salt spray resistance (over 500 hours without the use of a primer).
5 1
Figure 5: The static oven devoted to the drying and polymerisation of the powder coating.
Application Pump with SIT technology Improve your coating line's automation and achieve a more uniform finishing quality
- Improve the productivity of the line and minimize powder consumption. - Minimize human errors and achieve a more constant application quality. - Design ideal application processes to achieve the best coatings even on the most complex parts. - Improve the working environment and protect the operators health - Implement a more effective and professional management of your powder coating line
Gema Europe Srl | Via Goldoni, 29 Via Carlo Goldoni 29 | 20090 Trezzano Sul Naviglio (MI) | ITALY | T. +39 02 48 400 486 | F. +39 02 48 400 874
Industry 4.0 Ready
www.gemapowdercoating.com
© ipcm ®
It requires the operator to have special skills and be able to control the oxidation process and not to stop the chemical reaction too early or too late. Also in this case, we decided to rely on the experience of DN Chemicals,” says Alessio di Mattia. “In order to obtain a COR-TEN finish, we use acidic chemicals that are usually designed for other surface treatments, such as the pre-treatment of aluminium. In this way, we can oxidise steel thus obtaining the desired aesthetic effect, although this is a ‘non-standard’ application.”
Future projects “In order to show our commitment to high quality and perfectly meet the
6 1
needs of our customers, we intend to
Figure 6: The powders are applied with the dense phase technology through a Gema manual pump.
further expand our surface treatment range. The expansion of our paintshop is certainly among our future projects. In order to be even more competitive, we are planning to install a new liquid
“We now have a complex but flexible pre-treatment process that includes numerous stages: manual alkaline degreasing and spray
coating line. Finally, a few months ago, we started using Plascoat thermoplastic powder coatings, guaranteeing excellent results in terms of both quality, as they ensure greater paint yield, and resistance.”
© Steelpaint
In order to obtain a COR-TEN finish, Steelpaint uses acidic chemicals that are usually designed for other surface treatments, such as the pre-treatment of aluminium. In this way, they can oxidise steel thus obtaining the desired aesthetic effect, although this is a ‘non-standard’ application.”
rinse, phospho-pickling product application, second rinse, and nebulisation of the nanotechnological product that doubles the corrosion resistance of our products. The cycle ends with a drying phase in a static oven that also acts as a powder polymerisation oven (Fig. 5),” says Di Mattia. After pre-treatment, the components enter the static booth devoted to coating. The powder coating products, supplied almost entirely by Europolveri, are applied with the dense phase technology through a Gema manual pump (Fig. 6).
A chemical treatment producing a COR-TEN effect: a Steelpaint specialty “We have recently added the COR-TEN effect (Fig. 7) to the range of surface treatments that we offer to our clients. Creating the oxidised appearance typical of weathering steel without applying powder coatings but rather through a chemical reaction is not easy.
98
N. 54 - NOVEMBER/DECEMBER 2018 - international PAINT&COATING magazine
7 1
Figure 7: The COR-TEN finish created by Steelpaint using DN Chemicals products.
WASHING
COATING
IMPREGNATION
Passion is our engine. For over 60 years, we have come a long way. Our mission has always been reaching new horizons in industrial washing, coating and impregnation. It was a call of innovation that has led us to an outstanding achievement: to become the appreciated partner of the most important companies in the automotive market. For us, it is the recognition of our ability to offer solutions and to respond in the shortest time to constantly accelerating customers’demands. For our clients, making choice of our plants has guaranteed reaching their best performance over all type of surfaces, for all their products. All around the world.
TECNOFIRMA S.p.A. - Viale Elvezia, 35 - 20900 Monza (MB) Italy - Phone +39 039 236 01 - Fax +39 039 324 283 - www.tecnofirma.com - tecnofirma@tecnofirma.com - Company Certified ISO 9001 since 1992
BRAND-NEW
GRT Superior Series
G
RT srl (Modena, Italy) is a company
recovered powder. It is equipped with
weighing system to monitor and store
specialising in the design,
an integrated sieving system in its base,
powder consumption data. In fact, a load
production, and installation of
easily opened to facilitate cleaning
cell positioned directly beneath the powder
automatic booths and powder coating
and inspection. The new GRT powder
pack enables to control and register the
systems. In a market where it is difficult
management system called “Tidy Center”
powder consumption data for each batch.
to emerge, GRT focuses exclusively
is the ideal solution to perform quick
By connecting the GRT powder management
on the high quality and reliability of its
colour change operations without any
unit to its company network, a customer
products. All the components of its plants
coating leakage. Indeed, thanks to the
can monitor this figure along with various
are produced with the use of the most
dense phase transfer pumps, the paints
other processing data, such as the conveyor
modern equipment and following strict
are automatically, directly sent from their
operating and idle times, the amount and
quality and safety procedures, and they
pack to the airtight container both at
time of colour change operations, and so
are guaranteed and certified according
the beginning and during the coating,
on. All these data are directly sent to the
to the EC Directive and ATEX Directive
thus creating an optimal mix of fresh
company management system, helping to
2014/34/EU.
and recovered powder. A second dense
keep the costs of each coated batch under
The Superior series booth, installed by
phase pump handles the recovery and
control.
several leading companies in the field of
transport of the used powder directly
powder coating, is completely automatic
from the cyclone to the work container.
For further information:
and it represents GRT’s top of the range
Finally, the plant is equipped with a
www.grtsrl.com
required to guarantee compliance with ATEX regulations for fire safety and
© GRT
system. It is equipped with all the devices
prevention (Fig. 1). The new booth installed by Eredi Piana di Piana Carlo & C. (Martinengo, Bergamo) belongs to the Superior series and it includes all the devices required for compliance with the ATEX regulations for fire safety and prevention. Built completely in PVC and with a capacity of 20,000 m³, it is made according to the most modern and advanced standards and it is completely automatic. The automation system includes two reciprocators with motorised bases and three guns each, as well as optical bars for shape recognition that automatically control the positioning of axes and the switching on and off of guns as the workpieces passes through. The GRT Superior series cyclone with a dense phase recovery pump guarantees high recovery efficiency and it is equipped with a recirculation system for the
100
1
Figure 1: The Superior series booth by GRT is completely automatic and equipped with all the devices required to guarantee compliance with ATEX regulations for fire safety and prevention.
N. 54 - NOVEMBER/DECEMBER 2018 - international PAINT&COATING magazine
BRAND-NEW
The New Kawasaki 2019 Ninja H2 Will Feature a “Self-healing Paint”
K
PAINTING ROBOTS & SYSTEM INTEGRATOR We are able to provide the full range of articulated and cartesian robots for every painting need! LeBot MV A5-A6: 5 and 6 axis articulated robot with self-learning, point to point and 3D offline programming, also available in chariot, carriage and carousel configuration with 3D Lesta shape acquisition system.
awasaki’s new highly durable paint features a special coat that allows scratches to repair themselves, enabling the paint to maintain its high-quality finish.
Kawasaki is the first motorcycle manufacturer offering self-healing paint from the factory. The company hasn’t revealed how its proprietary system works but has stated on its website:b“Soft and hard segments in the coat work together like a chemical spring, creating a trampoline effect that absorbs impacts”.
LeBot C5: 5 axis cartesian robot with 3D Lesta shape acquisition system. acqui ystem.
Even though it’ll be a few years before we know how Kawasaki’s formulation holds up, the motorcycle manufacturer already pointed out some limitations of this self-healing paint. “In some cases, it takes about one week for recovery. The paint will not recover in the case of scratches caused by a coin or key, or zip fasteners”, stated Kawasaki. For further information:
© Kawasaki
www.kawasaki.com
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.
WWW.LESTA.IT
1
Figure 1: The new Kawasaki Ninja H2 features a special coat that allows scratches to repair themselves, enabling the paint to maintain its high-quality finish.
LESTA S.r.l.
Via D. Chiesa, 42 - 20020 Dairago (MI) - Italy +39 0331.430817 +39 0331.1581053 0331.158 info@lesta.it
© ipcm ®
102
N. 54 - NOVEMBER/DECEMBER 2018 - international PAINT&COATING magazine
FOCUS ON TECHNOLOGY
In the Portuguese Bike Valley, a Cutting-Edge Coating Plant Brings Automotive Technology and Quality to the Service of the Bicycle Industry Barbara Pennati ipcm®
B
ikes are one of the most widespread
that has brought together different firms
For its cutting-edge project, it chose
means of transport in the world. Their
specialising in the production of cycles and
Solintellysys (Águeda, Portugal), specialising
history dates back to three centuries
motorcycles for over ninety years. This is in fact
in the design and production of surface
ago: people have been using them for their
a joint venture among three bicycle component
treatment and coating plants (Fig. 1), as its
daily activities since 1818, when the first 13
manufacturers: Rodi, Miranda, and Ciclo-Fapril.
technological partner. © ipcm ®
kilometres were travelled by the world of sport and
Extreme process flexibility
by many movies and now a
The production area
part of the national identity
of Triangle’s covers
of several countries,
about 20,000 m²,
bikes are a symbol of
where fully automated
freedom, simplicity, and
hydroforming,
slow rhythms, as well as
robotic welding, heat
the response adopted by
treatment, superficial
many nations to address
preparation, coating,
on two wheels. Celebrated
environmental issues. Artisanship has been central to the long and peculiar history of this means of transport, but
and decal processes
1
are performed on
Figure 1: A bird’s eye view of the paint application station of the brand new system installed by Solintellysys.
nonetheless it has gone
aluminium frames for high-end bicycles. For this project, Solintellysys designed
hand in hand with the technological evolution
a complete surface treatment line, including
that has always distinguished it. Triangle’s –
the T6 heat treatment furnaces – this is a
Cycling Equipments SA has embraced these values by combining tradition and innovation: indeed, it has recently inaugurated the first completely automated system in the world for the production of aluminium bicycle frames (ref. Opening photo). The company was established in 2015 in Águeda (Portugal), in the renowned Bike Valley – an industrial area
Triangle’s – Cycling Equipments SA has recently inaugurated the first completely automated system in the world for the production of aluminium bicycle frames by combining tradition and innovation.”
fundamental phase in the frame hardening process, i.e. the last production phase before surface preparation prior to finishing (Fig. 2). One of the most technologically advanced aspects of the project was the integration of all the coating and decoration phases into a clean room, which allows to completely insulate the process from
Opening photo: Cycling Equipments SA produces aluminium frames for high-end bicycles.
international PAINT&COATING magazine - NOVEMBER/DECEMBER 2018 - N. 54
103
© ipcm ®
Solintellysys designed a complete surface treatment line, including the T6 heat treatment furnaces – this is a fundamental phase in the frame hardening process, i.e. the last production phase before surface preparation prior to finishing.”
This layout gives Triangle’s full production flexibility. In fact, not all workpieces undergo the same
2 1
production process: some frames
Figure 2: The furnaces for the heat treatment of frames before the finishing phase.
are subjects to (mechanical or chemical) pre-treatment and then they are stored; others immediately
any external contamination and thus
into two zones: the chemical pre-treatment
reach the coating department,”
station and the clean room where coating is
explains Solintellysys Ibérica Sales
performed. Each surface treatment station
Manager Luís Rodrigues (Fig. 4).
plant that was arranged in two buildings:
is linked to a separate one-rail conveyor – 4
After hydroforming and welding, all the
some machines were installed in the
circuits in total, designed and installed by
frames undergo a T6 heat treatment,
robotic welding department, the others in
Futura Convogliatori Aerei (Robecco Pavese,
which takes place in 4 furnaces that
the actual paintshop. This, in turn, is divided
Italy).
can be activated as needed, to increase
© ipcm ®
guarantee premium-quality coatings (Fig. 3). “We supplied a very complex treatment
3 1
Figure 3: Chemical pre-treatment, coating, and final decoration are performed in an insulated, air-conditioned, fully dust-free area.
104
N. 54 - NOVEMBER/DECEMBER 2018 - international PAINT&COATING magazine
FOCUS ON TECHNOLOGY
One of the most technologically advanced aspects of the project was the integration of all the coating and decoration phases into a clean room, which allows to completely insulate the process from any external contamination and thus guarantee premium-quality coatings.” © ipcm ®
AUTOMATIC POWDER COATING BOOTHS
4 1
Figure 4: From left to right: Sara Candeias (Solintellysys), Alessia Venturi (ipcm), Luís Rodrigues (Solintellysys), Luis Pedro (Ibérica Sales Manager at Triangle’s), and Catarina Pinheiro (Solintellysys).
their hardness and resistance. Then they may be subjected to mechanical deoxidation through a shotblasting process using stainless steel abrasive (Fig. 5) or they may directly reach the multi-metal chemical pre-treatment station, ensuring a salt spray resistance value of 1,200 hours. Each of the two process is linked to a dedicated one-rail conveyor. The loading and unloading stations of the pre-treatment tunnel are located in the welding
This layout gives Triangle’s full production flexibility. In fact, not all workpieces undergo the same production process: some frames are subjects to (mechanical or chemical) pre-treatment and then they are stored; others immediately reach the coating department.”
department (Fig. 6), whereas the actual tunnel constitutes the first operational area of the paintshop (Fig. 7). Chemetall provides the pre-treatment chemicals. The cycle includes 6 stages as follows:
G RT
© ipcm ®
© ipcm ®
5 1
6 1
Figure 5: The shotblasting plant.
Figure 6: The loading station.
Tailor-made, advanced technology
“In order to ensure optimal air
cleaning with demineralised water, acid conversion, and cleaning with
At the end of the chemical pre-treatment
contamination, the paintshop was
demineralised water. “The tunnel is
process, the bicycle frames can proceed
created inside a pressurised clean
equipped with automatic controls
on the same circuit and return to the
room with controlled humidity and
that enable to monitor the process
welding department to be stored or they
temperature,” states Rodrigues. “The
steps and tank levels. The different
can be unloaded, arranged on special
coating process includes the wet-on-
pre-treatment stages are activated
trolleys, and enter the clean room to be
wet application of a primer, a base coat,
progressively, as the workpiece
coated and decorated (Fig. 8).
and a clear coat, with a 15-minute flash-
2 rinses, cleaning with mains water,
quality and total absence of external
passes. This ensures optimal energy on the specifications, the products undergo a mechanical or chemical
© ipcm ®
savings,” says Rodrigues. Depending
pre-treatment process, or both.
The coating process includes the wet-on-wet application of a primer, a base coat, and a clear coat, with a 15-minute flashoff between each stage. All the coating stages are robotised and they are each performed in a dedicated booth. Only the base coat booth is equipped with a manual post-retouching station.”
7 1
Figure 7: The pre-treatment tunnel in the dust-free area.
