ipcm n. 84 | November - December 2023

The smart journal for surface treatments

®

In this issue: SPECIAL ON ACE & OFF ROAD VEHICLES & INDUSTRIAL CLEANING TECHNOLOGIES

INTERNATIONAL PAINT&COATING MAGAZINE

WE’RE ALREADY IN THE NEW ERA

PERFORMANCE COATINGS

ISSN 2280-6083

ipcm digital on www.myipcm.com 2023

14th Year - Bimonthly

N° 84 - NOVEMBER/DECEMBER

March 26-28, 2024 Paris Expo - Hall 2.2 Porte de Versailles France

Exhibit at the unique 2024 European event dedicated to production & formulation of paints, varnishes, inks, glues and adhesives!

RAW MATERIALS COATINGS PIGMENTS

SOLVENTS

ADDITIVES

INK ADHESIVES

POLYMERS

FILLERS CONSTRUCTION CHEMICALS

PRODUCTION EQUIPMENT

MIXERS & MILLING LABORATORY EQUIPMENT CONTROL & MEASURING EQUIPMENT

COLORIMETRY TINTING SYSTEMS

PACKAGING & CONTAINERS

LINERS FOR PACKAGING DRUMS, CANS, BUCKETS

HANDLING EQUIPMENT & FREIGHT

APPLICATION EQUIPMENT SERVICES

Information & contact: Cyril Ladet | + 33 (0)1 77 92 96 84 | cladet@infopro-digital.com

www.eurocoat-expo.com

An event co-organised by:

CONTENTS NOVEMBER/DECEMBER 2023 © AdobeStock

14

ANALYSIS

© ASSA ABLOY

32

Technology To Bridge the Skills Gap

HOW IT'S COATED

Ode to the Black Finish Enhancing the Elegance of Valli Handles

© ipcm

© Pilla Srl

46

FOCUS ON TECHNOLOGY

Flexible, Customised Production: Pilla Meets the Challenges of the Funerary Art Industry with a New Liquid Coating Plant

07 EDITOR’S LETTER 08 BRAND NEW 18 BRAND NEW 22 RESEARCH BREAKTHROUGH

A Transparent Wood-Based Coating That Does Not Fog Up

24 ROAD TO 2050

Arkema Will Install a New Purification System to Decarbonise its Acrylics Production

OF THE MONTH 26 HIGHLIGHT ON VOLUDE: The Theme of BASF’s 2023-2024 Automotive Color Trends Collection

60

OF THE MONTH 28 HIGHLIGHT Beyond Chemistry, Water: DN Chemicals Expands with a New Branch Devoted to Water Treatment

36 BRAND NEW STORY 40 SUCCESS Eurotherm Supplied an Automatic Powder Coating Plant to the British Manufacturer Broxap

42 ADVANCEMENTS Electrifying Efficiency: how Insulation Coatings can Enhance EV Design and Sustainability

FOCUS ON TECHNOLOGY

Water-Based Coatings for Finishing Mining and Construction Vehicles: Gervasi’s Green Choice Since 2010

52 WHERE WE HAVE BEEN 53 SPECIAL ISSUE ON

ACE & OFF ROAD VEHICLES

54 BRAND NEW 56 SUCCESS STORIES

A Record-Sized Booth for Industrial Vehicle Coating

68 FOCUS ON TECHNOLOGY

Industry 4.0 and Sustainability: the Two Cornerstones of John Deere Ibérica’s Investment in Paint Mixing and Feeding Equipment for Its Two Transmissions Finishing Lines

PRETREATMENT & WATER TREATMENT

OUR SKILLS INNOVATION PERFORMANCE NANO TECHNOLOGY R&D ESG TECHNICAL ASSISTANCE

a Dollmar Group Company

CONTENTS NOVEMBER/DECEMBER 2023 © Tikkurila

78

SUCCESS STORIES

© SEPPI

96

The World's Leading Manufacturer of Agricultural Machinery Chose Tikkurila Paint

FOCUS ON TECHNOLOGY

Seppi: a Pioneer in Mechanised Agricultural Mulching, a Pioneer in Environmentally Friendly Coating

© Mival

© AkzoNobel

118

HIGHLIGHT OF THE MONTH

128

Sweet Embrace: Interpon Colour of the Year 2024. Sweet on Colour, Strong on Design Performance

74 SUCCESS STORIES

Shot Blasting Pretreatment with AGTOS Technology for Liquid Coating of Agricultural Machinery

80 SUCCESS STORIES

Coatings from HMG Paints Employed for the Red Massey Ferguson 35X Tractor Restoration Project

82 ADVANCEMENTS

AQUAMIX WORLD: The New Fast-Hardening System

86 HIGHLIGHT OF THE MONTH

Europolveri Renews its Range of Anti-Corrosion Primers

88 FOCUS ON TECHNOLOGIES

Z3 Verniciatura Strengthens Its Core Business by Installing an Environmentally Friendly, Automatic, Hybrid Coating System Applying Both Liquid and Powder Products

104 FOCUS ON TECHNOLOGIES

2elle-engineering Chose to Electrify Its New Coating Plant for Zero-Emission Production of Forged Wheels

112 ANALYSIS

In Search for Competitiveness

122 FOCUS ON TECHNOLOGIES

VIV Group Continues to Upgrade Its Powder Coating Lines with Custom-Designed Hooks

FOCUS ON TECHNOLOGY

Mival Intensifies Automation with a Customised Self-Learning Robot and a New Water-Based Paint Dosing System

126 SUCCESS STORIES

Dürr Developed and Installed a Smart and Sustainable Coating Plant for Electric Cars

OF THE MONTH 136 HIGHLIGHT Nuova Catena: High Quality and Attention to Detail in the Production of a Wide Range of Conveyor Chains

OF THE MONTH 140 HIGHLIGHT The Brand-New PVC Cyclone Powder Booth Is a Game Changer for the US Powder Coating Market

OF THE MONTH 144 HIGHLIGHT Pulverit Celebrates Its 50 Anniversary th

with Huge Investments in Innovation

AXALTA COATING SYSTEMS

Voltatex® ECO Line Wire Enamels, designed for electrification and a sustainable future

Embrace innovation with a product that not only aligns with environmental consciousness but also delivers unparalleled performance.

•

Cresol- and phenol-free: our wire enamels are crafted without cresol and phenol, ensuring a cleaner and more sustainable solution.

•

Reduced voc emissions: committed to reducing our environmental footprint, our eco line minimizes voc emissions, contributing to a healthier planet.

•

Excellent electric insulation: experience top-notch electric insulation, providing reliability and efficiency for your applications.

•

Outstanding chemical resistance: our wire enamels offer superior protection with excellent resistance to various chemicals, ensuring durability and longevity.

•

Safer transport, storage, and handling: prioritize safety with our eco line, designed for secure transport, storage, and handling, minimizing risks for your team.

•

Thermal stability and mechanical properties: trust in the thermal stability and robust mechanical properties of our wire enamels, ensuring consistent performance under varying conditions.

Make a conscious choice for the environment without compromising on quality.

Elevate your projects with Voltatex® ECO Line – Wire Enamels, setting the standard for sustainability and performance in the world of electrification.