106
N. 54 - NOVEMBER/DECEMBER 2018 - international PAINT&COATING magazine
off between each stage. All the coating
© ipcm ®
FOCUS ON TECHNOLOGY
used in the automotive sector,
stages are robotised and they are each
in order to guarantee superior
performed in a dedicated booth.
quality. This is an evolution of the
Only the base coat booth is equipped
ready2_spray robot, developed by
with a manual post-retouching station
KUKA and Dürr’s joint venture (Fig.
(Fig. 9).”
12), ideal for industrial applications
“The coating and curing station is linked
where a very high coating quality is
to the third one-rail conveyor. Each
required,” explains Luís Rodrigues.
booth has its own coating management
“Actually, the standard dimensions
unit. A neutral area among the three
of ready2_spray were not suited
booths avoids paint contamination
to the requirements of Triangle’s,
as the component passes from one
which needed a larger robot.
application station to another, thanks
Therefore, Solintellysys developed
to the air pressurisation differential,”
the communication protocol that
says Rodrigues (Fig. 10).
enabled to integrate a bigger KUKA
The coating application is completely
robot with the EcoBell 2 atomiser
automated with the use of KUKA
(Fig. 13).”
robots equipped with Dürr EcoBell 2 atomisers (Fig. 11). “For this project, we opted for a technology and an application process that are usually
“After coating, the frames enter a
8 1
special curing oven with 2 plenum
Figure 8: Frames placed on trolleys, ready to be coated.
chambers for the insufflation of air from below and a top suction system.
FISMET SERVICE S.r.l.
© ipcm ®
This system helps to maintain
without sacrificing production
a uniform temperature, and
versatility.
therefore a consistent curing
“Aluminium welding could seem a
quality level,” says Rodrigues (Fig.
simple process, but several pitfalls
14). The last phase of the surface
may actually affect its final result.
finishing process is the manual
One of the most critical aspects
application of decorative decals:
is the need to perfectly weld the
this is done again in the clean
various components of a frame: if
room, with the frames hung on a
this is not done perfectly, there is
special conveyor (Fig. 15).
a high risk that the frame collapses due to the infiltration of corrosion.
A combination of technological progress and territorial development
Triangle’s has managed to master this skill and it is now among the leading experts in the field”, explains Luís Rodrigues. “It was
The project of Triangle’s to
therefore necessary to develop an
automate its production of
automatic process that guaranteed
bicycle aluminium frames fits into
the same care and attention to
the context of Portugal 2020, a cooperation agreement between Portugal and the European Commission for the granting
detail of a craft process. This is
9 1
also one of the reasons why the
Figure 9: The manual retouching station.
human factor remains crucial even in automated processes: it
of funds to promote economic,
guarantees more accurate controls
social, and territorial development.
and higher final quality.”
Started in June 2015 and ended in May 2017, this futuristic project required a total investment of more than 14 million Euros. The goal was to fully automate a mostly manual process and to reach a quality level equal to
“Solintellysys’ expertise is highly varied and stems from our direct experiences in the most diverse industrial sectors. Thanks to the knowledge acquired, we have been able to develop together with Triangle’s a system that enabled the company to achieve
© ipcm ®
© ipcm ®
that of the automotive industry,
For this project, Triangle’s opted for a technology and an application process that are usually used in the automotive sector, in order to guarantee superior quality. This is an evolution of the ready2_spray robot, developed by KUKA and Dürr’s joint venture.”
11 1
10 1
Figure 10: One of the coating management units.
108
N. 54 - NOVEMBER/DECEMBER 2018 - international PAINT&COATING magazine
Figure 11: The base coat application booth with two KUKA robots.
© ipcm ®
FOCUS ON TECHNOLOGY
FATI
srl
CATENE PER TRASPORTATORI CUSCINETTI A SFERA
CATENE AD ALTE PRESTAZIONI HIGH PERFORMANCE CHAINS LEISTUNGSFÄHIGE KETTEN
NOVITÀ NEW NEUHEIT
HPCOAT
12 1
Figure 12: All the automatic booths are equipped with KUKA robots and Dürr atomisers.
MORE
con | with | mit HPCOAT
13 1
Figure 13: Dürr EcoBell 2 atomiser.
A tt dopo Aspetto d 200 2 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
© ipcm ®
Particolare dei cuscinetti con HPCOAT Detail of bearing with HPCOAT Ausschnitt der Lager mit HPCOAT
Via C. Porta, 14 | 23861 Cesana B.za (LC) | Italy t. +39 031 655688 | f. +39 031 656772 info@fatisrl.com | www.fatisrl.com
© ipcm ®
The layout of the plant was also developed to ensure energy efficiency and maximum flexibility: with a simple control panel, the operators can define the route of each frame and the process phases to be activated based on customer specifications and needs.”
14 1
Figure 14: The interior of the curing oven.
each frame and the process phases to be
exporters of bikes, confirming the role
levels. The layout of the plant was also
activated based on customer specifications
of Portugal as a centre of technological
developed to ensure energy efficiency and
and needs,” says Rodrigues. These factors
excellence in the sector, as well as
maximum flexibility: with a simple control
have contributed to make Triangle’s and its
the third bicycle producing country in
panel, the operators can define the route of
partners some of the major producers and
Europe.
© ipcm ®
optimal quality as well as customisation
Aluminium welding could seem a simple process, but several pitfalls may actually affect its final result. One of the most critical aspects is the need to perfectly weld the various components of a frame: if this is not done perfectly, there is a high risk that the frame collapses due to the infiltration of corrosion. Triangle’s has managed to master this skill and it is now among the leading experts in the field.”
110
15 1
Figure 15: Also the final decoration of the frames is carried out in the clean room.
N. 54 - NOVEMBER/DECEMBER 2018 - international PAINT&COATING magazine
INTERNATIONAL PATENT
NITROROBOT Eurosider, a company with vast experience of using various fluid carriers for liquid painting, has developed a new system to produce a high density carrier in order to obtain better atomization which brings the advantages listed below. Nitrorobot can keep all day long the same settings and guarantee the best working conditions, independently from the conditions of the environment. The equipment, in Touch Screen version, is provided with the system of control of various settings, possible to monitor from any coating system control panel. Ideal application for Nitrorobot is on automatic coating systems with rotary bells, or it can be applied on conventional pneumatic guns, HVLP or electrostatic guns.
NITROTHERM The performance is reffered to fluid enriched in nitrogen with concentration of 93% ¹ 1%, at environment temperature of 20 °C and atmospheric pressure of 1013 mbar. Inlet compressed air must be free from impurities (water, oil, solid particles). We advise to use filter elements supplied by Eurosider. All the data and images are merely approximate and can be changed; the performance vary in accordance with environment and working process pressure and temperature. Eurosider reserves a right to make modifications, even without advanced notice.
EUROSIDER Piazzale Thailandia 6 | 58100 GROSSETO | ITALY ph. +39 0564 425117 | fax +39 0564 418833 www.eurosider.com | info@eurosider.com
© HangOn
112
N. 54 - NOVEMBER/DECEMBER 2018 - international PAINT&COATING magazine
INNOVATIONS: PRESENT&FUTURE
Times and Methods in Production Processes Adriano Antonelli Ibix Srl, Santa Maria in Fabriago (Ravenna) – Italy
A
adriano.antonelli@tecnosupply.com
that is recognisable and appreciated
fter several consecutive quarters with GDP steadily growing in the Eurozone and in Italy, in the
last few months the market has become stagnant again. There were many factors: American duties, which curb direct and indirect exports to the US; the Brexit deal, whose conditions and the economic effects have not been clarified, yet; widespread political instability; and the global economic slowdown. Unfortunately, some economic policies, such as US duties, severely penalise the countries with a vocation for export, Italy included. Once
Unfortunately, some economic policies, such as US duties, severely penalise the countries with a vocation for export, Italy included. Once again, therefore, innovative strategies are needed to be competitive and it is necessary to create new opportunities to expand and spread one’s own products.”
again, therefore, innovative strategies are it is necessary to create new opportunities to expand and
fair, the important event dedicated to agricultural machinery, was an important showcase. Its international level always ensures an exposure degree that can help boost the sales of the exhibiting companies. For the visitors of this trade fair, one of the first factors assessed by coating professionals is the attention paid to each component of machines. Their technological level is indeed enhanced by their design, and shapes and finishes are comparable to those of luxury car bodies. In this article, we will deal with why the quality level of surface
© HangOn
needed to be competitive and
internationally. That is why the EIMA trade
treatment, performed not only for aesthetic but
spread one’s own products. A
above all for corrosion
sound national economic system
resistance reasons, must
and, above all, the possibility
necessarily match with
to network thus become the
the effectiveness of the
minimum and necessary
industrial coating process.
prerequisites for penetrating
Let us now focus on the
distant and complex markets.
protection of parts that do
At the same time, an increase in
not need to be painted.
shares in international markets
This is an important
is the key to increasing domestic
operation, in order not to
demand, which remains weak.
jeopardise the efficiency
In Italy, some industries have
of subsequent processes,
reached excellence levels
such as assembly – an
recognised all over the world.
assembly line cannot be
In these sectors, technology, design, and mechanics merge to create a product
1
Figure 1: Masks for blind holes.
stopped because of a pin that does not screw in easily. Workpieces must
Opening photo: Many ready-to-use products from the Hang-On range have guaranteed the achievement of production goals in terms of time and methods, of management of the masking devices before and after use, and therefore of results.
international PAINT&COATING magazine - NOVEMBER/DECEMBER 2018 - N. 54
113
© HangOn
The possibility of visually distinguishing and selecting them is therefore of the essence. Another important aspect is pre-treatment, because some masks must be applied before this phase. In the case of sand blasting or shot blasting processes, they must be scratch resistant and able to prevent the media to enter the holes and cavities of the treated product; if this happens, these particles become a non-conformity for the coated workpiece. Other times, such as with phosphodegreasing, masks must be waterproof: otherwise, functional parts of the machine could be damaged. Finally, many components in this sector are treated with a cataphoresis process to guarantee corrosion protection: in this case, the use of watertight masks is essential. Many ready-to-use products from the Hang-On range have guaranteed the achievement of production goals in terms of time
© HangOn
and methods, of management of the masking devices before and
2 1
Figure 2: The GAP caps protect pins up to 50 mm and with variable lengths.
therefore exit the coating department in optimal conditions. For this to be possible, they must be carefully protected everywhere needed. For this purpose, masking speed, “infiltration” prevention, ease in the protection insertion, and the possibility to remove the component and recover the device for later use are key factors. Sometimes, one component may require the insertion of 50-60 masking devices, some of which are similar to each other.
Workpieces must therefore exit the coating department in optimal conditions. For this to be possible, they must be carefully protected everywhere needed. For this purpose, masking speed, “infiltration” prevention, ease in the protection insertion, and the possibility to remove the component and recover the device for later use are key factors.”
114
N. 54 - NOVEMBER/DECEMBER 2018 - international PAINT&COATING magazine
3 1
Figure 3: Magnetic silicone has the power to attach itself to ferrous material.
INNOVATIONS: PRESENT&FUTURE
Paint stripping Many ready-to-use products from the Hang-On range have guaranteed the achievement of production goals in terms of time and methods, of management of the masking devices before and after use, and therefore of results.” after use, and therefore of results (ref.
mask without air resistance. The GAQ caps,
Opening photo). The silicone range is
thanks to their particular configuration,
certainly among these high performance
significantly reduce the time required for this
products. The masks are coloured, and the
operation.
shade is guaranteed for each lot. The M4
In general, HangOn (distributed by Ibix) can
size of each configuration is white, so that
produce specially moulded products for any
the operator can recognise it easily and
out-of-standard request. By taking problems,
quickly. Colours can however be changed
tolerances, frictions, treatment processes,
and customised, in order to match a specific
etc. into consideration, it can design and
product with a given tint. Here below, you
manufacture products for any special need.
will find a few examples of these devices.
However, in the field of agricultural and earth
The GDM caps allow a through hole to be
moving machinery, components present many
sealed hermetically: the cylinder terminal
areas to be masked that have completely
part perfectly matches the countersunk
different characteristics, so that each type
shape of nuts. Currently, GDM caps up to
of mask is required in very small amounts.
83 mm are available. These caps are hollow
Producing a mould for each of them would
to allow easier insertion.
be excessively expensive. A quicker and
The QB caps are screwed caps for blind
more flexible solution that does not request
holes, i.e. parts where depth is minimal
minimum quantities are assembled masks.
and where it is necessary to close the hole
These also enable to mix different material,
hermetically and guarantee the mask stays
thus creating masks that are firm on the
still even during the movement of the
outside and soft on the inside. The materials
component (Fig. 1).
that can be employed are as follows:
With bushings and large through holes, good
• solid silicone, 1 to 6 mm. Solid silicone has
results have been obtained with expanded
the same characteristics as the silicone (caps
silicone. The SP expanded silicone tube,
and tops) used in coating plants. These
which can be cut to size, expands into the
sheets can be die-cut to size. They can be
hole creating a mask that prevents any
glued on top of one another to increase
shading and build up effects. The maximum
thickness. Extraction handles can be applied.
diameter is 60 mm.
The material can be cleaned like a conical
Again with large holes, the GBH cap masks
cap.
holes up to 110 mm.
… and always close to you
Worldwide leading and innovative technologies
guarantee the best solutions for our customers around the globe. PaintExpo 17. - 20. April 2018 Halle 2, Stand 2512
• Expanded silicone, 2 to 20 mm. The
With large-sized through holes, the
material looks like a sponge. It has a silicone
cylindrical GDM H caps are suitable for
nature, and therefore it is resistant to high
lengths up to 83 mm. They enable to mask
temperatures and it can be cleaned. Its
the components appropriately and above all
softness allows to insert the cap easily and
to protect the holes during sand blasting.
ensures efficient grip. If needed, it can be
As regards pins, we offer a few out-of- standard
glued to solid silicone.
caps, such as the GAP and GAQ ones,
worldwide
• EPDM, 1 to 6 mm. This material is hard and
protecting pins up to 50 mm and with variable
resistant to the abrasion of mechanical
lengths (Fig. 2). The GAP caps feature a
pre-treatments. It is resistant to a maximum
ventilation valve to insert and remove the
temperature of 170 °C.
info @ abl-technic.de www.abl-technic.de ABL-Germany | ABL-Austria ABL-France | ABL-Italy ABL-Turkey | ABL-Czechoslovakia ABL-Poland | ABL-Slovakia ABL-Hungary | ABL-Portugal ABL-USA
© HangOn
• Magnetic silicone, 1 to 2 mm. It has a magnetic
technical departments designs some
power that allows it to
alternatives and
attach to ferrous materials
then prototypes are
(Fig. 3). This prevents
provided to check
continuous disposal of tape.
protection coverage
It is resistant to a maximum
and efficiency.
temperature of 250 °C,
Properly arranging
it can be easily cleaned,
a mask ensures that
and it can be glued to the
there are no errors
materials mentioned above.
and exposed parts.
• MDF. Compared with the
The cost of the initial
other materials, this has
investment, obviously
a few limitations. It can
higher than that of
be inserted before the
polyester tape for
chemical pre-treatment
powders or crepe
phase, but not the
paper for liquids, is
mechanical one, because it
entirely amortised, also
impregnates with water. It
considering the ease of
is less flexible and therefore
removal at the end of
more difficult to clean.
the process.
However, it is cheaper and it
This also minimises any
is resistant up to 200 °C,
potential interpretation
and therefore it can
errors by the operator,
also be used for powder
who may mask some
applications.
wrong areas.
• Cork, 2 to 25 mm. Compressed cork is an
The flexibility of
economic material designed
these masks lies
for liquid applications
above all in quantity.
(Fig. 4). It is resistant up to 150 °C and it can be glued to other materials. In this type of masks, magnets can be added to improve
Without minimum
4 1
quantities, HangOn/
Figure 4: Compressed cork is an economic material designed for liquid applications. It is resistant up to 150 °C and it can be glued to other materials.
Tecno Supply can produce exactly the number of items you need. Should
stability and grip. It is also starting from the workpiece to be
your technical department change some
protected, the acceptable tolerance
workpiece dimensions, a new mask
The wide range of materials and possibilities
rates, the hanging method, the required
could be produced, since there are no
offered enables to always obtain the
masking easiness, the classification
fixed costs. Even in the event of damage
right mask depending on the times and
method, the durability required, the
or wear of some items, they could be
production methods. Masks are designed
budget, etc. The HangOn/Tecno Supply
replaced without any additional cost.
possible to add caps for better grip.
In the field of agricultural and earth moving machinery, components present many areas to be masked that have completely different characteristics, so that each type of mask is required in very small amounts. Producing a mould for each of them would be excessively expensive. A quicker and more flexible solution that does not request minimum quantities are assembled masks.
116
N. 54 - NOVEMBER/DECEMBER 2018 - international PAINT&COATING magazine
sataluminium.com SAT (Surface Aluminium Technologies) S.p.A. | Via Antonio Meucci, 4 | 37135 Verona | Italy | ph +39 045 8280601 | info@sataluminium.com
SUCCESS STORIES
Dürr Builds a Highly Automated Paint Shop with Integrated IIoT Solutions for VinFast
S
tart-ups from outside the automotive
achieve this ambitious investment objective
costs, not least since it only needs two
sector are entering the automotive
in the area of the paint shop, VinFast
levels and no so-called penthouse. The
market more and more frequently.
commissioned Dürr to handle this project.
compact design enabled the concreted
VinFast is a subsidiary of VinGroup and is the
“Our paint shop will be the biggest in Vietnam,
area to be reduced by approx. 15,000 m2.
first volume automotive manufacturer from
and highly automated through the integration
This corresponds to a saving of more
Vietnam with a particular ambition: a smart
of numerous IIoT applications. This makes
than 20% compared with a conventional
factory where 250,000 cars per year in the
it the benchmark for outstanding quality
concept.
first phase, initially with conventional drives
combined with the lowest operating costs, the
VinFast’s requirement of maximum
and in the future also with electric drives, will
highest ecological standards, and a high level of
automation of production processes
roll off the production line. The paint shop
occupational safety,” explains James Deluca,
and logistics is met with IIoT-capable
in the factory in Haiphong, that has been
CEO of VinFast Trading and Production Company.
machines from end to end. They are
is currently being installed by Dürr.
comprehensively controlled,
© Dürr
ordered in the first quarter of 2018,
monitored, and supervised
It is highly automated and features
in real time using control
integrated Industrial Internet of
technology from Dürr. This
Things (IIoT) technology. In addition,
makes it possible to test
an innovative layout concept permits
and optimize the overall
a building design that dramatically
equipment efficiency (OEE), for
reduces the space required and
example.
costs involved. the largest non-state owned listed
Flexible technology for future targets
company in Vietnam with a market
Just how precisely the paint
capitalization of approximately
shop technology meets the
VND 340 trillion (USD 14.6 billion)
requirements of VinFast while
as of July 31, 2018. The strategy of
remaining flexible for changes
VinFast is a start-up of the VinGroup,
VinGroup is to become the leading Vietnam and the region. The VinFast brand is the Group’s first foray into the mobility market, which offers
in the future is demonstrated
1
technology-industry company in
by the oven. ThebEcoInCure
Figure 1: The EcoInCure oven achieves the best possible quality when it comes to the top coat appearance thanks to its heating process from the inside out and optimized air flow.
enormous growth potential due to
oven achieves the best possible quality when it comes to the top coat appearance thanks to its heating process from the
Southeast Asia.
Patented layout concept for a lean building
Each body gets a digital quality certificate
VinFast intends to establish itself with various
The VinGroup constructed the building for
for the drying process. The data from
models delivering best-in-class quality and
the paint shop based on the patented layout
the IIoT-capable oven is collected and
produced in a factory equipped with
concept developed by Dürr in a record time
evaluated by the control technology for
state-of-the-art technology that enables
of just short of eight months. The layout
this. In addition,bEcoInCure’s innovative,
transparent, lean processes. In order to
minimizes the investment and operating
space-saving transverse mode of operation
the strong increase in demand for vehicles in
118
N. 54 - NOVEMBER/DECEMBER 2018 - international PAINT&COATING magazine
inside out and optimized air flow (Fig. 1).
SUCCESS STORIES
in combination with a central high-bay
range of sensors, they are prepared for
because the smaller tank capacity
warehouse makes it ideal for the compact
the requirements of an Industry 4.0
means that RoDip速 uses less energy,
building concept.
environment. The robots supply
less water, and fewer chemicals than
The principle of heating from the inside
real-time data that is analyzed and
other technical solutions.
is particularly beneficial for bodies with
evaluated using the latest software
different material thicknesses (a perfect
products from D端rr.
dry paint overspray separation is a
example is electric vehicles with their
In addition to the EcoInCure
multi-stage, easy-to-handle filter system
reinforced frame on the underbody).
innovations and seven-axis robots
that comprises filter trolleys with six
The innovative EcoInCure drying method
described, D端rr will also be installing
filter boxes each and downstream
significantly reduces thermal component
further technical highlights in the
pocket filters as the second filter stage.
stresses compared with conventional
VinFast paint shop:
The semi-automatic separation system
ovens. VinFast is therefore well prepared
- RoDip rotational dip process:
sets the standard for high separation
速
- EcoDry X dry separation: EcoDry X for
technically for the future expansion of the
the efficient RoDip rotational dip
model range to include electric vehicles.
process will be used at VinFast
With all of these state-of-the-art
The new VinFast paint shop will also be
throughout the PT/EC (pre-treatment
technologies, the new paint shop for
equipped with the latest generation of
and electro coating) area. The
VinFast is geared towards the strategic
the fully automaticbEcopaintbrobot. This
rotational movement of the bodies
goals of the start-up: highest quality
includes the extremely mobile painting
does away with the need for entry
standards at the lowest operating costs,
robots with seven-axis kinematics, which
and exit inclines at the immersion
low environmental impact, and high
do not need a rail. This saves space and
tank, thereby making the tanks more
health protection and occupational safety
investment costs. Equipped with a whole
compact. This reduces the unit costs,
with high future security.
capacity and low filter costs.
The Millennium Event The Aluspecialists’ Meeting
11th ALUMINIUM TWO THOUSAND WORLD CONGRESS BHR Treviso Hotel
9 – 13 APRIL 2019 Treviso, Italy
WHERE INNOVATION MEETS BUSINESS REGISTER AS SPEAKER, DELEGATE, EXHIBITOR Topics of the conference include (but are not limited to): Markets & Strategies - Alloys Billets & Related Equipment - Rolling Technology - Architecture & Special Uses - Transport & Automotive Industry – Extrusion • Process Sustainability • Process Management • Process Monitoring • Plant & Process • Process Simulation • Product Quality • Alloys • Dies • New Processes – Anodizing – Coating - Nano Technologies – Automation - Measuring, Testing & Quality Techniques Advanced Applications & Research - Environmental Protection & Recycling - Casting & Die Casting • Process Management • Process Quality • Process Monitoring • Process Innovation • Process Simulation - New Alloys
For Information: Interall Srl, Via G. Marinuzzi 38, 41122 Modena, +39059282390 info@interall.it – aluminium2000@interall.it – www.aluminium2000.com
TRADE FAIRS & CONFERENCES
DECEMBER 2018 COATING JAPAN
BUILD ASIA
Tokyo, Japan December 05-07, 2018 www.coating-japan.jp/en/
Karachi, Pakistan December 15-17, 2018 www.buildasia.net
ipcm
®
media partner
METAL JAPAN
Tokyo, Japan December 05-07, 2018 www.metal-japan.jp/en
JANUARY 2019 BOUW&RENO
IPCC 2019
AQUA-THERM MOSCOW
AGROMASHEXPO
STEEL FAB
IMTEX
AHR EXPO
OPTI
Tehran, Iran January 23-26, 2019 www.ipcc.ir
Antwerp, Belgium January 12-20, 2019 www.bouwreno.be
Moscow, Russia January 12-15, 2019 www.aquatherm-moscow.ru
Budapest, Hungary January 23-26, 2019 www.agromashexpo.hu
Sharjah, UAE January 14-17, 2019 www.steelfabme.com
Bangalore, India January 24 -30, 2019 www.imtex.in
Atlanta, USA January 14-16, 2019 www.ahrexpo.com
Munich, Germany January 25-27, 2019 www.opti.de
BAU
Munich, Germany January 14-19, 2019 www.bau-muenchen.com
HVACR SAUDI
ipcm
®
distribution
AUTOZUM
Salzburg, Austria January 16-19, 2019 www.autozum.at
Riyadh, Saudi Arabia January 28-30, 2019 www.hvacrexposaudi.com
INTERPLASTICA
ipcm
®
distribution
IFEX
Greater Noida, India January 18-20, 2019 www.ifexindia.com
Moscow, Russia January 29 - February 1, 2019 www.interplastica.de
ASTEC
Tokyo, Japan January 30 - February 1, 2019 www.astecexpo.jp
CONSTRUCTION & ARCHITECTURE SHOW Krasnoyarsk, Russia January 22-25, 2019 www.krasfair.ru/en/events/build_en/
international PAINT&COATING magazine - NOVEMBER/DECEMBER 2018 - N. 54
121
ZOOM ON EVENTS
© Titan
Titan’s 10th Technical Day: A Focus on the State of the Art of Powder Coatings
1
Figure 1: The tenth Technical Day organised by Industrias Titan was dedicated to the current technological level of powder systems. © ipcm ®
F
or the tenth meeting of the round of
the second report, titled “The new
Technical Days it is holding, powder
sublimation system Eazy Vacuum (wood
coating manufacturer Industrias
effect) for steel/aluminium”. He described
Titan has organised an event on the
the advantages of the new sublimation
current technological level of powder
technology Eazy Vacuum, developed to
systems on October 27 in Madrid (Fig. 1).
improve the application quality and the
The introduction of José Manuel Azpeitia
service life of products while reducing
(Fig. 2), the Director of the Powder
process and labour costs.
Coating Division of Titan, was followed by
The morning session continued with the
several reports that compared different
speech delivered by Carlos Avendaño, the
powder technologies currently used on
Quality Manager of the Gonvarri Group, a
various substrates and materials.
leading company in the steel processing
Antonio Maeso from Ldo CC. Quimicas
sector. He presented the characteristics
spoke about coating quality in the
required for a steel galvanising
architectural field, comparing the
process to achieve high quality and
powder coating of aluminium profiles for architecture in the geographical areas using QUALICOAT or AAMA certifications. Davide Agostini from Miroglio presented
122
2 1
Figure 2: José Manuel Azpeitia, the Director of the Powder Coating Division of Titan.
N. 54 - NOVEMBER/DECEMBER 2018 - international PAINT&COATING magazine
excellent performance levels, from the steelworking of the component to the corrosion protection of the galvanising process.
© ipcm ®
ZOOM ON EVENTS
3 1
Figure 3: The event ended with a round table discussion moderated by José Manuel Azpeitia and involving José Antonio Arrieta (Titan), Elena Montesino (MARSAN Group), and Diogo Barreto (Lacoviana).
After the coffee break, José Antonio Arrieta, the Technical Manager of the Powder Coating Division of Titan, presented his report comparing pre-anodising + powder with powder + powder systems (Seaside) in order to determine which one offers the best corrosion resistance results. After illustrating the results of the Toyota tests carried out on super-durable powder coatings (200 hours/10 years Qualicoat), José Manuel Azpeitia concluded the event as the moderator of the round table discussion involving Elena Montesino from the MARSAN Group, specialising in the surface treatment of automotive components, and Diogo Barreto, the Production Manager of Lacoviana, a Portuguese company specialising in aluminium finishes (Fig. 3). By presenting their own practical experience, these users offered to the vast audience present an overview of the state of the art of the powder coating sector. For further information: www.titanpowdercoatings.com
ZOOM ON EVENTS
ECCA Conference – “Pre-Painted Metal: The Future of Construction”
O
n October 17, 2018, on the
substrate and of an optimal geometric
Alubel Spa Sales Manager Davide
occasion of the 53rd edition of
shape and the use of corrosion inhibitors.
Lorusso presented the advantages of
SAIE, the trade fair dedicated
Rossi also highlighted the importance of
pre-painted metal for roofing, including
to the technologies for construction and
coating and above all of duplex systems, i.e.
durability, lightness, impermeability,
built environment 4.0, ipcm® held the
the combination of hot-dip galvanising and
chemical resistance, and environmental
conference “Pre-Painted Metal:
painting, to further prevent corrosion.
sustainability. Thanks to these quality and eco-friendliness benefits, pre-painted
The Future of Construction” organised in European Coil Coating Association ECCA
metal is going to play an increasingly
© ipcm ®
collaboration with the Italian branch of the
important role in the civil and
Italia. Indeed, this association was created
commercial building sector: this
in 1967 in Brussels precisely with the
was the main theme addressed by
aim of promoting and spreading culture
ipcm®_International Paint&Coating
on pre-painted metal.