Axalta Coating Systems Uferstrasse 90 4057 Basel Switzerland www.axalta.com/electricalinsulation

CONTENTS NOVEMBER/DECEMBER 2023 © Ecoclean GmbH

© Merck

150

HIGHLIGHT OF THE MONTH

Merck Effect Day 2023: Special-Effect Colours and Digital Solutions for Multiple Sectors

174

TECHNOLOGY OVERVIEW

Answers to the Transformation Processes in the Industry: Ecoclean Meets Current and Future Challenges with Diversification

© Sanelli

182

CASE STUDY

© Tor.Met

192

Coltellerie Sanelli: Sustainable, High-Quality Cleaning of High-End Cutting Tools

146 ASK JOE POWDER

171 ICT - INDUSTRIAL CLEANING

154 UCIF Informs

172 HIGHLIGHT OF THE MONTH

The “Ask an Expert” Column

The Value of a Trade Association Today

WITHIN SURFACES 156 ART IMPERFECTION/EVOLUTION: The Futurism-Inspired Book Created

by VRB to Celebrate Its 40th Anniversary

TO 2050 160 ROAD Fraunhofer IFAM Developed the Sustainable PFAS-Free Non-Stick PLASLON® Coating

162 MEETING THE INDUSTRY

TECHNOLOGIES

From the Black Forest to the Global Industry: 25 Years of Ultrasonic Cleaning by Weber

178 CASE STUDY

Snow Ensures Cleanliness for Space Missions: quattroClean Technology for Cleaning Lightweight CFRP Structures

188 TECHNOLOGY OVERVIEW

The Operational and Economic Benefits of Recycling Process Water with Centrifugal Technology

CASE STUDY

A Cleaning Plant for Small Metal Parts That Is Perfectly in Line with the Principles of Tor.Met’s New, People-Oriented Factory

198 CASE STUDY

MMV and the Importance of Choosing Circular Products and Processes in the Industrial Cleaning of Small Metal Parts

204 INDUSTRY NEWS 206 MEETING THE INDUSTRY

EDITOR’S LETTER

Richiedi la versione in italiano a info@ipcm.it

W

ater-soluble coatings’ technological performance has been consolidating since the 2000s, undermining the reign of solvent-based products in many industrial sectors. In those early years, using them was a bold decision: their application called for much more care in terms

of technical requirements and operating conditions (humidity, temperature, booth air quality, suction) and their performance degree still seemed unable to match that of solvent-based coatings.

Water-based paints were thus a green but brave choice, an option that forward-thinking companies took into consideration wherever possible to reduce the environmental impact of their finishing operations and avoid investing in air purification equipment. Heterogeneous environmental regulations (from country to country and even from region to region) also resulted in the uneven adoption of these environmentally friendly technologies: where regulations were more restrictive, companies were more inclined to transition to water-based coatings, whereas elsewhere many firms preferred to stick to solvent-based products.

Sustainability was not yet a competitive market factor as it is today, nor was it a concept embraced by the industry at all levels.

Over the years, however, with the development of increasingly high-performance paint products and of application equipment specially developed to enhance the performance of water-based paints and foster the required mindset change, these coatings have conquered numerous markets – first and foremost, that of agricultural, earth-moving, and construction machinery and off-road vehicles in general, to which this issue of ipcm® is devoted.

What has happened during these twenty years? In this sector, which we will call ACE for the sake of brevity, water-based paints are now a well-established technological choice: they are reliable and long-lasting and guarantee glossy finishes with excellent film distension and mechanical, chemical, and corrosion resistance properties. Their adoption by numerous European companies has also brought with it a renewal of the coating systems employed and breathed life into the equipment and plant sector, which has responded by developing new generations of energy-saving, efficient, digitised products. That is the ideal combination for sustainable, quality production. This is also proven by the reports we have written by visiting numerous companies throughout Europe that have chosen waterbased coatings for their commercial success.

R&D in the field of water-based paint is now especially focussing on fast-drying, energy-efficient systems made highly versatile by the possibility of modulating their performance level according to requirements. You will find an extensive analysis of this topic in the central pages of this magazine.

At the same time, of course, the ACE sector is also seeing a progressively wider adoption of powder coatings, thanks to the development of corrosion protection primers that are ideal for mixed systems and for any company looking to reduce further the environmental impact of its coating activities. You will also find ample proof of this on the following pages.

Because sustainability is a competitive market factor nowadays: a company’s environmental, social, and corporate governance (ESG) has become a business factor capable of making a difference. Because sustainability is synonymous with quality, durability, and products designed and manufactured to last.

Finally, as usual, this issue of ipcm® also contains much more interesting and appealing information for the eye and mind of anyone dealing with coating: what better time than the holiday season to enjoy it to the fullest?

Season’s greetings to all of you from ipcm®!

Alessia Venturi Editor-in-chief Direttore Responsabile

Erratum: in Issue no. 83 of September/October 2023, we gave the wrong age to company MI Due, which celebrated its 50th, not 45th, anniversary. We apologise to our readers and those directly concerned.

international PAINT&COATING magazine - NOVEMBER/DECEMBER 2023 - N. 84

07

BRAND-NEW © Sherwin-Williams

Sherwin-Williams Coil Coatings Presented Upward, Its Colour of the Year 2024 The breezy and tranquil shade Upward has been selected as colour of the year 2024 by Sherwin-Williams Coil Coatings to brings a clean slate and a sense of possibility to any setting.

T

he Coil Coatings division of the international paints manufacturer

“Color of the Year is researched across our organization. This team,

Sherwin-Williams has recently presented its new colour of the

which represents each of our business units, gathers throughout the

year 2024: Upward, a breezy and tranquil shade of blue that

year to share updates on their research of trends and colour. We are

brings a clean slate and a sense of possibility to any setting, allowing

taking those effects and bringing it to an application that people do not

creativity to soar.

typically expect. It is an inspiration thing: we push peoples’ expectations

Each year, Sherwin-Williams brings together a panel of colour-

and inspire them to consider other options,” has stated Brynn

minded experts who combine research, analytics and trend tracking

Wildenauer, the architectural colour designer of Sherwin-Williams.

to conceptualise not only what the markets want, but also what they

By using the available range of finishes and effects, the colour team

need. From this methodical analysis, they then determine how the

pushes expectations and helps customers to break out of a rut of

colour space is evolving and consider which enhancements, effects and

muted palettes. For Upward, options include base, low gloss, high

finishes could be employed in the various markets for long-term use. As

gloss, texture, Fluropon® Classic II, Kameleon, Nova, WeatherXL™ and

a matter of fact, it is important to establish that a colour or a palette for

WeatherXL Crinkle. Applying Upward with a wood grain might be more

the industrial market is sustainable for years to come, since longevity is

residential, for example, while combining it with a mid-tone grey in a

fundamental.

concrete print could make a statement on a commercial building. In the

The previous colours, the mid-tone Evergreen Fog and the light

agricultural market, it might be the siding of a barn or a garage door,

terracotta of Redend Point, lightened up the palette of the company.

whereas in commercial buildings, a colour like Upward could be used as

Upward continues the shift while still working cohesively with it: the new

a small accent in siding or on a larger scale on panels.

airy hue works as an accent but could also serve as a base neutral. For instance, when paired with darker tones such as Urbane Bronze and

For further information:

Naval, they behave as two neutral tones working together.

industrial.sherwin-williams.com/na/us/en/coil-extrusion.html

08

N. 84 - NOVEMBER/DECEMBER 2023 - international PAINT&COATING magazine

BRAND-NEW

Ryan Harrison Will Be the New Managing Director of IMCD Australia and New Zealand The future Managing Director of IMCD in Australia and New Zealand will help the company to strengthen its position in the chemicals market.

T

he specialty chemicals supplier IMCD has

of the Asia-Pacific region Andreas Igerl, holds

recently announced that Ryan Harrison will be

a bachelor’s degree in Chemistry and applied

the new Managing Director for its subsidiaries

Chemistry from the Gordon Institute of Business

in Australia and New Zealand, starting from January

Science Business School and has a vast experience

1st 2024. He will help the company to grow in the

in the chemical industry. Before joining IMCD, he

local markets by promoting business operations,

covered several management positions for various

exploring mergers and acquisitions opportunities as

multinational companies, such as AECi Limited.

well as advancing the digitalisation of the business

“Australia and New Zealand is our longest-serving

and expanding relationships with partners and

market in the APAC region, and we appreciate the

customers.

foundation the team built over the years. Ryan’s

“I am honoured and excited to take on this new

strategic vision and proven leadership skills will

role in Australia. I thoroughly enjoyed the last four

play a pivotal role in guiding our Australia and New

years at IMCD South Africa, and I look forward to

Zealand business towards the next level of growth

working with the talented team here to build on the

and development,” has commented Igerl.

PASSION FOR MASKING SOLUTIONS www.global-mask.com

WHEELS

company’s successes and drive it to even greater heights in the future,” has stated Harrison.

The future managing director, who will be based in

For further information:

Melbourne (Australia) and report to the president

www.imcdgroup.com

CUSTOM

© IMCD

STANDARD

BRAND-NEW

Imel Increases its Portfolio of Coating Plants in the Automotive Market Imel has successfully installed a strategic coating line for a very important automotive customer in Asia.

I

mel Spa, a company based in Codroipo (Udine, Italy) and specialised in the design and construction of coating plants since

1964, is honoured to announce it has been chosen by the BMW Group as the supplier of a new E-Coat + powder coating line for motorbike frames, which is very strategic for the eastern market.