Magazine Editor-in-Chief Alessia
This innovative material is mainly used in
Venturi, who also showed some
the construction and architectural sector,
projects realised all over the world,
it is produced through a coil coating
including the famous Ferrari World
process, and it offers high environmental,
in Abu Dhabi.Finally, Prof. Stefano
economic, and quality benefits. With
Rossi concluded the conference
1
the aim of pursuing the association’s mission, ECCA Italia annually organises meetings and conferences to present the latest technical innovations to the main
talking about the influence that Figure 1: From left to right, Davide Lorusso from Alubel, Antonio Bonoli from Marcegaglia, Alessia Venturi from ipcm®, and Prof. Stefano Rossi from the University of Trento.
colours, finishes, and pigments can have on the thermal behaviour of buildings. Then, an interesting debate was started on the need
material producers to end users, including
to inform the building and town
© ipcm ®
players of the coil coating sector, from raw designers and architects.
planning commissions of public bodies on the endless application possibilities
“Pre-painted metal: the future of construction”
of pre-painted metal as an innovative, lightweight, and sustainable material that
The conference opened with a greeting
can replace traditional materials such as
from ECCA Italia President Antonio
brick roofing.
Bonoli, the Coil Coating Lines Operation
In addition to this meeting, ECCA
Manager of Marcegaglia (Fig. 1).
participated in the SAIE trade fair with
The meeting then continued with a series
a stand, in which the numerous visitors
of technical reports.
were able to see some pre-painted
Prof. Stefano Rossi from the Department
metal roofing samples, as well as a video
of Industrial Engineering of the University
presentation on the most important
of Trento presented the main corrosive
projects made with this material
phenomena that degrade the properties
worldwide (Fig. 2).
of metal and how to fight them in order to protect the materials used. This include the choice of a more resistant
124
2 1
Figure 2: The ECCA booth at SAIE 2018.
N. 54 - NOVEMBER/DECEMBER 2018 - international PAINT&COATING magazine
For further information: www.prepaintedmetal.eu
ZOOM ON EVENTS
PCI’s POWDER COATING 2019 Heads to Orlando
T
the basics of powder coating operations,
facets of powder coating that I will
is pleased to announce the PCI
led by PCI member company experts in a
utilize in my career.” The event will
POWDER COATING 2019 Technical
non-commercial setting (Fig. 1). The Custom
include social activities and ample
Conference & Tabletop Exhibition will be
Coater Forum is the only industry event
networking time with tabletop
held April 1-4, at the Renaissance Orlando
designed specifically for custom coaters,
exhibitors and speakers.
© PCI
he Powder Coating Institute (PCI)
1
Figure 1: Attendees learn about the latest in industry technology from powder coating experts.
with a focus on
The tabletop display area will feature
business processes
powder coating manufacturers,
and technologies
powder coating application
that can improve
equipment companies, systems
custom coater
houses, chemical suppliers and
operations.
various services that support the
Workshop and
powder coating industry. A current
Forum attendees
list of exhibitors can be found at
will enjoy a discount
conference.powdercoating.org/
when registering
exhibitors.html.
for the technical
Don’t miss this unique opportunity
conference and
to learn from the best in the powder
exhibition as well.
coating industry. Save the week of
The PCI Technical
April 1-4, 2019 and plan to join PCI
Conference and
in Orlando, FL for PCI’s POWDER
Tabletop Exhibition
COATING 2019 Technical Conference.
will follow the Powder Coating 101 Workshop and Custom
For further information:
excited about the location selected for
Coater Forum on Wednesday, April 3 through
conference.powdercoating.org
PCI’s Powder Coating 2019,” states PCI’s
Thursday, April 4
Executive Director, Trena Benson. “Following
(Fig. 2).
the very positive comments about Powder
Complete with
Coating 2018 and the increased attendance,
general sessions and
we are enthusiastic about getting to work on
concurrent technical
PCI’s next technical conference. Continuing
programming,
to deliver outstanding education to the
attendees will have
powder coating industry is a top priority for
access to a variety
us.” Orlando is an easy fly-in destination with
of powder coating
service from across the USA and around the
information as well as
world and the hotel is ideally located near
personal interaction
many theme parks and restaurants.
with suppliers. A
The four-day event will kick off with PCI’s
recent conference
popular Powder Coating 101: Basic Essentials
attendee remarks:
Workshop and PCI’s Custom Coater Forum,
“There was a great
to be held April 1 & 2. The workshop includes
variety of sessions
a comprehensive agenda that covers all
addressing the many
© PCI
at SeaWorld® in Orlando, FL. “We are very
2 1
Figure 2: The Tabletop Exhibition offers the opportunity to meet with suppliers face-to-face.
international PAINT&COATING magazine - NOVEMBER/DECEMBER 2018 - N. 54
125
ZOOM ON EVENTS
MADE expo 2019: Interiors and Finishes
M
ADE expo Milan stands out for
The journey then continues through the
value of investments in properties
being a showcase of the best
exhibition pavilions which will present a
dedicated to hospitality will exceed
of Made in Italy and not only in
wide range of interior finishes ranging
the remarkable threshold of €3 billion
architecture and interior design.
from entrance doors to interior doors,
to reach 3.2 billion next year (source:
Within the multi-specialized MADE
handles, partitions, floors, walls and a
Scenari immobiliari).
expo, the Interiors and Finishes section
wide selection of finishing products for
In order to develop Italy’s potential in
represents the place to discover new
architecture, consolidating the logic of
the hotel and hospitality sector and fully
fashions and products for interior
the event to represent a single place
seize the opportunities that will derive
architecture through trends, materials
in which to find the widest and most
from the growth of quality tourism, the
and aesthetic and technological
integrated range of solutions possible.
redevelopment of structures that can
solutions presented by companies that
Within a project, the choice of finishes
offer a contribution in terms of design
represent the most advanced products
and architectural features for interiors
but also sustainability can therefore be
on the market.
is a fundamental element in defining
of great value.
Considering the developments in living
and renewing the identity of the
MADE expo will tackle this topic with a
styles this is a rapidly evolving area
environments, the experience of those
series of events that will embrace market
that entails serious changes in what
who live there and optimizing the use of
perspectives, trends/architecture and
is expected from new materials in
space; for this reason, it is particularly
aspects of management in collaboration
terms of aesthetics, performance and
relevant for example in the hotel and
with Confindustria Alberghi, Hotel
sustainability, distribution methods and
catering sector. This is why the next
Rewind, ELLE DECOR and other sector
new business spaces.
edition of MADE expo will pay particular
associations and businesses.
In order to highlight the importance
attention to hospitality, a sector that is
of finishes in architecture and interior
enjoying a particularly positive moment.
For further information:
design and create a centre of attention
In actual fact, at the end of 2018 the
www.madeexpo.it
that suggests new uses of © MADE expo
interior finishes to designers and decorators, MADE expo 2019 will host an exclusive exhibition event created in collaboration with the internationally renowned magazine ELLE DECOR and designed by the Calvi Brambilla studio. The journey/installation focuses on excellence in terms of finishes and coatings giving life to evocative settings. The interpretation of traditional and innovative materials and products turns the spotlight onto finishes in an emotional journey into decoration.
126
Pic.: MADE expo 2019 will take place from March 13 to March 16 at Fiera Milano (Rho, MI).
N. 54 - NOVEMBER/DECEMBER 2018 - international PAINT&COATING magazine
13/16 INTERNATIONAL TRADE SHOW FIERA MARCH FOR AR C H IT E C T U R E A ND MILANO RHO 2019 THE CONSTRUCTION INDUSTRY ITALY
PICK NEW IDEAS MADE IN MILAN madeexpo.it THE LEADING TRADE SHOW IN ITALY TO DESIGN, BUILD & RENOVATE. CONSTRUCTION AND MATERIALS, BUILDING ENVELOPE & WINDOWS, INTERIORS AND FINISHES, SOFTWARE & TECNOLOGIES. Promoted by
Partner
ZOOM ON EVENTS
PaintExpo 2020 with Strong Demand for Booth Locations
J
ust a few months after the
visitors came from countries other
many other companies: 304 companies
seventh edition of the world’s
than Germany. Most of the visitors
from 19 countries have already made
leading trade fair for industrial
brought concrete tasks and projects
firm bookings for their booth floor space
coating technologies closed – which
along with them. “We participate at
at the world’s leading trade fair in 2020,
achieved new record-breaking
numerous trade fairs – in Asia and
and they enjoyed a full range of options
numbers with regard to exhibitors,
America too – but where the quality
in selecting their booth locations.
visitors and internationalism – firm
of the exhibitors and visitors are
The list includes nearly all of the national
bookings for booth floor space
concerned, as well as product quality
and international market and technology
at PaintExpo 2020 have already
and coverage, PaintExpo is the global
leaders from the various exhibition
been submitted by 304 companies
leader. That’s why we’ll exhibit in
segments.
from 19 countries. At a current
At a current level of
level of 124,000 square feet, net
124,000 square feet, net
exhibition floor space already
exhibition floor space
amounts to more than 74% of the
already amounts to more
level reached at the last event.
than 74% of the level
This is a strong indication that the
reached at the event in
upcoming PaintExpo will once
2018. The strong demand
again be larger than ever before.
for booth floor space long
For the eighth time, PaintExpo
before the event opens
will showcase innovations,
2020 again,” explains Frank Berg,
once more underscores the outstanding
applications, future technologies
Managing Director of Caldan Service
position enjoyed by PaintExpo as a
and trends covering all aspects
GmbH. Professor Dr. Nils A. Reinke,
global industry meet.
of coating from the 21st through
CEO of Winterthur Instruments AG in
the 24th of April, 2020. It presents
Switzerland, has already made firm
the full spectrum of international
plans to participate as well: “We’ve
Focus on Future-Oriented Coating
product and service offerings
been exhibiting at PaintExpo ever
Jürgen Haußmann, managing
in the field of industrial coating
since our company was founded
director of trade fair promoters
technology throughout the
seven years ago, and participation
FairFair GmbH, is convinced
entire value creation chain.
at the trade fair has had a significant
that PaintExpo will continue to
This internationally unique
impact on the development of our
experience strong development
concentration of companies from
business. It provides us with an ideal
where visitor numbers are concerned
industrial coating technology is
platform for the presentation of our
as well: “Even if requirements and
the basis for the event’s strong
products. Aside from this, we gain
developments differ in the various
ability to attract users from job-
a great deal of input for the further
user sectors and countries – as key
shop coaters and companies
development of our products thanks
technologies, painting and coating
with in-house painting operations
to the broad spectrum of visitors.”
are an important success factor.”
from around the globe. 11,790
A look at the exhibitor list, which is
And it’s correspondingly important
expert visitors from 88 countries
already full of world-class enterprises
for companies with in-house painting
travelled to Karlsruhe in 2018
17 months before the trade fair
operations and coating job-shops
(representing a 12% increase).
opens, makes it apparent that these
to prepare themselves for new
More than one third of the
assessments coincide with those of
requirements. In addition to ever
128
N. 54 - NOVEMBER/DECEMBER 2018 - international PAINT&COATING magazine
© PaintExpo
ZOOM ON EVENTS
1
Figure 1: The next edition of PaintExpo will take place from the 21st through the 24th of April, 2020 in Karlsruhe, Germany.
stricter customer demands for
be presented with correspondingly
and conveyor technology, cleaning
quality, economy and flexibility, this
adapted product, process and
and pre-treatment, drying and
also involves more efficient use of
problem solutions thanks to the
curing, environmental technology,
materials and resources, as well
unique, future-oriented offerings
pneumatics, compressed air
as sustainability. Additional issues
shown by the exhibitors,” says Jürgen
supply and exhaust purification,
include advancing digitalisation and
Haußmann with confidence already
water treatment, recycling and
networking of production processes,
today.
disposal, accessories, masking,
the use of new materials and material
The exhibition programme of
measuring and test technology,
combinations, and the trend towards
the world’s leading trade fair for
quality assurance, identification,
individualisation.
industrial coatings technology
paint stripping, job-shop coating,
“Regardless of whether coatings
covers coating equipment for liquid,
services, packaging and technical
for metal, plastic, wood or wooden
powder, UV, immersion and coil
literature.
materials, glass, composites or other
processes, paints and enamels for all
materials are involved, visitors to the
processes, application systems, spray
For further information:
upcoming PaintExpo will once again
guns and atomisers, automation
www.paintexpo.com
international PAINT&COATING magazine - NOVEMBER/DECEMBER 2018 - N. 54
129
WELCOME TO THE INDUSTRY’S LEADING TRADE SHOW NUREMBERG // GERMANY European Coatings Show: 19 – 21 March 2019 European Coatings Show Conference: 18 –19 March 2019
Most recently over 1,100 international exhibitors and over 30,000 visitors Accompanied by Europe’s largest and most important industry conference w Plan your visit online: european-coatings-show.com/shownavigator Organisation: NürnbergMesse european-coatings-show.com
Organiser: Vincentz Network european-coatings.com
Supplemento a IPCM n° 54 - November/December 2018
INDUSTRIAL CLEANING TECHNOLOGIES
ICT digital on
www.myipcm.com
ÂŽ
Automatic sealed ultrasonic cleaning machine 2S 90/24-P-F PCT AC Our machine requires only 5 kW about 20% of the normal power requested by type Ib machines)
The future of green technology 1HZ JHQHUDWLRQ VROYHQWV with ORZ-boiling point (19-50°C) QRQ à DPPDEle DQG HQYLURQPHQWDOly friendly
MEG S.r.l. Via Rometta, 13/G - S. Martino di Lupari (PD) - Italy Phone +39 049 9461165 - Fax +39 049 9461133 e-mail megpd@tin.it – www.meg.it
PRECISION CLEANING
ICT - INDUSTRY NEWS
F
Š acp systems AG
Partial or Full-Surface Inline Removal of Filmic Contamination ilmic contamination is becoming ever-more important in the component
Dry and environmentally friendly cleaning process With the quattroClean technology
manufacturing industry. No
from acp systems AG, a proven
wonder, because the quality of
solution is now available for
manufacturing processes such
components made of practically
as bonding, sealing, welding
any technical material. The
and coating depends to a large
environmentally-friendly process
extent on surface cleanliness.
works with liquid carbon dioxide,
With its environmentally friendly
which has a virtually unlimited shelf
quattroClean snow jet technology,
life and is generated as a by-product
acp systems AG offers a proven
from chemical processes as well as
solution for the partial and
energy generation from biomass.
full-surface cleaning of parts made
In the cleaning process, carbon
from any technical material.
dioxide is fed through the
In addition, the scalable and
non-wearing two-component ring
inline-capable cleaning step is a dry
nozzle of the quattroClean system,
process that leaves no residues
expanding as it exits to form fine CO2
from the medium itself.
snow (Fig. 2).
This is then bundled by a jacketed jet While component cleaning used to
of compressed air and accelerated
be mainly concerned with removing
to supersonic speed. The patented
particulate contamination, today
technology ensures uniform cleaning
filmic residues are increasingly
results - even with large-surface
becoming the focus of attention in
applications using several nozzles.
industries such as the automotive
When the easily-focused jet of
and associated supplier
snow and compressed air impacts
industries, medical equipment, aviation, precision engineering, micromechanics and mechanical engineering. This is due to new and modified manufacturing, joining and coating processes. Filmic
on the surface to be cleaned at a
1
temperature of minus 78.5°C, a
Figure 1: Filmic contamination (here an anti-corrosion oil), which impairs quality in subsequent processes such as welding or bonding, is removed reliably in an inline process with the quattroClean system.
contamination, such as residues of
combination of thermal, mechanical, sublimation and solvent effects take place. Thanks to these four mechanisms of action, the quattroClean system reliably
processing and preserving media,
for the subsequent process need to
removes filmic contaminants such as residues
separating agents, silicon and other
be cleaned, e.g. where sealants and
of cooling lubricants, machining oils, separating
auxiliary manufacturing materials,
adhesives are applied or for welding,
agents and silicon. The quattroClean cleaning
as well as fingerprints, can impair
bonding, coating or assembly
process also reproducibly removes particulate
quality (Fig. 1). Added to this, often
steps – with a requirement for a
contamination. The cleaning process is so
only those areas of the component
production-integrated process wherever
gentle on materials that it can even be used to
that are relevant to cleanliness
possible.
clean delicate and finely-structured surfaces.
132
N. 54 - NOVEMBER/DECEMBER 2018 - international PAINT&COATING magazine
ICT - INDUSTRY NEWS
Through pilot tests in the acp systems technical center, the process parameters, such as volume flows for compressed air and carbon dioxide, jet zone and jet time, are precisely tailored to the respective application. The parameters also account for material properties and contamination requiring removal and can be filed as part-specific © acp systems AG
cleaning programs in the system control.
The system can be integrated into production lines and networked production environments
Figure 2: The technology with its non-wearing two-component ring nozzle ensures a consistently high and homogeneous cleaning performance - even for large-surface applications with several nozzles.
KMU LOFT – because resources are limited
Tailored to the respective cleanliness and cycle time specifications, acp systems develops customized, manual, partially and
2 1
fully automated plant concepts based on standard modules - both as stand-alone solutions as well as for integration into production lines and networked
During the cleaning step, the crystalline carbon
production facilities (Fig. 3).
dioxide is completely converted into a gaseous
The latter is made possible by the system’s
state, meaning that the cleaned material dries
Industry 4.0 capability. The system can be easily
instantly. Detached impurities are removed from
integrated into and controlled by higher-level
the component surface by the aerodynamic
master computers via standardized interfaces.
force of the compressed air and transported
To ensure full documentation and traceability, all
away together with the sublimated carbon
process parameters are automatically recorded and
dioxide by a suction unit integrated into the
transferred to the host computer.
cleaning module. For further information:
Partial or full-surface cleaning
www.acp-systems.com
The scalable quattroClean process component geometries to enable partial or full-surface cleaning.
© acp systems AG
can be easily adapted to different
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;
Compared to classic wet chemical cleaning methods, the system requires significantly less production space and investment and operating costs are lower.
Figure 3: The industry 4.0-capable quattroClean system enables the production-integrated, partial or total removal of filmic contamination with consistent results.
• soluzioni economicamente all’avan-guardia nella riduzione degli scarichi e nel recupero delle risorse 3 1
www.kmu-loft.it
ICT - INDUSTRY NEWS
Kemet Adds FPI to Range
T
he perfect non-destructive-test (NDT)
provide a small footprint. The FPI systems are
mass production with dipping
solution for inspection of components,
durable, safe, ergonomic and user-friendly.
penetrant application, “Dust Storm”
Liquid Penetrant Testing, or Fluorescent
A variety of systems are available, from
developer chamber and integrated
Penetrant Inspection (FPI), is commonly used in
flexible manual roll track spray lines with
pre and post wash. Further options
the aerospace and medical industries. Precision
a small footprint, to fully automated roll
include material handling and
surface finishing leaders, Kemet, now offers
conveyor immersion lines for high capacity,
batch traceability via a data log, fully
FPI systems with control that ensures repeatability, process safety and traceability of each
automated penetrant and developer Figure 1: The Fluorescent Penetrant Inspection (FPI) is commonly used in the aerospace and medical industries.
© Kemet International Ltd
advanced process
batch within the set parameters (Fig. 1). The systems are
spray, basket rotation, basket trolleys and automatic loading/unloading conveyors (Fig. 3). These FPI systems complement Kemet’s existing Ultrasonic Cleaning programme which incorporates a broad range of aqueous cleaning solutions to suit all types of components and budgets.
designed and built to meet the ASTM
the aerospace and medical industries. Kemet offers a range of standard systems
www.kemet.co.uk Figure 2: The FPI systems by Kemet offer flexibility to combine automated and manual operation.
© Kemet International Ltd
common to both
For further information:
1
E1417 FPI standard
as well as the flexibility to combine automated and manual operation to provide streamlined, maintainable NDT inspection, with water handling and
2 1
extraction systems as options, to generate cost savings on process chemicals, labour and energy consumption (Fig. 2). These can be supplied as fully automated
© Kemet International Ltd
integrated waste
systems for airframe components, turbine blades, and medical implants as well as smaller manual systems for less critical parts. An intelligent combination of automation and manual handling can reduce labour requirements, while an adjustable layout can
134
N. 54 - NOVEMBER/DECEMBER 2018 - international PAINT&COATING magazine
3 1
Figure 3: Further options include material handling and batch traceability via a data log, fully automated penetrant and developer spray, basket rotation, basket trolleys and automatic loading/unloading conveyors.
ICT - CASE STUDY
Opting for a Modified Alcohol Cleaning Technology for Oil-Hydraulic Components in the Framework of a Smart Factory Project © ipcm ®
Monica Fumagalli ipcm®
Opening photo: Some of the oil-hydraulic components produced by HBS.
T
he report on the future of jobs in the
concept of work, the creation of new job
In this article, we present a case study on
new digital age presented during the
opportunities, but also the loss of 5 million
HBS (Monzambano, Mantua, Italy), a company
World Economic Forum 2016 in Davos
jobs. After almost three years, it is perhaps still
specialising in the production of oil-hydraulic
(Switzerland)1 illustrated the future prospects
early to draw conclusions on this revolution
valves and components for every use, from
of the fourth industrial revolution, more
well under way that has involved all industrial
transport to earth-moving vehicles, from
commonly called “Industry 4.0”. The report
sectors; however, we can continue to record
building to agriculture, from ecology to
stated that the following five years would
on the pages of our magazines the ways in
industrial plants. Present worldwide with
have seen a profound transformation of the
which several companies from the world of
production facilities in China and Brazil,
surface treatments are dealing with this radical
plus one under design in India and two
change.
soon-to-open ones in the United States and
1 The complete report can be downloaded at the following link: www3.weforum.org/docs/WEF_FOJ_Executive_Summary_Jobs.pdf
136
N. 54 - NOVEMBER/DECEMBER 2018 - international PAINT&COATING magazine
© ipcm ®
ICT - CASE STUDY
machinery and equipment often operating in harsh conditions (ref. Opening photo). Therefore, we looked for a supplier able to offer a system solution that would make our cleaning cycle fast, easy to manage, and with a low environmental impact: we found this partner in IFP Europe (Galliera Veneta, Padua, Italy). This firm fully understood the principles that had inspired us and followed them to optimise our production flow through the integration of production units, the interconnection among operators, machines, and devices, and the implementation of eco-friendly solutions.”
From design to end products: quality means perfect synergy with customers
1
Figure 1: The two cleaning systems installed by IFP Europe.
The entire production cycle, except for heat and surface treatments, takes place inside the Monzambano factory, covering
Russia, this company is gradually adapting
of about 3 components per day.
a 12,000 m2 area and consisting of two
its production process to the Industry 4.0
“With such a massive production, the
production units, to which a new structure
parameters in order to offer high quality
first goal to adapt our company structure
of about 7.500 m2 will be added in the next
products in terms of both performance and
to the Industry 4.0 principles was
two years. “Our R&D department starts
innovation capacity.
streamlining our production process. One
designing a component based on the
“HBS was established in 1967,” says CEO Ezio
of the main bottlenecks was the cleaning
suggestions of a customer, on a new need
Bompieri at the beginning of our meeting,
phase, a crucial step to guarantee the
detected by our sales network, or on an
“as a machining contractor. Since 1980, it
correct functioning and long service life
innovative product that our technical team
has integrated its production activity with
of our products, which are intended for
deems appropriate to place on the market. © ipcm ®
the design of solutions meeting the different needs of its
We therefore create the prototype to be tested in
customers. In 1995, it started
our 500 m2 lab, equipped
manufacturing an entire range
with test benches for
of HBS branded products,
destructive and durability
then integrating its production
tests. The prototype is
of valves and oil-hydraulic
approved after performing
components with that of
functional tests on the
hydraulic swivel joints and, since
customer’s machine. At that
2009, of slip rings.” The HBS
point, the component can
standard product range now
be industrialised.”
includes 3600 components in
The production process is
addition to the special products
standardised and starts with
manufactured as a contractor.
the receipt of bars of steel,
Every year, HBS puts around 600 new products on the market, with a very high average
2 1
Figure 2: The cleaning machine for small components.
constituting 90% of the company’s products, and aluminium. This is followed
international PAINT&COATING magazine - NOVEMBER/DECEMBER 2018 - N. 54
137
© ipcm ®
ICT - CASE STUDY
3 1
Figure 3: The IFP Europe cleaning plant for large components.
Therefore, we
since HBS is about to get the ISO 14001
had to perform a
environmental certification, we reduced our
manual blow off
production’s impact on the environment
operation on every
and solved the problem of water and sludge
part to remove
disposal, which, with the previous plant, had
any residues, thus
a significant impact due to the costs for the
wasting time and
elimination of hazardous waste.
employing labour
Now, no waste water to be disposed of
in hazardous
comes from our cleaning phase, because
operations for
the plant has a self-purification system
health and safety.”
that activates after the process, separating
The critical issues resolved
the dry residue (e.g. chips) from the oil contained in the cleaning chemical and the alcohol to be recirculated.
In 2013, HBS
Thanks to this system, we perform a
contacted the
replenishing process once a year, contrary to
by operations performed with machining
technical staff of IFP Europe to install the
what happened previously with weekly tank
centres and lathes, a first cleaning process
first cleaning machine, followed by the
checks, continuous addition of additives to
for the removal of any scraps and emulsions
larger one in 2017 after checking the
keep the cleaning result optimal, and tank
left on the surfaces, thermal and superficial
efficiency of the first plant. “The two systems
emptying operations two times a month
treatments, and for some products a final
use the same technology,” states Bompieri
resulting in an enormous consumption of
cleaning phase. The cleaning process occurs in
(Figs. 2 and 3).
water.”
two IFP modified alcohol systems, a smaller one
“Thanks to this solution, we streamlined our
for small workpieces and a larger one for
production flow, reducing our cleaning time
large-sized components (Fig. 1).
from about 30 to 20 minutes.
The cycle and structure of the two IFP cleaning plants
We also solved the issue of workpieces left
Both systems consist of a single-stage chamber.
The previous cleaning process
oxidising in the air: the modified alcohol
The chamber of the smaller machine is
“Before installing the IFP plants,” says
process does not require any drying phase,
equipped with 2 small baskets (40x30x20 cm),
Bompieri, “we cleaned our components in a
so that after cleaning the components are
whereas that of the larger one hosts two 2
conventional ultrasound system, with different
ready for the next phases without needing
baskets with a dimension of 120x80x45 cm,
cycles depending on the type of material and
any blow off operation. Last but not least,
able to handle workpieces up to 800 kg. For the latter, HBS defined the © ipcm ®
component to be treated. If we had to treat both steel and aluminium parts, we had to set two different cycles not to pollute water, using
cell’s volume based on the average specific
different degreasing additives and applying an
weight of its treated
anti-rust protection on steel products, as they
products, so it can
oxidise quickly if washed with water and left to
always work at full load
air dry for too long.
for maximum energy
“In addition to this critical issue, since that
efficiency.
was a static plant, machining scraps often
“In order to meet our
remained in the hollow areas of workpieces.
lean production and
Despite the powerful action of ultrasound,
Industry 4.0 needs,
the internal cleaning of parts has always been
we developed an ad
one of our biggest problems, because such
hoc system for the
residues in the inside of the most complex-shaped products risked compromising the result of subsequent stages.
138
4 1
Figure 4: The baskets holding the workpieces to be cleaned.
N. 54 - NOVEMBER/DECEMBER 2018 - international PAINT&COATING magazine
handling of containers,” explains Bompieri (Fig. 4). “It is no longer
necessary to transfer parts from the
© ipcm ®
ICT - CASE STUDY
production chain containers to those of the cleaning system, because the baskets used during machining are also suitable for our cleaning plant. IFP’s machines are equipped with a roller conveyor on which the baskets are arranged (Fig. 5). They have been specially designed to guarantee an unattended working time of at least 2 hours.” After the baskets have entered the plant (Fig. 6), the system closes automatically to allow the chamber to be flooded with modified alcohols that heat up under vacuum conditions, at a temperature of about 70 °C. Inside the baskets, the components are subjected to a tilting movement and they are cleaned with ultrasound, favouring the removal of
5 1
Figure 5: The roller conveyor installed at the entrance of the two cleaning machines guarantees an unattended working time of at least 2 hours.
COMPLEX CLEANING REQUIREMENTS – SAFECHEM offers customised cleaning solutions SAFECHEM offers complete solutions for high quality parts cleaning in line with ecological, social, and economic requirements. Comprehensive services and individual chemical-technical consulting help for an optimised cleaning process.
NECESSITÀ COMPLESSE DI LAVAGGIO – SAFECHEM offre soluzioni di lavaggio su misura SAFECHEM offre soluzioni complete per un lavaggio ad alte prestazioni di componenti industriali, che soddisfa i requisiti ambientali, sociali ed economici. Una vasta gamma di servizi e consulenza personalizzata tecnico-chimica per un processo di lavaggio ottimizzato.
SAFECHEM Europe GmbH Phone: +49 211 4389-300 service@safechem.com www.safechem.com
© ipcm ®
© ipcm ®
ICT - CASE STUDY
6 1
7 1
Figure 6: A detail of the opening compartment of the cleaning system.