Counting over 1500 systems produced on a global scale, Imel wants to strengthen its presence in the Asian market and this new reference enabled the company to consolidate its position as a ‘High level quality supplier’ in the coating market.

Following meticulous cooperation work with local businesses and the coordination of on-site activities, Imel successfully achieved

© Imel Spa

the start-up of the line within the required timeframe. After only 10 days of laboratory testing since the start of pilot production, the company obtained validation of the coating quality by BMW for the launch of series production. In addition, after only one week of testing and adjustments, the powder and electrocoating curing ovens obtained the client validation of the curing curves.

“This new partnership with such a prestigious customer has enabled us to acquire the necessary skills to work in the top-of-the-line automotive sector,” has stated the company.

The advantage of this new electrocoating + powder line is the employment of different energy carriers with efficient power recovery to make the system green.

For further information: www.imelspa.com

© Imel Spa

10

N. 84 - NOVEMBER/DECEMBER 2023 - international PAINT&COATING magazine

BRAND-NEW

Kraton Launched the Nexar Anti-Fog Coatings for Medical Personal Protection Equipment The new coating developed by Kraton prevents fogging from face shields and eye protection equipment worn by healthcare professionals. and the use of proper PPE. The same also survey

© Pexels

revealed that fogging eyewear prompted individuals to touch their faces more frequently, compromising safety protocols.

Through extensive research processes, Kraton has developed the new Nexar Anti-Fog coatings and films to offer a cutting-edge solution to the fogging problems commonly associated with certain PPE. The new technology helps to provide healthcare workers with a useful tool that creates prolonged fog-free eyewear, ensuring uncompromised visibility.

Nexar Anti-Fog coatings and films incorporate a highly advanced technology that combines hydrophobic and hydrophilic segments to effectively remove moisture that causes fogging while providing exceptional strength and flexibility at the same time.

The specialised nanochannels integrated into the surface can swiftly capture and absorb moisture upon contact, leaving no time for fog to form: they

K

can indeed absorb over 200% of its weight in water. raton has recently presented its Nexar Anti-

In addition, the coating developed by Kraton does

Fog coatings and films: the international

not include per- and poly-fluoroalkyl substances

manufacturer of sustainable specialty

(PFAS).

polymers and high-value biobased products derived

“As a company committed to the well-being of

from pine wood pulping co-products has developed

healthcare workers and patients, Kraton understands

the new solution in order to specifically address

the importance of clear vision in delivering

persistent fogging issues experienced by healthcare

exceptional care. We are proud to introduce Nexar

professionals when using personal protection

Anti-Fog coatings and films, which address the

equipment (PPE), such as face shields and eye

daily challenges healthcare professionals face. Our

protection. Traditional face shields and goggles are

advanced technology enables healthcare workers

prone to fogging, causing discomfort and hindering

to work comfortably with prolonged vision clarity,

clear vision during critical procedures. Several surveys

making their daily tasks safer and more efficient,” has

and studies have highlighted fogging as the primary

stated Jeff Mathers, General Manager at Kraton.

concern expressed by healthcare workers. As a matter of fact, in a comprehensive survey conducted with over 1,600 healthcare professionals, fogging

For further information:

has been identified as a significant barrier to comfort

www.nexar-antifog.com

BRAND-NEW

X-Rite Showcased Colour Measurement and Appearance Solutions at Western Coatings Show At the Western Coatings Show, X-Rite presented advanced formulation software and its latest spectrophotometers.

X

-Rite Incorporated has showcased

advanced formulation software and the X-Rite

measurement. At Western Coatings Show,

its latest colour measurement and

Ci7000 Series, MA-T12 and MetaVue VS3200

attendees learnt how X-Rite measurement

appearance solutions for a sustainable

spectrophotometers.

devices go beyond spectral measurements

workflow at the Western Coatings Symposium

The colour experts from the company

to characterise material appearance and

and Show, an international trade fair

discussed with the attendees of the event,

connect to a digital workflow, streamlining

dedicated to paints and coatings that took

in order to help them identify which

colour communication, formulation, and

place from 15 to 18 October 2023 at the

X-Rite spectrophotometer is best for

quality control,” has stated Matthew Adby, the

Paris Las Vegas Hotel & Convention Centre in

their application and create digital colour

director of product management for X-Rite.

Las Vegas (Nevada, United States).

standards that can be shared across the

The global provider colour science solutions

international supply chain. Moreover, they

and technologies allowed visitors to

could learn about the extensive colour

Appearance characterisation for effect and structured coatings

understand how a digital colour workflow

education and employee training of the

In addition, X-Rite presented a session on

helps coating manufacturers accelerate

company, which offered free webinars, on

appearance characterisation for effect and

colour formulation, ensure an accurate

demand seminars and on-site trainings.

structured coatings. The speakers explained

colour match, avoid colour rejections, create

“The complexity of using new bio-based and

how portable measurement devices now

digital material renderings and improve

recycled material and the need for a more

include Spatially Varying Bidirectional

customer satisfaction. Among the showcased

sustainable and efficient manufacturing

Reflectance Distribution Function (SVBRDF),

solutions there were the Color iMatch

process is driving innovation in colour

which is used to characterise and control

th

th

multiple appearance attributes such as sparkle, flip & flop, roughness and texture.

These material appearance properties

© X-Rite

can now be communicated throughout a workflow from design visualisation through the supply chain for quality control, allowing for accurate virtual prototyping and quality control and eliminating wasteful iterations in the design, physical prototyping and manufacturing process.

“Manufacturers can eliminate subjective colour communication and assessment that often ends with unnecessary waste, reduce the need for physical prototypes, and verify colour is on target through all stages of the manufacturing process,” has added Adby.

For further information: https://shorturl.at/qrtyW

12

N. 84 - NOVEMBER/DECEMBER 2023 - international PAINT&COATING magazine

BRAND-NEW

Dürr and Kawasaki Robotics Developed the ready2integrate Automated Painting System Concept Dürr and Kawasaki Robotics collaborated to adapt robot technology and painting components to compatible solutions for automated painting processes.

A

utomatic flexible and high-quality painting

leading industry robotics. Compatible Kawasaki robots

processes are now a long-established standard

and Dürr applications and control technology are

in the automotive industry and are also

the perfect addition to the ready2integrate product

increasingly requested in several other sectors as

range,” has stated Ulrich Tautz, the sales manager of

well. So, the German engineering company Dürr is

industrial products of Dürr.

aligning its painting technology with robotics solutions

“I see great potential in the collaboration. Dürr is a

for general industrial needs in collaboration with

global market leader for painting technology and the

Kawasaki Robotics.

perfect partner for Kawasaki Robotics to combine

As a matter of fact, both partners have

state-of-the-art solutions and economy. It was great

electromechanically adapted products from their

to see how our teams brought their know-how and

respective portfolios, simplifying and speeding up the

ideas together, and we are delighted to bring the

integration of robots and painting equipment into

fruits of our joint labour to the market now,” has also

automatic coating systems. The “ready2integrate”

added Marc Kluge, the leader of the marketing team

concept encompasses Dürr products such as

of Kawasaki Robotics.

metering pumps, colour changers, spray guns, EcoAUC controller and the EcoBell2 that seamlessly interface with Kawasaki RS007L high-speed robot and the new KJ155 painting robot. In this way, customers will be able to quickly choose compatible Kawasaki and Dürr products that, after a quick installation process, can operate with a simple selection matrix.

“We want to enable a range of businesses to automate their painting processes.

Therefore, it is crucial to keep effort and obstacles for integrators and end customers to a minimum.

This is precisely the aim of our ready2integrate concept. It includes the perfect matching of our painting technology with

© Dürr

For further information: www.durr.com

© AdobeStock

ANALYSIS

Technology To Bridge the Skills Gap Derek DeGeest DeGeest Corporation - Tea, South Dakota (SD) – United States

derek@degeestmfg.com

Referred to as the manufacturing skills gap, this issue continues to plague companies unable all over the western world to find workers who have the skills needed to take open positions, particularly in finishing. This issue affects mature markets, in particular, and it is something that USA and Europe have in common. The following editorial shows how technology can be leveraged to bridge the skills gap with both existing and new employees. It was taken from a speech held by Derek DeGeest, President of LestaUSA and DeGeest Corporation, during an educational session at the last FABTECH Chicago, the North America’s largest metal forming, fabricating, welding and finishing event.

I

t has been over ten years since manufacturers started talking about a

risk of missing the next evolution in manufacturing, and it will be difficult

skills gap. Yet positions remain empty because companies are unable

to play catch-up.

to attract workers.

Applicants today either assume manufacturing is still an old-school job

Instead of waiting for the skills gap to be fixed by our education system

or that it has transformed into smart factories with jobs made easy from

or by stealing workers from each other to fill open positions, you can be

automation. Whichever industry, career path or job they choose, there

part of the solution by changing your mindset. If you do not, you are at

is a general expectation that technology will augment their tasks and

14

N. 84 - NOVEMBER/DECEMBER 2023 - international PAINT&COATING magazine

ANALYSIS

digital information will be available. No matter where your company is

© DeGeest Corporation

at in your technology journey, manufacturing as a whole has to step up its game. With the endless job options the available workforce has today, when an applicant walks in the door, we owe it to our industry to be ready. The good news is that today’s manufacturing can actually deliver what these new workers are looking for. Technology allows manufacturers to reduce tedious manual tasks through automation.

Technology can retain legacy knowledge and present it in an interactive way for the next generation to learn skills for the job.

A technology change affects your workforce differently The goal is to capture the experience and knowledge that exists in the people you have today before it is gone. To successfully do this, we need to understand the impact technology has on two distinct groups:

Derek DeGeest

• Current skilled employee that teaches and works with a new employee: - Expects the new employee will go through all the trials they did to learn

Using technology to bridge the skills gap has impact

their skills over time.

When we are able to capture legacy knowledge, training new employees

- If the new employee does not, it causes distrust and a lack of earned

impacts your production and resources differently than it did before.

respect that is hard to overcome.

• You do not have to take your skilled people out of production to

- Protects what they know instead of teaching what they know.

retrain new hires repeatedly.

• New employees will feel empowered to be able to have the

• Incoming new employee that needs to learn the skills:

information to reference and use without bothering another employee.

- Expects to have access to technology and automated equipment to

• Brings instant information and confirmation to employees that they did

help them learn new tasks and skills.

a job correctly. This instant gratification can be very engaging.

- Does not have patience for being held back by continually asking for

• You are going to get an entry level person or new hire up to speed

legacy knowledge.

quicker because that is how they are used to learning.

- Will not stay in a manual task they feel should be automated.

Technology and process create new ways to systematize legacy knowledge

Technology does not replace employees. It strengthens them Many industries have successfully integrated technology into their

The legacy knowledge and experience of your people was learned over

workflows. For example, some fast-food restaurants and coffee shops

many years. That process is in direct conflict with the expectations of

have dashboards that practically gamify the customer seating and order

incoming employees. Coupled with the average length of employment at

fulfilment process. If they can do it, so can manufacturing.

a job in manufacturing going from 8 years for Baby Boomers to less than

At DeGeest Corporation, technology allows people to see the work

2 years for Gen Z, companies need to change their training programs

they are accomplishing with touchscreens at every station to view job

before the knowledge of your experienced people is gone.

queues and bring about transparency. Instead of being told what to do,

Access to the Internet has changed how we learn. Most people are

these screens provide real-time information and put decision-making in

learning independently from others experience. How often have you

workers’ hands to give them a feeling of empowerment.

watched a YouTube video to learn how to do something? By creating

Machine metrics allow people to see how long each machine is running,

opportunities for existing employees to save their knowledge it actually

which helps to set and attain production goals. It is no longer about

frees them from their current tasks instead of forever training the next

just punching in and punching out. Instead, information is presented

new employee all over again.

in a way that results in people feeling good about what they are

This simultaneously creates engaging ways to allow new hires to learn

accomplishing. It is the difference between being engaged and being

more independently.

present.

international PAINT&COATING magazine - NOVEMBER/DECEMBER 2023 - N. 84

15

Automated repetitive tasks to elevate skills Instead of the wear and tear on the body that comes from manual finishing, automation gives workers a chance to work with robots.

Technology has become a desire, if not an expectation.

In the past, there was the belief that finishing automation only made sense for manufacturers such as automakers because a painting robot only needs to be programmed to paint a limited variety of parts.

Self-learning finishing robots, on the other hand, are for high mix production. A person “teaches” the robot how to paint a part in real time. The robot records every gun angle, pre-set spray patterns, path speed, and technique.

These movements and application equipment controls ultimately © DeGeest Corporation

encompass the finisher’s knowledge, which can then be replicated as a saved program on all future parts. This allows finishers to train the robot to be an extension of themselves, including all of their legacy knowledge of the part.

This process empowers teams to use their application knowledge to not just get through a day-to-day job, but create a career in which they can improve the quality and production of the entire system.

Say goodbye to repetitive tasks.

Say hello to engaging challenges It is hard to have an engaged workforce if all they are doing is asking someone how to do everything or doing repetitive tasks. That is where technology comes into play.

When finishing parts, there are many complex processes. These unique processes are typically learned over time, and rely on part repetition and © DeGeest Corporation

Lesta Self-Learning technology saves the painter's knowledge of each individual part in real-time while the painter uses the robot to make the program. Lesta's Production Manager calls up the saved program once the parts enter the booth.

memory. Now the legacy knowledge of your parts can be saved in digital work instructions that automatically display for all workers to reference for each specific task with Lesta's Production Manager.

Imagine what it would be like to have the process know-how of all of your parts saved and displayed for every step of hanging, masking, plugging, painting, assembly, and packaging. Instead of relying on legacy knowledge of each unique part and process, the information allows skilled employees to move to higher value areas of the department and can rely on entry level employees to follow the instructions that include the part specific knowledge needed for the task.

Do not fear technology. Embrace it Manufacturers need to implement new technology to recruit and retain new talent. Those who sit on the sidelines will fall behind.

Embracing technology gives your employees the tools they need to © DeGeest Corporation

Production Manager saves valuable time and knowledge for both operators and robots to know exactly how to process the parts with unique hanging, masking, prepping, painting programs, and packaging instructions.

16

N. 84 - NOVEMBER/DECEMBER 2023 - international PAINT&COATING magazine

get their work done efficiently. Embracing technology also helps new talent get up to speed quicker by growing their confidence. In doing so, these new team members will become better accepted by existing team members to create that all-important level of chemistry needed for a manufacturer to thrive.

ANALYSIS

So, the next time you hear about a skills gap, it may really be a

skills are needed. It is so easy; you can be finishing robotically on Day

technology gap that needs to be bridged.

One following installation.

The more you embrace it, the quicker your path to success through

Versatile: whether it is continuous, power & free, batch or cart, Lesta

rising production and employee retention and engagement.

robotic technology works with any new or existing system.

Self-learning: Lesta self-learning robots and solutions allow finishers to

The LestaUSA advantage

be able to teach the robot how to coat complicated parts in a weightless

Our finishing solutions use proven European self-learning robotic

self-learning mode allowing precise control of every gun angle, trigger

technology that has been adapted within the DeGeest production

pull, path speed and spray technique recorded in real time and saved

environment so manufacturers can thrive in a range of applications.

for future use.

The entire solution is then integrated by DeGeest for peace of mind.

That means expert training and support by a team of craftsmen with

Not your typical integrator

a deep bench of knowledge and experience. DeGeest is the only

Proven: solutions are born in a production environment. Each Lesta

integrator that uses what it sells in its own production environment to

system is built and tested at DeGeest to ensure all components work

elevate the entire system beyond just a robot’s path generation.

together after they are installed.

Experienced: installation, training, and support are delivered by an

Not your typical robot

experienced in-house team.

Simple: while traditional robotic technology can be complex and

Robust: robots are more than a standalone; they are skilfully integrated

intimidating, LestaUSA allows manufacturers to take advantage of

with system and equipment partner components for a more robust

robotic finishing quickly and easily because no advanced programming

solution.

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BRAND-NEW

Clariant Launched the New Ceridust® 8170 M PTFE-free Texturing Agent for Powder Coatings The newly additive Ceridust® 8170 M developed by Clariant is REACH compliant and ensures a lower energy usage compared to PTFE containing products.