Figure 7: Residues from a few precision finishing treatments, such as lapping and grinding, may remain on the surfaces of some components.
contaminants even from the most
systems in our heat treatment and
Conclusions
difficult-to-reach areas.
finishing department. These systems
“Much has been done in the
At the end of the cycle, vacuum
would be specifically designed for
Industry 4.0-oriented updating of
pumps empty the chamber
our needs and installed near the
our company, but a lot can still be
creating a vortex and dragging all
machines in order to eliminate any
done,” states Bompieri. “We intend
the removed residues.
travel time between departments.
to interconnect our suppliers and
The parts are unloaded from the
Also in this case, we intend to rely on
customers to HBS’ internal network
cleaning plant and, after cooling for
the expertise of IFP Europe, which
by 2020. That is why we are already
a few minutes, they are sent to the
has shown an excellent reliability
selecting suppliers like IFP Europe,
subsequent heat treatment and
degree in terms of both technology
which designs systems already
finishing stages. From there, a few
and service.”
prepared for this purpose. We also
parts come back to undergo a last
More generally, HBS’ Smart Factory
intend to improve our product range
cleaning treatment.
project also aims at creating a
by adding to our solenoid valve
paperless production process. “We
design and manufacturing activity
envision a factory where paper will
(started this year) a production of
A cleaning process for a Smart Factory
no longer be used. The automation
lever-operated valves. We aim at
“One of the problems we still
of our processes will start from
offering to our customers complete
have to solve are the travel times
the design operations of our R&D
kits for setting up their machinery,
of those components returning
department, up to our shipping
from distribution components to
to the cleaning plants after the
phases. This will be made possible
control and management systems.
thermal and finishing treatments.
by 85 touch screen stations through
Thanks to IFP’s cleaning technology,
This is a necessary step in order to
which the operators will be able
we will able to manage also this new
remove any oil traces from some
to follow the process phases and
type of production, with the certainty
of those phases, such as lapping
update their progress. This project
to reach such a cleanliness degree
and grinding, which leave residues
will start in January and it will be the
to guarantee optimal quality and
that could compromise the sliding
prerequisite for starting a robotised
functional performance. Moreover,
and functioning of valves (Fig. 7).
handling program that will replace
we will be ready for the integration of
Therefore, we are considering
the forklifts led by operators with
any new production units required by
installing a few small cleaning
small automatic trains.”
our Smart Factory project.”
140
N. 54 - NOVEMBER/DECEMBER 2018 - international PAINT&COATING magazine
ICT - HIGHLIGHT OF THE MONTH
MicroCare Corporation Expands at the European Level: Inaugurated a New English Plant for the Mixing and Packaging of Industrial Cleaning Solutions MihailŠfotolia
Ilaria Paolomelo ipcmÂŽ
Opening photo: One of the two divisions of the MicroCare new English factory will manufacture critical cleaning fluids for PCBs.
W
hen cleaning printed electronic
Registration, Evaluation, Authorisation,
of the REACH regulation, MicroCare, an
components, an effective
and restriction of Chemicals (REACH)
American leading manufacturer of cleaning,
cleaning process is crucial to
regulation, which affects the chemicals
coating, and lubrication solutions, has further
meet both the growing market demand
used in all main industrial processes
strengthened its presence in Europe with
for reliability and the increasingly stringent
and by most companies all over Europe.
a new plant in England, near Birmingham.
European regulations. These include the
Precisely to meet the requirements
Whereas its headquarters and customer
142
N. 54 - NOVEMBER/DECEMBER 2018 - international PAINT&COATING magazine
© ipcm ®
ICT - HIGHLIGHT OF THE MONTH
service office will remain in Brussels, the new English factory will handle the mixing and packaging of chemicals. “The new plant consists of two divisions, one of which is totally dedicated to cleaning printed circuit boards (PCBs, ref. Opening photo). In fact, after soldering, electronic boards often need thorough cleaning in order to remove any residues of fluxes, soldering pastes, or other contaminants. Currently, the cleaning of these electronic components is a true challenge, because modern PCBs are much smaller and more complex than ever before. This calls for the use of advanced cleaning technologies. In this framework, MicroCare offers a wide range of special fluids that can reach even the most hidden, narrow slots and guarantee a deep, accurate cleaning process, thus averting some of the most common problems such as dendritic
1
Figure 1: MicroCare COO Thomas Tattersall with ipcm® Editor-in-Chief Alessia Venturi.
growth and corrosion,” states MicroCare Chief Operating Officer Thomas Tattersall
processes. Indeed, the use of this product
glues and inks used during production. Another
(Fig. 1).
in standard vapour degreasers instead
typical application for Tergo™ is cleaning
“Tergo™ Chlorine-Free Cleaning Fluid,
of other water or hydrocarbon cleaning
medical devices to remove oils and particulates
launched on the European market about
processes reduces both the dangers to the
prior to sterilization. Finally, our fluid is also
eighteen months ago, stands out among
health of workers and the environment.
used in the aerospace industry, where it is
our special fluids. This is a new, unique
This also reduces process costs. Depending
essential to remove any contamination that
chlorine-free formulation that removes
on the size of the machine and the
could lead to poor performance,” says the COO.
even the most difficult contaminants quickly
components to be treated, a very short
“Tergo™ and all other fluids in our range
and effectively.
cycle of 8 to 10 minutes can be achieved,”
are a great help in the cleaning of critical
This cleaning agent can replace
says Tattersall.
components and they are a safe, reliable choice
water-based processes and it is compatible
“Tergo™ is also suitable for cleaning medical
complying with all European regulations.”
with conventional vapour degreasing
devices, which may contain residues of
says Tattersall.
DRY CLEANING
with
to perfect
advanced clean production
PAINTING ! Cleaning with CO2 - snow jet www.acp-V\VWHPV.com Phone: +49 7156 48014-0
ICT - CASE STUDY
An Environmentally Friendly and Low Energy Consumption Cleaning Process for Tailor-Made Oil-Hydraulic Components © Power Hydraulik
Barbara Pennati ipcm®
Opening photo: Power Hydraulik has been active in the hydraulic sector for over twenty years, operating in different industries such as food, oil & gas, earth moving machines, amusement, subsea, and machine tools.
O
il hydraulics is among the most
quality standards, because the success
in San Martino Buon Albergo (Verona, Italy)
versatile industrial processes,
of an application is strictly linked to the
in 1993, the company is now managed
able to meet the needs of various
quality of every system component. Power
by Claudio and Lorenzo Merzari and has
sectors and to handle considerable power
Hydraulik has been operating in this
about thirty employees who take care of
ranges. It therefore requires very high
industry for over twenty years. Established
the entire production cycle.
144
N. 54 - NOVEMBER/DECEMBER 2018 - international PAINT&COATING magazine
© ipcm ®
ICT - CASE STUDY
The service life of oil-hydraulic components is closely linked to their cleanliness degree. Indeed, cleanliness is decisive not only for the components themselves, but also for hydraulic oils: these are filtered and cleaned, and they must not be exposed to any contaminants present on the workpieces in order to remain clean and ensure optimal operation. With the aim of offering a competitive, functional, and high quality product, Power Hydraulik turned to STS (Ravenna, Italy), a company specialising in the design and production of industrial cleaning plants, to install a machine for cleaning components and hydraulic blocks in various sizes and materials.
© ipcm ®
1
Figure 1: Hydraulic blocks ready to be cleaned.
“Power Hydraulik designs oil-hydraulic
Another field in which our skills are often
plants and systems for different industrial
applied is subsea engineering, for which we
sectors, including food, oil & gas, earth
produce equipment specifically designed
moving machines, amusement, and
for underwater machines, used for
machine tools (ref. Opening photo).
example for laying submarine pipelines.”
Indeed, oil-hydraulics can be applied in
Power Hydraulik deals with the whole
numerous fields, even the most particular
production process, from design to
ones such as subsea, where applications
installation at the customer premises.
are used in submerged marine
The firm stands out for its ability to
environments,” explains Carlo Dal Forno
meet every specific need, placing itself
from the technical sales department of
as a technological partner able to offer
Power Hydraulik. “We operate on the
customised solutions in a sector where
Italian market, but we also collaborate
mass-produced series generally prevail.
with international companies. Despite
“Every element we produce is ‘out of
boasting a capillary presence in many
standard’, that is, it is developed based
industrial sectors, one of our main target
on customer specifications,” says Carlo
markets is that of amusement parks, for
Dal Forno. “This is one of the strengths of
which we manufacture special cylinders
Power Hydraulik, which places itself as an
for handle safety fasteners and motion
‘artisan’ company able to offer targeted
control systems, calling for great accuracy
solutions for the production of
in terms of both design and assembly.
small-medium volume batches.”
2 1
Figure 2: STS’ AQUAROLL® E30 system installed at the premises of Power Hydraulik about one year ago.
international PAINT&COATING magazine - NOVEMBER/DECEMBER 2018 - N. 54
145
© ipcm ®
ICT - CASE STUDY
Figure 3: The single-stage cleaning cycle includes spray cleaning, ultrasonic cleaning, spray rinsing, ultrasonic rinsing, drying, and vacuum drying.
3 1
Energy and production efficiency
types of parts and materials.”
The cleaning cycle is a single-stage
Collaborating actively with STS, the firm carried
process lasting about 20 minutes and
Before installing this automatic machine,
out different cleaning tests that eventually
it includes spray cleaning, ultrasonic
Power Hydraulik cleaned its products
led to the installation of the AQUAROLL® E30
cleaning, spray rinsing, ultrasonic rinsing,
manually, which however did not
system about one year ago (Fig. 2).
drying, and vacuum drying (Fig. 3).
“One of our flagship products are hydraulic blocks, which are systems for
© ipcm ®
guarantee any quality consistency.
creating complex hydraulic circuits by gathering various devices in one block (Fig. 1),” explains Power Hydraulik owner Claudio Merzari. “These blocks feature deep, small, often interconnected holes that need to be perfectly cleaned from emulsions and cutting oil residues from the previous machining operations.” “Moreover, since we do not manufacture standard components, our production includes both smaller and lighter workpieces and components weighing 100 kg, available in various materials such as aluminium, cast iron, and steel. We therefore needed a cleaning machine able to achieve our required quality level, but also flexible enough to treat different
146
4 1
Figure 4: During cleaning, water is constantly renewed through the closing and opening of a valve.
N. 54 - NOVEMBER/DECEMBER 2018 - international PAINT&COATING magazine
© ipcm ®
ICT - CASE STUDY
5 1
Figure 5: The machine can load up to two stackable baskets for small workpieces or one basket with an anterior dimension of 30 cm in the case of larger-sized parts.
During cleaning, water is constantly renewed through the closing and opening of a valve (Fig. 4). The cleaning programs are pre-set and selectable by the operators according to the type of workpiece to be treated. The machine can load up to two stackable baskets for small workpieces or one basket with an anterior dimension of 30 cm in the case of larger-sized parts (Fig. 5). The process occurs at 60/70 °C, a temperature suitable for cleaning both aluminium, which could blacken at higher temperatures, and cast iron and steel. The baskets can be rotated, tilted, or kept still according to requirements. “The system we have installed for Power Hydraulik was designed to guarantee maximum production flexibility. It cleans parts in various sizes and alloys, always ensuring result repeatability,” states STS Technical Manager Mauro Ballo. “It uses environmentally friendly and VOC-free water-based detergents, so that it is not necessary to connect it to any suction system. This allows the machine to be easily and quickly reinstalled in any production area.” “Our cleaning plant also guarantees very low consumption of water because it performs closed-loop operations, recovering water through a filter that recovers and recirculates the vapours. Energy consumption is also very low as the tanks are insulated: even when the machine is idle, the thermal loss in the tanks does not exceed 8 °C,” says Ballo. “Finally, the system employs products based on bicarbonate that, being a salt, reduces their evaporation, thus helping minimise environmental and energy impact.”
ICT - CASE STUDY
About 90% of Power Hydraulik’s
“Power Hydraulik has always
products are subjected to cleaning,
evolved in terms of production
“We do not manufacture
now performed by the STS system.
and design. This has allowed us to
mass-produced components: our
“In the past, we only used a manual
count some very important global
target clients are businesses needing
system that however did not achieve
players among our customers.
products with unique characteristics.
the required results, especially
Thanks to the high quality level
Therefore, we often handle smaller
in terms of repeatability,” says
guaranteed by our cleaning
volume orders. This is our strength, as
Claudio Merzari. “Thanks to this
process, we now manufacture
well as the distinctive feature that has
new machine, we have halved our
products with an added value that
enabled us to establish ourselves in a
cleaning times and achieved excellent
has turned out to be a great calling
very competitive and highly professional
quality consistency for all types of
card for several projects,” states
market,” states Claudio Merzari. “That
workpieces (Fig. 6). This is crucial
Merzari. “In future, we intend to
is why it was important for us to find
for us, because oil-hydraulics often
continue to experiment with the
a technological partner that was
apply to increasingly sophisticated
cleaning phase, collaborating with
professional and reliable, but also able
(also in terms of electronics) pumps
STS to develop the best method
to meet our need for flexibility and
and valves, which require extreme
to offer a more and more versatile
production versatility. We found this
cleanliness of all components before
service and increasingly competitive
partner in STS.”
assembly.”
products.”
© ipcm ®
Italian-made solutions for global markets
6 1
Figure 6: The installation of this automatic cleaning machine has reduced the cleaning times and improved quality consistency for all types of components.
148
N. 54 - NOVEMBER/DECEMBER 2018 - international PAINT&COATING magazine
efficacia, ecologia e sicurezza
effective, ecological and safe
sistema di lavaggio rotazionale rotational washing system Asciugatura rotazionale sottovuoto
Lavaggio rotazionale ad immersione
Lavaggio rotazionale spray Asciugatura rotazionale ad aria calda
Immissione rotazionale di aria Immissione rotazionale di aria
Risciacquo rotazionale spray
EE 30 R
EE 40 S
Risciacquo rotazionale ad immersione
EE 60 R
soluzioni ecologiche per il lavaggio e trattamento delle superfici ecological solutions for washing and treatment of surfaces STS Srl - Via Galvani, 8 - 48123 Ravenna RA (Italia) Tel. +39 0544 456731 - Fax +39 0544 456733 w e b : w w w. s t s i t a l y. i t e m a i l : s t s @ s t s i t a l y. i t Customer Care STS: tel. +39 0544 456732 email: info.sts@stsitaly.it
ICT - HIGHLIGHT OF THE MONTH
MAFAC Cleaning Solutions: A New Dimension of Dynamic Cleaning Bettina Kern bettina.kern@mafac.de
© MAFAC
MAFAC – E. Schwarz GmbH & Co. KG, Alpirsbach - Germany
Opening photo: MAFAC PURA completes MAFAC’s product range downwards. The single-tank machine with spray cleaning is suitable for quick and easy component cleaning.