I

n order to address the growing concerns around the impact of

can then be employed to formulate paints and coatings for window

PFAS (per- and polyfluoroalkyl) substances on human health and

frames, fence surfaces and furniture as well as bicycle rims and several

the environment and the consequently rising demand for PTFE

other industrial products. It is also compliant with the REACH legislation

alternatives, Clariant has launched the new PFAS/PTFE-free Ceridust

of the European Union and can help to lower energy consumption

8170 M agent with texturing effects specifically developed for

during the extrusion process.

architectural powder coatings. Global regulations are now increasingly

“As a sustainability front-runner, Clariant is taking a proactive, pro-

targeting PFAS-related compounds. As a matter of fact, the European

safety and pro-environment approach to help customers navigate

Union has developed legislation to further restrict or ban PFAS products

this uncertain and fast-moving landscape. With Ceridust® 8170 M,

from as early as 2026, the Japanese environment agency has approved

the challenge was to create a product for texturing effects in powder

a ban on the manufacture, import and use of 56 PFOA- related

coatings that was PTFE-free and that offered equal performance to

compounds and the Environment Protection Agency of the United

PTFE-containing predecessors. As PTFE-free additives will soon be

States of America is going to designate PFOAs and PFOS as hazardous

a major business imperative, we are proud to have developed this

substances. Furthermore, Green Seal will prohibit PFAS in its certified

leading alternative for Architectural Powder Coatings,” has stated Simon

paints and coatings.

Bodendorfer, the technical business development manager of Clariant.

®

Ceridust® 8170 M provides then a valid alternative, as it is suitable for both dark and light colours with no extrudate swelling, allowing to also adjust gloss and texturing levels. As a matter of fact, the new additive

© Clariant

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N. 84 - NOVEMBER/DECEMBER 2023 - international PAINT&COATING magazine

For further information: www.clariant.com

BRAND-NEW

Topping-out Ceremony for New Gema Company Headquarters

Engineering specialized in the supply of systems for surface treatment, painting and coating

The new headquarters of Gema will help the company to meet the powder coating market growing demands.

G

ema Switzerland GmbH, a company specialised in manufacturing systems and equipment for industrial powder coating, has recently celebrated the traditional topping-out

ceremony for the construction of its new headquarters in Gossau (Switzerland). Together with the contracted construction company HRS, the architectural office ThomasMauchle, the executing trades as well as representatives of the management, the guests were able to get a first impression of the new building. Gema will move into the

E-COAT SYSTEMS

new premises during the summer of 2024.

The new 20,000 m2 site paves the way for an optimised manufacturing

LIQUID PAINTING SYSTEMS

structure and higher production capacities. The area will once again unite all assembly groups, which are currently distributed externally across various locations. Moreover, the modern test and customer

POWDER COATING SYSTEMS

application laboratory will offer approximately 60% more space and be equipped with four modern coating lines, enabling the company to

SELF-LEARNING ROBOTS FOR AUTOMATED PAINTING

carry out coating trials for its global clientele more efficiently.

“We are looking forward to the new company headquarters, which will be optimally tailored to our needs. The building offers us and our employees state-of-the-art working environments with plenty of communication and meeting space, is technically up-to-date and provides enough space for our current and future growth. In addition, we remain loyal to our location in Eastern Switzerland. Our heartfelt thanks go to all those involved who contributed to the success of this project, has stated Felix Mauchle, a member of the management board of Gema.

For further information: www.gemapowdercoating.com

SYSTEMS FOR THE TREATMENT OF VOCs EMISSIONS

BRAND-NEW © AkzoNobel

AkzoNobel Launches Interpon D Anodic Collection in North America The Interpon D Anodic collection will enable architects and designers to achieve anodised aluminium finishes with minimal environmental impact and superior performance.

T

he paint manufacturer AkzoNobel has launched a range of

designs that were not previously possible.

powder coatings in North America, which will help architects

Interpon D Anodic is weather resistant and is backed by a 20-year

and designers imagine designs that have the stunning look

warranty for AAMA 2604 and a 30-year warranty for AAMA 2605

of anodised aluminium but with minimal environmental impact and

on coating performance when applied by an Interpon D approved

superior performance.

applicator. Additionally, Anodic III powder coatings are free from VOCs

The collection includes 12 matte and metallic-effect finishes, offering

and are supported by Environmental Product Declarations (EPDs) to

more choice and flexibility than traditional anodising. Importantly, the

demonstrate that both D2525 and D3000 have been independently

powder coating process does not require metal to be immersed in

validated for their sustainability credentials.

an acid bath, avoiding the need to dispose of hazardous waste and

“The Interpon D Anodic III collection has been innovated to give

supporting a significantly more sustainable process. Surfaces are also

architects and designers all the upsides of anodized aluminium, but with

much easier to repair should the coating be chipped or damaged during

none of the disadvantages, to leave a lasting legacy of which they can be

fabrication or installation.

proud. It is further proof of our commitment that your imagination starts

This collection is not simply an alternative to anodised aluminium for

with our finish, and the perfect alternative for those who want the effect

windows and facades. Switching to an Interpon D2525 (AAMA 2604)

of beautiful metals without it having to cost the earth”, has stated Alan

or D3000 (AAMA 2605) Anodic III finish helps provide superior levels of

Alex, the regional commercial director for AkzoNobel Powder Coatings in

colour and gloss retention and better colour consistency. Colours range

North America.

from shiny blacks to soft silvers, steely blues to earthy bronzes, enabling architects and designers to match every mood and style and imagine

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For further information: www.interpon.com

BRAND-NEW

WACKER Celebrated the 30th Anniversary of Its Subsidiary in China WACKER held a grand ceremony in Shanghai to celebrate the 30th anniversary of its Chinese subsidiary.

W

ACKER has recently announced that it has held a grand

Over the past 30 years, we invested nearly €1 billion in production,

ceremony in Shanghai to celebrate the 30 anniversary of its

in customer and technical service and in research in China,” stated

subsidiary in China together with customers, local authority

Christian Hartel, the president and Chief Executive Officer of WACKER.

th

representatives and long-standing business partners.

WACKER China has now over 1,700 employees and operates an

The company started building its presence in China by opening its first

extensive network composed by four production sites, three technical

offices in 1993. Seven years later, it opened its first regional technical

centres, eight sales offices and a training facility. In 2022, it generated

application centre equipped with multiple application and research

around €2.45 billion, which corresponds to approximately 30% of

laboratories for developing tailor-made products in in Shanghai, in order

WACKER's worldwide sales.

to meet regional needs and serve multiple sectors such as construction,

Alvin Hu, President of WACKER China, briefly reviewed the company’s

coatings, adhesives, electronics, automotive and personal care. The

30 year journey in China. “Our track record is impressive: equipped

facility also operates nowadays different global competence centres

with a comprehensive network of integrated production sites, four joint

for consumer care, cement and concrete, e-mobility and thermal

ventures, research and development and technical service centres

interface materials. In addition, in May 2023 the Group ramped up new

as well as several sales offices we are well positioned strategically,

production facilities for dispersions and dispersible polymer powders

especially with a view to key growth topics like the burgeoning

in Nanjing, while in September it also announced the expansion of

electrification of vehicles in China. This will benefit our silicone business,

several new production lines for manufacturing functional silicone fluids,

as our high performance silicones are essential for the development

silicone emulsions and silicone elastomer gels at the Zhangjiagang site.

and production of electric vehicles,” Alvin Hu, the president of WACKER

“China is the largest chemical market in the world and an important

China, emphasized.

growth driver for the global economy. The country offers a wide range of development opportunities which we intend to leverage continuously.

For further information: www.wacker.com

© WACKER

international PAINT&COATING magazine - NOVEMBER/DECEMBER 2023 - N. 84

21

©Alexander Henn/Aalto University

Lignin nanoparticles form colourful coatings when they are applied as multilayer films.

RESEARCH BREAKTHROUGH

A Transparent Wood-Based Coating That Does Not Fog Up Edited by Aalto University Helsinki - Finland

Researchers have developed a way to turn a waste material from wood into a bio-based transparent film that can be used for anti-fogging or anti-reflective coatings on glasses or vehicle windows. In addition to offering an alternative to the toxic synthetic materials currently used, this approach transforms a waste product into a valuable carbon sink.