S
ince their entry into the aqueous parts
receptacle system is a crucial component
and time, clean component surfaces well and,
cleaning market, MAFAC cleaning
of this corporate success. It is based on the
at the same time, efficiently. In continuing
machines have set global standards
understanding that cleaning with motion
the development of this kinematic system
in terms of cleaning quality, efficiency and
is more efficient. Consequently, all MAFAC
approach, MAFAC now presents a new cleaning
application diversity. The patented process
machines work systematically with targeted
process, the MAFAC vector kinematics - a new
technology of counter- or co-rotating
turbulences. The combination of mechanical
dimension of dynamic cleaning - and a new
movements of spraying system and basket
components, temperature, cleaning additives
machine: the MAFAC PURA.
150
N. 54 - NOVEMBER/DECEMBER 2018 - international PAINT&COATING magazine
Figure 1: In cleaning processes with a rigid nozzle system, the partial regions which are not exposed (red) outweigh those which are optimally exposed (green).
© MAFAC
© MAFAC
ICT - HIGHLIGHT OF THE MONTH
Figure 2: Thanks to angular variance, the MAFAC vector kinematics leads to a significantly better exposure of the components. Optimally (green) and partially (yellow) exposed regions clearly outweigh unreached locations (red).
MAFAC vector kinematics more movement and focused turbulences
Innovative technology for more flexibility In particular, manufacturers of complex workpieces with geometries and
With the MAFAC vector kinematics process, there is even more
surfaces that can be reached in
movement to clean and dry
different ways benefit from
components. In contrast to the
this innovative process. The
process in a rigid nozzle system,
various angles of impact
the workpieces are not hit
lead to significantly less
at a specific angle (Figs. 1
spray shadows, so that excessive cleaning of easily
permits optimal angular
accessible component
variance on the surfaces of
regions with valuable
© MAFAC
and 2). The new method
the components (Fig. 3).
resources is avoided. The complete cleaning
The nozzle tube performs a rocking movement about
process is more efficient
its own axis through 35° to
and economical, which is
either side, while the basket
particularly advantageous in view of the requirements
receptacle system rotates
for constantly improving
synchronously at an optimally
cleanliness and increasingly
adapted speed. The maviatic
tighter budgets. In the future, users
controller of the machines calculates
will also be able to react with significantly
the movement of the basket rotation beforehand, whereby co- and counter-rotation are both possible. This coordinated interaction
greater flexibility to a wide range of parts
3 1
or to changes in the part program: thanks to the high angle variance, a large variety of
of nozzle tube and basket movements leads to a targeted and, depending on the part geometry, up to 60 % higher application on the component surfaces.
Figure 3: The new MAFAC vector kinematics permits a wide range of different angles for the application onto the component surfaces.
significantly different workpiece batches can be processed - from standard operation to sophisticated and varied angular application
international PAINT&COATING magazine - NOVEMBER/DECEMBER 2018 - N. 54
151
ICT - HIGHLIGHT OF THE MONTH
(Figs. 4a and 4b). The new MAFAC vector
programming have been reduced to
of individual workpieces. An optional
kinematics permits an effective execution
the essentials. Since the patented and
coalescence oil separator and high-quality
of many cleaning tasks.
proven MAFAC process technology with
main-stream filtration ensure long and
counter- or co-rotating basket-nozzle
stable bath service lives. Another benefit:
rotation is the indispensable core of the
the voltage range of the machine is
Stefan Schaal, Head of Development
machine, MAFAC PURA works specifically
suitable for worldwide use. The modern
and Design at MAFAC, is convinced of
with turbulences, thus achieving a safe
machine design, where MAFAC focuses
the pioneering importance of vector
and effective cleaning of the component
on the use of new materials, presents a
kinematics: “With the vector-kinematic
surfaces. The parts are dried via a hot-air
visually appealing appearance within the
movement of the nozzle and spraying
impulse blower system.
production process.
Pioneering technology
© MAFAC
system, we have succeeded in taking a first
“With the MAFAC PURA we round off
step into a new
our product
dimension of
range in the
dynamic cleaning.
lower range
The process
and specifically
permits its users to
address those
achieve the speed,
who are
quality and
entering the
cost-effectiveness
field of aqueous
that will be
parts cleaning,
required in
have little
industrial parts cleaning in the future”. In its current form, the new technology is
4A 1
experience or
4B 1
are operating
Figures 4a and 4b: Workpieces with complex geometries such as drilled holes and undercuts, in particular, benefit from the targeted turbulences of MAFAC vector kinematics.
a promising start
within a tight budget,” Peter Ruoff, Head of Marketing
further developments. “The innovation
High-quality technology for a small budget
approaches of vector kinematics are
In addition to powerful technology,
manifold. We are still at the beginning, and
the jubilee machine impresses with its
Available from stock
are moving into an exciting time.”
functionality and simplicity. The MAFAC
In this context, MAFAC also decided for
PURA standard selection program has
the first time to use the “machine to go
been designed such that it is easy for
principle”. The MAFAC PURA is built in
that offers great potential for numerous
Small and Fine: The Jubilee Machine MAFAC PURA
and Sales at MAFAC explains the machine concept.
anyone to operate. This enables the
batches of 10 and is therefore immediately
To mark its 50th anniversary, MAFAC
customer to start up the system on his
available from stock. “The purchase shall
is launching a new machine onto the
or her own. MAFAC telephone support
not be preceded by test cleaning. For
market: the MAFAC PURA, a powerful
or a service technician will be available if
the simple applications for which MAFAC
entry-level model for rapid, thorough
required. The equipment also supports
PURA has been designed, we rely on
cleaning (ref. Opening photo).
uncomplicated handling of the machine
our experience. It influenced product
The spray cleaning machine of compact
in other ways: the starter kit with basket
development fully in a standardized way,
design with single bath technology is
and cleaner makes it easy to get started.
so that no individual adjustments are
intended to be used as an all-round
The small basket size (471x321x200 mm)
necessary”, explains Peter Ruoff.
parts washer for decentralised use.
permits small batches to be processed, or
This makes “Plug and Play” possible for the
Accordingly, its structure and its
allows an intermediate and final cleaning
user.
152
N. 54 - NOVEMBER/DECEMBER 2018 - international PAINT&COATING magazine
ICT - ZOOM ON EVENTS
DeburringEXPO 2019 - Strong Demand for Booth Floor Space
R
oughly one year before
experience at the trade for as well: “We were
surface finishes, DeburringEXPO provides
DeburringEXPO opens its doors
able to establish contact with numerous tier
a representative overview of the relevant
for the third time, more than
2 and 3 companies and smaller businesses
systems, processes, tools and equipment,
70 companies have already made firm
from the automotive and aviation industries
as well as measuring, test and analysis
bookings for their booth floor space. This is
at DeburringEXPO, as well as from the fields
systems. The exhibition portfolio covers
a strong indication of growth for the trade
of hydraulics and pneumatics, with whom
processing of workpieces and components
fair for deburring technology and precision
we weren’t previously familiar – not only with
made of practically all technical materials
surface finishing, which will be held in
companies from Germany, but from many
and from nearly all industry sectors. “At the
Karlsruhe from the 8th through the 10th of
other countries as well such as Italy, France,
upcoming trade fair, even more attention
October, 2019.
Belgium, Sweden, Denmark, the USA, India
will be focused on the deburring of sheet
Even greater attention will be focused at
and Brazil. Participation at the trade fair
metal components than at previous
the upcoming event on the optimisation
has paid off for us and we’ll be back again
events, in particular lasered parts and
of deburring processes for sheet-metal
in two years,” reports Keisuke Kaga, Head
stampings, flame-cut and fine-blanked
components and additively manufactured
of Europe Sales at Sugino Machine Limited
parts, as well as additively manufactured
parts, as well as parts cleaning after
from Japan.
workpieces. Furthermore, we’ll also place
deburring. Added value will be provided by
Numerous other exhibitors at the last
more emphasis on parts cleaning after the
the DeburringEXPO expert forum which is
trade fair for deburring technology and
deburring process”, adds Hartmut Herdin.
in great demand as a source of knowledge
precision surface finishing arrived at this
Further issues covered by the exhibition
and will offer simultaneously interpreted
conclusion as well, and have thus already
portfolio include training and technical
(German<> English), highly practical
made firm bookings for their booth floor
literature.
presentations.
space at DeburringEXPO 2019. “Thanks
DeburringEXPO’s exhibition spectrum,
to a high exhibitor return rate, frequently
which is consistently aligned to deburring,
associated with increased booth size, as
Knowledge as Added Value – Bilingual Expert Forum
rounding and the production of precision
well as new exhibiting companies who have
Offerings presented by the exhibitors will
surface finishes, deals with processes which
already decided in favour of participating
be rounded out by the integrated 3-day
are becoming more and more important
at the upcoming event, the exhibitor list
expert forum at DeburringEXPO, which
in parts manufacturing: despite all of the
already included more than 70 companies
has established itself as a highly popular
optimisation measures implemented prior
in mid-October 2018,” says Hartmut Herdin,
source of knowledge. With simultaneously
to workpiece processing, residues remain
managing director of trade fair promoters
interpreted (German <> English)
which have to be removed for high quality
fairXperts GmbH & Co. KG. These currently
presentations, it provides visitors with the
downstream processes, and in order to
registered exhibitors will occupy nearly
opportunity of expanding their knowledge
assure flawless functioning.
70% of all exhibition floor space rented
in the fields of deburring and rounding, as
After only two events, the trade fair for
out in 2017, which is a good indication
well as the production of precision surface
deburring technologies and precision
that exhibition offerings will once again be
finishes. Beyond this, examples based on
surface finishing has already established
significantly increased.
actual practice and benchmark solutions
itself as an international information and
provide ideas and stimulation for the
of decision-making authority, 94% of whom
A Single Trade Fair for All Materials and All Industry Sectors
are involved in company decision-making
As a technology platform for deburring,
For further information:
processes, but rather by the exhibitors’
rounding and the production of precision
www.deburring-expo.de
procurement platform in this area. This is not only confirmed by the visitors’ high levels
154
N. 54 - NOVEMBER/DECEMBER 2018 - international PAINT&COATING magazine
optimisation of processes at one’s own company.
ICT - ZOOM ON EVENTS
Milan Hosts Second Successful Fastener Fair Italy. Dates Set For 2020 Show
A
total of 2700 managers, engineers and
attending the show. Department heads and
opportunities in the Italian market for the
buyers visited the highly successful
senior managers totalled 17% of attendees,
fastener and fixings industry. And with Milan
Fastener Fair Italy 2018, which took
while a further 11% were engineers and
such a dynamic business centre, it is the ideal
place at the Mico Milano Congressi on
technicians.
host city for Fastener Fair Italy.”
September 26-27. This was the second of these
The most strongly represented industry
events to take place in Italy.
sectors were the automotive industry,
Popular seminars
The number of suppliers of fastener and fixing
construction, mechanical engineering,
Adding a further important dimension to
products and systems taking part in the show
hardware / do-it yourself retailing, electrical
Fastener Fair Italy was an accompanying
was 210, filling the venue’s South Hall. While
products / domestic appliances, aerospace,
programme of technical seminars. These
22% of exhibitors were foreign companies
agricultural / off highway machinery and
proved highly popular, attracting a total of 175
representing 13 countries, participation by
furniture manufacturing.
delegates over the two days. Three sessions
Italian firms increased compared to the 2016
Exhibitors were delighted to welcome high
were devised by Show Partner Fasten.it
show, confirming that Fastener Fair Italy is
calibre Italian and international visitors,
(www.fasten.it), providing insights into issues
now established as the reference point for the
including the science-based technology
currently affecting the fasteners market.
market in this country. Among foreign nations
company 3M Italia, multinational corporation
These included seminars curated by A.I.F.M.
strongly represented were Germany, Turkey,
ABB S.p.A., world’s leading chemical company
Associazione Italiana Finiture dei Metalli,
the UK, Spain, while companies from Slovenia,
BASF, top global engineering companies
E.C.A.P. European Consortium of Anchors
Denmark, India, France and the USA also took
Ansaldo Energia, HILTI Corporation, Altran
Producers and Kistler Group. Also, selected
part.
Technologies.
exhibitors took to the big stage with their most
Leading industry associations supported
Among automotive companies represented
innovative ideas and solutions – the experts
the event and welcomed delegations on
by visitors were Ducati Motor Holding, LISI
from Coventya Group, Atotech Group, Frontline
their stands: the Italian Union of Fastener
Automotive, IVECO S.p.A. Buyers from the
Consulting and Filtereco Filtration Technologies
Manufacturers U.P.I.V.E.B., the Italian Union of
well-known appliance manufacturers Electrolux
presented the latest solutions to the issues
Fastener Distributors U.D.I.B. and the Italian
and De’Longhi attended the fair, as did
concerning fastener and fixing sector and
Association of Metal Finishing A.I.F.M.
technical specialists from IKEA Components.
related industries.
The mix of visitors to the show reflected the
In addition, there were visitors from
diversity of markets served by the fastener
the multinational steel manufacturers
More stand space in 2020
and fixing industry. Majority of visitors were
ArcelorMittal and Aferpi Steel Company. Local
Dates have now been set for the next Fastener
either wholesalers (24%) or distributors (42%),
and international representatives of leading
Fair Italy. The third show in the series will take
all playing a vital role in the supply chain to
fastener distributors and manufacturers,
place on November 11-12, 2020. The venue will
resellers and end-users. Around 20% were
including Würth, Fontana Gruppo, Stamperia
be Fiera Milano City and there has already been
end-users themselves. Fastener and fixings
Carcano Giuseppe, F.lli Mauri, A. Agrati S.p.A.
very strong demand for stand space. Following
manufacturers accounted for 34% of those
and many others.
the success of the show, some 50 companies
attending.
Commenting on the success of the event,
have confirmed their participation in Fastener
A significant number of visitors –28% –were
Olivia Griscelli, Exhibition Director at
Fair Italy 2020, with around 1,900 m² already
foreign, representing 62 countries.
organisers Mack Brooks Exhibitions said:
booked. In response, this next exhibition will
“We were especially pleased to receive very
occupy a large Pavilion 3 to provide additional
favourable feedback from exhibitors on the
stand space.
High visitor quality Visitor quality was also noteworthy, with
quality of visitors to this show. It was also good
managing directors, partners and board
to see such strong international participation.
For further information:
members accounting for 38% of those
This strengthens our belief in the many
www.fastenerfairitalia.com
international PAINT&COATING magazine - NOVEMBER/DECEMBER 2018 - N. 54
155
ICT - ZOOM ON EVENTS
T
he 16th parts2clean proved to be a complete success.