R

esearchers from the Finnish Aalto university have published a

films. “Optical coatings need to be transparent, but so far even rather

study demonstrating how to convert waste material from wood

thin lignin particle films have been visible. We knew that small particles

into a bio-based transparent film that can be employed for anti-

appear less turbid, so I wanted to see if I could make invisible particle

fogging or anti-reflective coatings on glasses or vehicle windows.

films by pushing the particle size to a minimum”, has stated Alexander

Lignin is an abundant waste product in paper and pulp production that

Henn, the doctoral researcher who led the study.

is very difficult to process, so it is usually burned to produce heat.

The team used acetylated lignin and developed an improved way to

Creating lignin nanoparticles to use for anti-fogging coatings is not a new

esterify it in a reaction that takes just a few minutes and happens

idea, but scientists have not yet been able to turn them into transparent

at the relatively low temperature of 60 °C. The lignin particles made

22

N. 84 - NOVEMBER/DECEMBER 2023 - international PAINT&COATING magazine

EPISTOLIO EPISTOLIO

RESEARCH BREAKTHROUGH

towards the future

from the acetylated lignin had rather surprising properties, which made the rest of the study very interesting. The possibility to make photonic films, for example, came as a total surprise. In addition to anti-fogging and anti-reflective coatings, the new approach can

SOLUZIONI ROBOTIZZATE DI ROBOTIC PAINTING SOLUTIONS VERNICIATURA

also make coloured films from lignin nanoparticles. By controlling the coating’s thickness the team created materials with different structural colours.

According to the team’s feasibility study, the ease of the reaction and its high yield mean that it could profitably be scaled up to industrial levels. "Lignin-based products could be commercially valuable and simultaneously act as carbon sinks, helping relieve the current fossil fuel-dependence and reduce carbon dioxide emissions,’ says Professor Monika Österberg, who leads the Bioproduct Chemistry group at Aalto University. ‘High value-added applications like this are important to drive lignin valorisation and move us away from using lignin only as a fuel."

The study benefited from having perspectives that took it beyond the lab bench. “Teamwork was an important part of making this study impactful. We were able to include the techno-economic analysis with the help of Professor Pekka Oinas and doctoral researcher Susanna Forssell and the efforts of Sahar Babaeipour were key to controlling the photonic properties particles, while researchers Paula Nousiainen and Kristoffer Meinander brought expertise in lignin chemistry and photonic phenomena respectively, helping the team make sense of their results and use them effectively”, has noted Henn.

The study was published in Chemical Engineering Journal and was carried out as part of FinnCERES, the Academy of Finland’s flagship centre for materials bioeconomy research.

©Alexander Henn/Aalto University

Epistolio Srl.

Via Piemonte 120 21100 Varese (VA) ITALY Ph: +39 0332 212692 Fax: +39 0332 223666 info@epistolio.com www.epistolio.it Publierre_Milano

The doctoral researcher Alexander Henn demonstrates the anti-fogging in eyewear.

ROAD TO 2050

Arkema Will Install a New Purification System to Decarbonise its Acrylics Production The future installation of a purification system will allow Arkema to decarbonise the acrylics production and strengthen its European market position.

A

rkema will implement by 2026 a new, patented purification

to supply lower carbon footprint solutions in all of these markets.

technology at its production site in Carling, France, to improve

“This investment at the Carling facility represents a strong and long-term

the site’s operational efficiency and environmental footprint

commitment to support our customers in their growth and sustainability

toward the highest standard.

journey. After the introduction of bio-based acrylic monomers in 2022

This investment will enable to reduce the site’s CO2 emissions by 20 %,

using the mass balance approach, this new project at Carling is another

thus contributing to the Group’s ambitious climate plan validated by

key step to position Arkema as a leader in low carbon acrylic materials,

SBTi on a 1.5°C trajectory by 2030.

and to help our customers reduce their Scope 3 emissions” said Richard

The Carling facility is one of the major acrylic plants in Europe. It

Jenkins, Senior Vice-President, Coating Solutions.

produces acrylic monomers used in performance coatings, adhesives,

This €130 million investment in a new purification process will lead to

water treatment and other performance materials, that are increasingly

more energy efficient and lower carbon intensive operations, optimized

required in electronics, electric vehicle batteries, new energies, 3D

resources and waste management, as well as a significant reduction

printing, as well as for home energy efficiency and living comfort

of solvent use, while also enabling an incremental increase in capacity.

improvement. Combined with the progressive introduction of bio-

This strategic project is part of Arkema’s global decarbonization capital

renewable feedstocks, this lower energy intensive technology will enable

expenditure roadmap and has been partly funded by the French State

Arkema to decarbonize further its acrylic monomers, specialty resins

as part of the France 2030 program, operated by ADEME, and funded by

and additives offer and reinforce the Group’s position as a key partner

the European Union – NextGenerationEU.

© Adobe Stock

24

N. 84 - NOVEMBER/DECEMBER 2023 - international PAINT&COATING magazine

We convey the future since 1959

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© BASF

HIGHLIGHT OF THE MONTH

ON VOLUDE: the Theme of BASF’s 2023-2024 Automotive Color Trends Collection Joerg Zumkley, BASF Coatings GmbH – Münster, Germany

joerg.zumkley@basf.com

For the first time a combination of human and non-human intelligence partnered up to create the ON VOLUDE collection from Automotive Color Trends by BASF for 2023-2024.

E

ach year, designers for BASF’s Coatings division create a new

collection to design automotive colours for their future models, one will

collection of colours to inspire automotive designers around

see the new direction on the road or in the driveway in the next three to

the globe. This year, non-human intelligence was a strong driver

five model years.

for the creation of the ON VOLUDE collection from Automotive Color Trends by BASF for 2023-2024.

EMEA – Exploring features beyond colour position

When BASF’s designers looked at what their trend signals were

The palette for Europe, the Middle East and Africa (EMEA) puts a

telling them, they realized it’s time for a colour update, as the classic

highlight on bright beige colours. Pastels also play an important role,

automobile colour wheel has had its day. Non-classic automotive hues

introducing interesting non-automotive colour positions into automotive

emerged, propelling colours through a series of shifts reflecting a

design. As seen throughout the ON VOLUDE collection, colours in EMEA

positive mood, with a focus on lighter shades and the exploration of

explore features far beyond colour position. They add sustainable,

new, expressive colour spaces.

recycled raw materials, LiDAR and RADAR compatible concepts, and

ON VOLUDE provides exciting colours that also adopt an increasing

haptic surfaces.

focus on sustainability and functionality. As customers rely on the BASF

“Expressive colours reflect our will to communicate and speak up,”

26

N. 84 - NOVEMBER/DECEMBER 2023 - international PAINT&COATING magazine

HIGHLIGHT OF THE MONTH

said Mark Gutjahr, head of Automotive Color Design for EMEA. “When

reflectance, work with sensor-based mobility concepts, and explore

we bring non-automotive colours into the mix, we broaden that

more approaches with responsible raw material sourcing.

conversation even further into new and exciting colour spaces.”

“In this year’s collection, red leaning pastels and mid-tones are

Asia Pacific – Realistic approaches to sustainable concepts For ON VOLUDE, designers in Asia Pacific (APAC) explored and enriched the important colour spaces for whites and greys, while adventurous

replaced by restorative yellow and green effects suggesting renewal,” said Liz Hoffman, head of Automotive Color Design for the Americas.

“The connection complements both grounded colour spaces and otherworldly escapes. It shows evolving mindsets in automotive design.”

new colour spaces like shimmering green pastel and fluorescent red

Colour Expertise of BASF Coatings

offer new expressions to meet the growing individuality of car buyers

Every year, the designers of BASF’s Coatings division study future trends

in APAC. The collection shows realistic approaches to sustainable

which they use as foundation for the development of surface, texture

materials, sustainable processes, and a diversity of sustainable concepts

and colour positions. They draw inspiration from industry, fashion,

and effects. “This palette can create amazing colour harmonies that are

consumer products, nature, technology, and more. This research is

futuristic, modern and playful interactions between colour and effect

shared with BASF’s customers, the automotive designers, to drive future

combinations,” said Chiharu Matsuhara, head of Automotive Color

mass production plans.

Design for APAC. “These sustainable concepts are reimagined in a more

ON VOLUDE contains functional concepts with realistic approaches.

realistic way, boosting BASF’s leadership in sustainability.”

BASF’s designers set a global benchmark in colour by also focusing

Americas – colours evolving in their functionality

on technology and innovation, which are important drivers for the automotive industry.

The Americas palette seeks optimism and divergence that celebrates

The target is to meet those functional requirements while still being

possibilities in all modes of art and design. The colour spaces are

visually and haptically exciting.

evolving in their functionality while building in excitement.

BASF also leads the world in the global tools it uses to create new

The collection features softer hues, minimized textures and subtle

designs and share them with automotive designers. By using BASF’s

moves that aspire toward future goals near and far. Colours in

AUROOM® – a digital platform providing digital colour – the design

the Americas contribute to cooling effects in the vehicle with solar

process is faster and more efficient.

AMERICAS

ASIA PACIFIC

EMEA

© BASF

international PAINT&COATING magazine - NOVEMBER/DECEMBER 2023 - N. 84

27

HIGHLIGHT OF THE MONTH

Beyond Chemistry, Water: DN Chemicals Expands with a New Branch Devoted to Water Treatment Interview with Silvia Borghi, Water Treatment Division Business Development Manager, and André Bernasconi, General Manager of DN Chemicals Caleppio di Settala (Milan), Italy

DN Chemicals complemented its division devoted to the treatment of water generated in coating booths, cooling towers, and boilers with an upgraded range of products and expertise in the field of waste water, collected in particular from coating and galvanising departments as well as from the industrial processes of the textile, pharmaceutical, tanning, cosmetics, and many other sectors.

“W

ater is the essence of all industrial processes, regardless

more than 70% of the world’s freshwater use and pollution.” In more

of the sector,” begins Silvia Borghi, the new head of DN

detail, the report highlights significant differences between low- and

Chemicals’ water treatment division, during the interview

high-income regions. “A regional distribution shows that industrial water

our editorial staff conducted with both her and André Bernasconi, the

withdrawal averages 17% of total water use in high-income countries

General Manager of this Milan-based company belonging to the Dollmar

but only 2% in low-income countries. The average for industrial use

Group and specialising in solutions for surface pre-treatment, industrial

hides a huge range, from 49–96% in the European Union (with the

water treatment, and paint stripping. In fact, the increasingly essential

highest level in Estonia) to 0–5% in many countries of various income

need to provide services for consumption reduction and optimisation,

levels in other regions.”

environmental compliance, and cost reduction has recently become the

This data confirms that no industrial process can be carried out without

core business of a new branch of this company.

the use of water, neither within the production operations themselves

According to the United Nations World Water Development Report

nor for the cleaning of plants and facilities. The industry therefore plays

20231, “while the percentage of industrial and energy-related use is

a key role in the responsible management of this important resource.

much lower than that attributed to agricultural use (30% compared

Indeed, the report concludes: “Companies within industries that rely

with 70%, Ed.), it is nonetheless a considerable amount of water that

heavily on water for their core business – such as manufacturing

requires careful stewardship in the watersheds that industry and energy

of goods or production of inputs and raw materials – have become

share with so many other users. On the other hand, these data do not

increasingly attuned to water stress and the risks it poses to business

provide a complete picture, as it has been estimated that two-thirds of

interests. As a result, many companies are exploring and testing ways

all water consumption is involved in corporate supply chains. Supporting

to reduce or mitigate water risks across their business and supply

this estimate, companies in seven major sectors – food, textile, energy,

chains.”

manufacturing, chemicals, pharmaceuticals, and mining – are affecting

“That is exactly where our new activity fits in,” explains Borghi. “We would like to create a new industrial culture of water, turning it from

1

https://unesdoc.unesco.org/ark:/48223/pf0000384655

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N. 84 - NOVEMBER/DECEMBER 2023 - international PAINT&COATING magazine

an expense item associated with excessive costs into an added value

HIGHLIGHT OF THE MONTH

André Bernasconi with Silvia Borghi.

© DN Chemicals

© AdobeStock

for the industry. This can be done not only by providing innovative and

aspects, including osmosis, ultrafiltration, and biological plants and

high-performance water treatment chemicals and plants but also by

their chemicals. Over time, we will develop different technologies, from

offering an all-round consultancy service that helps customers achieve

chemical-physical plants used for the treatment of water generated

real savings instead of wasting.”

in paint shops to aerobic and anaerobic biological plants for the treatment of organic waste.”

What technological solutions will this new division develop?

Silvia Borghi: “We start from the consideration that every industrial

Do you intend to target other sectors as well?

process needs water, both as part of the production cycle itself and for

André Bernasconi: “Yes, exactly. Over the past few years, we have

cleaning machinery. The economic value of supplying this resource is

received numerous requests from the manufacturing sector, not

considerable due to the high costs involved in its extraction, treatment,

only for chemical products but also for plant solutions to meet an

and discharge. Especially in Italy, this weighs heavily on companies’

increasingly pressing need: saving water, an indispensable resource

balance sheets. At DN Chemicals, we want to change perspective by

not only for the industry but for the entire community. We have already

elevating water purification to an added value through the development

successfully dealt with this in our target sector, that of surface pre-

of products and plants that enable the most innovative companies

treatment. Now the time has come to expand our approach and reach

to create closed or semi-closed loop recovery systems guaranteeing

other markets that already rely on the Dollmar Group for the supply

considerable savings. We can provide different solutions, such as the

of chemical products, from the pharmaceutical sector to the food and

introduction of demineralisation plants along manufacturing lines

automotive industries. We intend to build on the profound know-how

to improve production quality and reduce waste water flow rates,

we have acquired through years of research and development of water

in some cases with the possibility of recycling water in the tanks of

purification solutions for the coating industry and broaden the range of

some production cycles or even within cooling circuits or boilers. This

companies from the manufacturing world at large that can benefit from

development will not only concern coating water but also all the sectors

our projects.

mentioned before and will entail both chemical and plant engineering

international PAINT&COATING magazine - NOVEMBER/DECEMBER 2023 - N. 84

29

What aspects will the new division develop further within your

What are going to be the first steps of this new branch?

core market, that of coating?

AB: “We decided to structure this new division in the same way as we

SB: “We will start with traditional chemical-physical plants for the

have already successfully done for the surface pre-treatment one. We

removal of organic and inorganic pollutants and with formulations for

therefore have a dedicated laboratory where specialised technicians

flocculation, for the preservation and maintenance of osmosis and

work under the supervision of Silvia Borghi and with very advanced

ultrafiltration membranes, for sludge dewatering, and for soil washing

instrumentation together with the conventional tools already available

up to a complete range of products for cooling systems and boilers.

to carry out special and in-depth analyses, such as those performed with

Gradually, we will complete this with the design and supply of the plants

Raman spectroscopy to obtain reliable results very quickly, pursuing

mentioned above.”

the analytical approach that has always characterised DN Chemicals. At first, we are going to focus on the European market because its needs

What will be the added value of this new division of DN

are similar to those in our country also in terms of legislation, and then

Chemicals compared to its competitors?

broaden our horizons and reach even the most complex markets, not

SB: “Certainly, our ability to offer high-performance solutions not only in

only in the coating sector but to others as well, such as food or textiles,

terms of plant engineering but also of chemicals. I have many years of

to name but a couple. We will start from the customer base of the

experience in the industry and I have noticed that, especially in recent

Dollmar Group, which has been producing and marketing high-quality

years, perhaps due to a generational change among the operators in

raw materials and formulating chemicals for more than seventy years:

the sector, customers are often advised to solve their water treatment-

for example, we have already acquired a number of pharmaceutical

related issues by replacing or revamping their systems as an immediate

companies.”

solution. However, other paths can be taken before coming to this point, and that is the route that DN Chemicals is going to pursue. Many

To summarise, can we conclude that your activity will be

developments and many evolutions have occurred since the 1970s

characterised by synergy both with customers and with the

at both the chemical level, such as nanotechnology, and the plant

other divisions of the group?

engineering one. And these can help those of us who have gained

SB: “The manufacturing industry is now moving from isolationism

experience by “getting their hands dirty” to provide the most cost-

to a collective approach. Water is not a circumscribed asset, but a

effective and suitable solution for every customer’s needs. This is also

resource that must be shared. Unless we act together, the impact of

why I am convinced that the path I am starting today with DN Chemicals

the investments made to save water resources is going to be minimal.

will bring interesting innovations not only for the coating sector but for

That is why it is important to create a new culture of water and its value.

several industries.”