From 23 - 25 October
© Deutsche Messe AG
parts2clean 2018: First-class Contacts, Projects and Contracts
2018 the 240 exhibitors at parts2clean transformed Halls 3 and 5 of the Stuttgart Exhibition Grounds into an international hub for the industrial components and surface cleaning sectors. Companies from 16 countries exhibited at the event, including 26% from outside the host nation Germany. Approximately 4,500 trade visitors from 42 countries attended, a response that underlines the consistently sound performance of this international flagship event. Some 21% of the trade visitors came from outside
1
Figure 1: From 23 - 25 October 2018 the 240 exhibitors at parts2clean transformed Halls 3 and 5 of the Stuttgart Exhibition Grounds into an international hub for the industrial components and surface cleaning sectors.
Germany, including 76% from member nations of the EU and a further
contacts made at our stand was slightly
important role played by industrial parts
18% from non-EU European countries.
down on the previous year, but quality
and surface cleaning in maintaining
Germany, of course, accounted for the
clearly made up for quantity. In the past,
quality standards in diverse stages of
largest contingent of visitors. This year the
some of the discussions at the stand
production. This was made evident not
biggest groups of visitors from outside the
tended to be a bit cursory, but this year
only by the extraordinarily high proportion
host nation came from Austria, followed by
we were able to talk in more depth. These
of professionals who attended the event
Switzerland, France, the Czech Republic,
discussions led to concrete projects,
(99%), but also by the decision-making
Italy and the Netherlands.
dates for visits and even some tests of our
competence of the visitors within their
“We are entirely satisfied with the results
cleaning technology. We will definitely be
companies. One in two visitors came
of parts2clean 2018”, says Olaf Daebler,
exhibiting at parts2clean 2019.”
from management and 85% of all visitors
Global Director parts2clean at Deutsche
stated that they played a role in their
of the quality of the visitors.” This view
Decision-makers welcome this platform for information and acquisitions
was shared by Jens Emmerich, Product
The 16th parts2clean clearly showed
them came with clear ideas on acquisition
Manager for R&D, Surface Technology
that more companies from different
and investment, a figure that was slightly
at BCD Chemie GmbH: “The number of
sectors are beginning to recognize the
higher than at last year’s trade show.
Messe AG, adding: “Many exhibitors noted a further improvement in terms
156
N. 54 - NOVEMBER/DECEMBER 2018 - international PAINT&COATING magazine
company’s investment decisions. It was also clear that the visitors to parts2clean were keen to invest. No fewer than 82% of
ICT - ZOOM ON EVENTS
Marketing & Sales and a member of senior
“We have been exhibiting successfully at
had an investment budget of over 100,000
management at MAFAC – E. Schwarz
parts2clean for many years and 2018 was
euros at their disposal. In other words,
GmbH & Co., enthused about an order
another success. This trade fair only attracts
many of the trade visitors arrived at the
for the company’s latest cleaning system:
serious trade visitors interested in concrete
International Trade Fair for Industrial Parts
“parts2clean 2018 proved better for us
business and it gives us the time to discuss
and Surface Cleaning with clear intentions
than last year’s event, not simply because
their requirements and specific objectives
and concrete projects in mind.
we concluded a direct sale of a cleaning
with them in detail. parts2clean is always
Consequently, the exhibiting companies
system at our stand, but also due to the
a great opportunity to meet first-class
were able to report some excellent
number of enquiries received from new
contacts and convert them into potential
contacts, new projects and even contracts
contacts. The conversations with trade
new customers, as well as nurture existing
negotiated at the trade fair. “We could
visitors revealed that the trend towards
customer contacts and business partners.”
convert high-calibre contacts into potential
increased industrial cleanliness continues
Elia Bosco, Sales, Everest Elektromekanik
new customers at this year’s parts2clean
unabated. The main focus of interest is in
Makine Ve Sistemleri Sanayi ve Tic Ltd.
and were able to conclude a big order
the removal of particulates, residues and
Sti., Turkey, also considers parts2clean an
almost on the spot. That is relatively
film-like contaminants.”
ideal platform for initiating new business:
rare at a capital goods fairs such as
This positive experience was echoed by
“parts2clean offers an excellent opportunity
parts2clean,” explained Carola Maurer,
Raffaela Tessari, Sales and Customer
to promote our products and new
Market Development Assistant, Hobart
Care with the Italian manufacturer of
developments among the right audience.
GmbH. Similarly, Peter Ruoff, Head of
cleaning plant and systems, NOVATEC S.r.l.:
The quality of the international professional
© ipcm ®
Some 41% of these potential investors
2 1
Figure 2: Companies from 16 countries exhibited at the event. The team of ICT_ Industrial Cleaning Technologies were also present with the latest issues of the magazines.
international PAINT&COATING magazine - NOVEMBER/DECEMBER 2018 - N. 54
157
ICT - ZOOM ON EVENTS
visitors is outstanding and we will
The outcome of this year’s parts2clean
their specific needs, for example with
definitely exhibit again at next year’s
justifies our decision to exhibit at this
respect to both the partial or complete
parts2clean.”
trade fair every year.”
removal of residual, film-like
The manufacturers of cleaning plant
contamination of surfaces, as
register overwhelming satisfaction
Focus on trends and future requirements
with their trade fair participation.
A tour of parts2clean showed that this
AG, reported: “Compared to last
Suppliers of equipment from other
flagship event is not solely focused on
year, the number of leads was up by
areas of industrial cleaning were
current needs and demand for clean
about 30 %. These were primarily
also impressed. For example, Sandra
industrial components and surfaces. As
contacts from the automobile and
Gruber, from Sales & Marketing at
parts2clean organizer Daebler pointed
components industries, aerospace and
SensAction AG, said: “The number of
out: “We established that digitization and
electronics. The most frequent issue
visitors at our stand was similar to last
automation are making rapid inroads
was the partial removal of film-like
year, but the quality of the contacts
into industrial components and surface
contaminates, a challenge for which
made was higher. We are therefore
cleaning.” The organizers responded,
many companies do not yet have an
expecting good post-fair business.”
therefore, by including new display
adequate solution.”
Hans-Jürgen Oberdiek, Sales Marketing
formats, special presentations and
Manager, Carl Zeiss Microscopy GmbH,
various exhibits covering these
was also optimistic: “The visitors
future-focused areas. “This year, by
A cross-section of sectors and materials
approached us with a quite diverse
exhibiting combined preliminary solvent
The cleaning of industrial parts and
range of interests and requirements,
treatment and plasma technology, as
surfaces involves an extremely broad
which really underlines the growing
well as our digitization solutions, we
range of tasks and requirements,
importance of clean parts and surfaces
addressed the core needs of many users.
and this diversity is matched by the
within an increasing number of
We received an excellent response from
number of sectors from which the
sectors. Accordingly, we were able to
the visitors, particularly from customers
professional visitors at parts2clean
make a large number of new contacts
and existing business partners with
came. The sector with the biggest
at parts2clean, and this could generate
high expectations and requirements in
contingent of visitors this year was
more orders.”
specific areas such as film-like residual
the automobile industry with approx.
Florian Weber, Sales Director of
contamination or the digitization of
42%, followed by mechanical and plant
Weber Ultrasonics AG, had the same
cleaning processes. We were able to give
engineering, metalworking and metal
experience: “Yet again, we are very
them a clearer idea about the direction
processing, electrical engineering and
pleased with this trade fair. The
that this sector is taking”, said Rainer
electronics, precision engineering,
number of trade visitors and the
Straub, Board of Management, Vice
optics, pharmaceuticals, chemicals and
quality of the contacts was excellent.
President Sales & Customer Service,
production technology. The verdict
parts2clean is the only trade fair in
Ecoclean GmbH. His comments were
of the visitors at parts2clean was
this sector and we will be back next
echoed by Andreas Rosenbusch, Business
positive. An overwhelming majority
year.” Likewise, Tobias Jessberger,
Development Manager at Stäubli Tec-
stated that the event covered almost
managing director of Dr. Jessberger
Systems GmbH Robotics: “parts2clean
every aspect. Nine out of ten visitors
GmbH, reported: “Due to the
has signposted the role of Industrie 4.0
are confident that they will again
extremely high quality of the contacts
in the cleaning of industrial parts and
attend the International Trade Fair for
and the international outreach of
surfaces. The digitization of cleaning
Industrial Parts and Surface Cleaning
the trade show, parts2clean has a
plant and processes, as well as the
in the future. The next parts2clean will
firm place in our trade fair schedule.”
acquisition, evaluation and use of data
take place from 22-24 October 2019 at
Anja Wächter, managing director of
are huge topics that will assume greater
the Stuttgart Exhibition Grounds.
Metallform Wächter GmbH, came to
significance and for which we can offer
the same conclusion: “Our trade fair
an array of solutions.” However, many
For further information:
participation has again paid off - 100%.
sectors are still seeking a solution to
www.parts2clean.de
were not the only exhibitors to
158
N. 54 - NOVEMBER/DECEMBER 2018 - international PAINT&COATING magazine
Karl-Hein Menauer, Senior Manager Sales & Technologie at acp systems
eos eos
MKTG & COMMUNICATION MKTG & COMMUNICATION
&
W I S H YO U
2019
®
Questo periodico è associato all’Unione Stampa Periodica Italiana
INTERNATIONAL PAINT&COATING MAGAZINE TECHNICAL ADVISORY BOARD
Eos Mktg&Communication srl www.myipcm.com info@ipcm.it
Adolfo Acquati: Enamelling lines
Redazione - Sede Legale: Via Pietro Mascagni, 8 20811 - Cesano Maderno (MB) - Italy Tel. +39.0362.503215 - Fax. +39.0362.1794768
Attilio Bernasconi:
Paint stripping technologies and cryogenic processes
Ernesto Caldana:
EDITOR IN CHIEF / DIRETTORE RESPONSABILE
Franco Falcone:
ZLD Water treatment specialist
Gianfranco Verona: Water treatment
Coil coating pretreatment
ALESSIA VENTURI
The first international magazine for surface treatments
venturi@ipcm.it
®
EDITORIAL DIRECTOR / DIRETTORE EDITORIALE
Loris Rossi:
Surface treatment on aluminium
ISSN 2280-6083
ipcm digital on In this issue :
SPECIAL ON ACE & OFF ROAD VEHICLES
&
INDUSTRIAL CLEANING TECHNOLOGIES
INTERNATIONAL PAINT&COATING MAGAZINE
www.myipcm.com 2018
9th Year - Bimonthly N° 54 - NOVEMBER/DECEMBER
FRANCESCO STUCCHI
Michele Cattarin: Electrostatic application of powder coatings
Dr. Fabrizio Pitacco:
stucchi@ipcm.it
PVD coatings
EDITORIAL OFFICE / REDAZIONE
Dr. Ezio Pedroni:
PAOLA GIRALDO
Coil coating
giraldo@ipcm.it
Dario Zucchetti: Coating lines
Lauro Gatti: Air treatment
Oscar García Palop: Electrostatic application of liquid paints
MONICA FUMAGALLI fumagalli@ipcm.it
EDITORIAL BOARD
NICOLE KRAUS kraus@ipcm.it
Dr. Felice Ambrosino:
MATTEO SOTTI sotti@ipcm.it
Marketing
BARBARA PENNATI pennati@ipcm.it
ILARIA PAOLOMELO paolomelo@ipcm.it
MEDIA SALES
Prof. Massimiliano Bestetti:
The first international magazine for surface treatments
Department of Chemistry, Material and Chemical Engineering, Politecnico of Milan – Section of Applied Chemistry and Physics
Prof. Fabrizio Pirri:
Department of Material Sciences and Chemical Engineering, Politecnico of Turin, Micro and Nanosystems, Nanomaterials and Surfaces
Prof. Stefano Rossi:
Dr. Franco Busato:
NICOLE KRAUS
European environmental legislation and new technologies
Material Engineering and Industrial Technologies, University of Trento - Product Design
JONATHAN LOWE lowe@ipcm.it
Prof. Paolo Gronchi:
Marine and industrial anticorrosive coating cycles
FRANCESCO STUCCHI stucchi@ipcm.it
La prima rivista internazionale sui trattamenti superficiali
kraus@ipcm.it
Registrazione al Tribunale di Monza N° 1970 del 10 Dicembre 2009 Eos Mktg&Communication srl è iscritta nel Registro degli Operatori di Comunicazione con il numero 19244
POSTE ITALIANE S.P.A. – SPEDIZIONE IN ABBONAMENTO POSTALE – D.L. 353/2003 (CONV. IN L. 27/02/2004 N.46) ART. 1, COMMA 1 LOM/MI/4351
SUBSCRIPTION SERVICE - SERVIZIO ABBONAMENTI: Sale only on subscription - Vendita solo su abbonamento E.mail info@ipcm.it Subscription Rates 2019 - Tariffe Abbonamento 2019: Annual subscription print + digital: EMEA 90,00 € (postage included) Rest of world 300,00 € (fast airmail shipping included) Abbonamento annuale cartaceo + digitale: EMEA 90,00 € (spese postali incluse) Resto del mondo 300,00 € (spedizione via aerea inclusa) Single copy: 15,00 € EMEA (postage included) - Rest of world (postage excluded) Back issues: 30,00 € EMEA (postage included) - Rest of world (postage excluded) Fascicolo singolo: 15,00 € EMEA (spese postali incluse) - resto del mondo (spese postali escluse) Arretrati: 30,00 € EMEA (spese postali incluse) - resto del mondo (spese postali escluse)
LAYOUT/ IMPAGINAZIONE
P PRINT/ STAMPA S
LASER GRAFICA Digital srl www.lasergrafica.it
N NEW PRESS EDIZIONI srl www.newpressedizioni.com w
Department of Chemistry, Material and Chemical Engineering, Politecnico of Milan – Chemical Engineering Section
Dr. Antonio Tolotto:
Dr. Fulvio Zocco:
Environment and quality
Kevin Biller
The Powder Coating Research Group
Subscriptions can be made by bank transfer to the following account: Eos Mktg&Communication Srl IBAN IT97F0844033270000000084801 - SWIFT CODE CRCBIT22 or via payment online at: www.myipcm.com Gli abbonamenti possono essere sottoscritti versando il relativo importo a mezzo b/b IBAN IT97F0844033270000000084801 intestato a eos Mktg&Communication Srl oppure con carta di credito direttamente dal sito www.myipcm.com L’Iva sugli abbonamenti, nonchè sulla vendita di singole copie è assolta ai sensi dell’art.74 comma 1 lett. C DPR 633/72, DM 29/12/1989.
It is forbidden to reproduce articles and illustrations of “ipcm®” without authorization and without mentioning the source. The ideas expressed by the authors do not commit nor magazine nor eos Mktg&Communication S.r.l and responsibility for what is published is the authors themselves. È vietata la riproduzione di articoli e illustrazioni di “ipcm®” senza autorizzazione e senza citarne la fonte. Le idee espresse dagli autori non impegnano nè la rivista nè eos Mktg&Communication S.r.l e la responsabilità di quanto viene pubblicato rimane degli autori stessi.