This is what I plan to build with my team, in order to become the reliable partner that our customers deserve, aware that they are managing a truly unique and precious resource.”

© DN Chemicals

The spectrophotometer for the analysis of metal pollutants in water.

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N. 84 - NOVEMBER/DECEMBER 2023 - international PAINT&COATING magazine

© DN Chemicals

The ICP instrumentation for plasma emission spectrometry.

The only European producer of customized electrodialysis cells and ultrafiltration membranes for cataphoresis / anaphoresis application.

Our cells are made with tubular extruded membrane.

ELECTRODIALYSIS CELLS models available: AUF65 diameter 65 mm - AUFL80 CELL diameter 80 mm ULTRAFILTRATION MEMBRANES models available: AUF80 - AUF80 PLUS HIGH-PERFORMANCE new model 2023!

ENERGY SAVING | QUALITY PROCESS | IMPROVED LIFETIME | REDUCED MAINTENANCE

info@avin.it professionality

know-how

punctuality

www.avinsrl.com

?

HOW IT’S COATED

Ode to the Black Finish Enhancing the Elegance of Valli Handles Antonella Del Sole MCS & Partners – Milan, Italy

Polished Black Nickel and Dull Black: these are the shades of black that Valli offers for its range of handles and accessories for doors and windows.

T

imeless as well as contemporary, with superlative elegance, enhancing the design of the handle as the main

character of the window and the surrounding space: black, in its different shades and finishes, has played a crucial role for years at the Valli company, Valli, since 1934 specializing in the manufacturing of handles created by famous designers and today known and appreciated globally for the design and quality of its products.

Pasquale Valli, its founder, imagined the handle as a work of art, a sculpture with its own personality. Not just an industrial mechanism, therefore, but the synthesis of function and aesthetics, brought together in a single product, in which colour and shades play a fundamental role. Valli has chosen to enhance the design of its handles with an elegant and eclectic colour: the Black.

The choice of the Black Synonymous with minimalism, simple but never common. Timeless and contemporary at the same time, Black is today a trendy colour that allows architects and interior designers to elegantly characterize any project.

Handles in black stand out from the classic chrome and brass handles for their strong personality, becoming furnishing accessories in all respects and enhancing doors or windows.

Black is eclectic and the dark handle adapts perfectly to furnishings with modern or classic design, as well as industrial or shabby chic, © ASSA ABLOY

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N. 84 - NOVEMBER/DECEMBER 2023 - international PAINT&COATING magazine

sophisticated or essential style.

Get more from water Turn key solutions for industrial wastewater treatment Design and manufacturing of plants and chemicals for industrial wastewater treatment Chemical-physical plants Sludge treatment and compactor systems Ion exchange demineralization systems and reverse osmosis systems Oil separators Filtering systems Batch type systems Flotation units Chemicals and spare parts for water treatment Technical service, support and maintenance of wastewater treatment plants

© ASSA ABLOY

The optical effect in strong contrast with white lacquered doors represents a minimal style choice perfect for furnishing homes with a contemporary taste. Combined with more classic doors and windows, they highlight the warmth and beauty of the wood essences.

The matt finish allows tone-on-tone combinations, the glossy finish brings movement to the surface of the handle, enhancing its shapes and profiles in a play of light and shadow.

Technology thought for blacks Valli offers a complete range of dark finishes, from matt blacks made with powder coating, to bright glossy black obtained with galvanic treatment and polishing.

Beware of imitations, buy the original!

info@waterenergy.it

www.waterenergy.it

?

HOW IT’S COATED

All processes guarantee excellent wear resistance for an aesthetic that remains unaltered over time. In circumstances where the handle or knob must be used outside the home and resist atmospheric agents, the Super Black PVD version is available on request, for surfaces up to three times more resistant to scratches, wear and atmospheric agents.

Valli models Among the Valli models available in “black” version, some find in dark finishes the exaltation of their stylistic features. For the Fusital collection, the Dull Black finish underlines the rounded shapes of the H 386 Meneghello Paolelli, as well as highlight the sinuosity of the H 385 Federica Biasi handle, © ASSA ABLOY

which recalls the beauty of a branch; the Polished Black Nickel envelops the starshaped geometric element of the H 378 Yabu Pushelberg. Dull Black dresses the H 377 Steve Leung enhancing its minimalist and elegant design, with slightly retro accents.

For the Lab collection the Dull Black finish underlines the essential and clean profile of the H 1062 Carmen. Dull Black also covers the perfectly squared shapes of handles H 1046 Nais and H 1049 Divara.

“Total Black” for a coordinated design throughout the home Not just handles, but a whole range of accessories for a total look and integrated coordinated design.

Knobs, handles, pocket doors and privacy bolts acquire a new expressive force in the black tones, the right completion of design © ASSA ABLOY

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handles by Valli.

VELVET

SUPER MATT APPEARANCE SUPER SOFT TEXTURE

w w w. s t p o w d e r c o a t i n g s . c o m

BRAND-NEW

Smart Materials for the Entrepreneurs of Tomorrow: NoxorSokem Group Awarded Confindustria Pordenone has awarded NoxorSokem Group with the ‘Confindustria Alto Adriatico’ prize to celebrate the company’s 40th anniversary.

O

n the occasion of the “Forty for future” event organised

materials with Silvia Marchesan, professor of chemistry at the University

on Friday 20th October 2023 by D&Co. at the Magredi

of Trieste and one of the eleven brightest emerging researchers in the

documentation and cataloguing centre in San Quirino

world of natural sciences, Michele Scian, the young creative and content

(Pordenone, Italy), NoxorSokem Group received the ‘Confindustria Alto

manager of Maize H-Farm, and Franco Scolari, the general director of

Adriatico’ recognition from Confindustria Pordenone to celebrate its 40th

the Pordenone Technology Centre. The session, which attracted a large

anniversary.

audience of entrepreneurs and business executives from all over north-

“This is not the finishing line, but a new starting point. Because we can

east Italy, was coordinated by the journalist and writer Letterio Scopelliti.

find the direction for the future that awaits us only by looking at our

​“Nowadays, the world needs entrepreneurs who think outside the box,

past,” have jointly declared Gianluca Pinna and Fulvio Truant, the board

open new paths, offer new possibilities and glimpse roads that others

of NoxorSokem Group.

do not see,” has concluded Scopelliti.

The event was also an interesting opportunity to discuss important topics such as artificial intelligence, innovation of thought and smart

© NoxorSokem Group

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For further information: www.noxorsokem.it

BRAND-NEW

Wayne Daniell Is the New Director of ChemQuest for the EMEA Region Wayne Daniell will support the business strategy, the technology development and the operational and manufacturing efficiency of ChemQuest. © ChemQuest Group

and advanced materials combined with the entrepreneurial spirit of Wayne are an ideal addition to the ChemQuest team, particularly as we continue to expand our reach in the EMEA region.

His contributions will help us support the profitable growth of our clients through a broad range of projects,” has stated Daniel Murad, the CEO of ChemQuest.

In 2011, Daniell co-founded NanoScape AG and served as the CEO until its acquisition in 2015. He then managed the post-acquisition integration as well as a ten-fold production capacity expansion, before taking on operational responsibility for all production, quality control and product development

T

activities. Most recently, Daniell served as business

(Europe, Middle East and Africa) region: he will

with a focus on the commercialisation of functional

support the company to expand and optimise the

additives.

business strategy, the technology development, the

“I was very fortunate to have worked with

operational and manufacturing efficiency and its

ChemQuest in a previous role, where their team’s

M&A advisory services.

breadth of applications coverage and in-depth

Daniell possesses a wide knowledge and experience

insight into a range of market segments provided us

on nanomaterials and coatings additives used for

with guidance on how to strategically reposition the

consumer electronics, renewable energy and white

company. Having spent my career commercializing

biotechnology. The new director of ChemQuest

technologies in the additives and advanced materials

obtained a bachelor’s degree in chemistry from

space, moving from the lab through scale-up to

the University of Reading (United Kingdom) and

full commercialization, I am hoping to bring this

a doctorate in chemistry from the University of

experience to my new role. I’m very excited about

Nottingham (United Kingdom). He also participated

joining the ChemQuest team and look forward to

in an EU-funded Researcher Exchange Program with

helping our clients develop appropriate strategies in

the Weizmann Institute of Science and served as a

order to achieve their goals,” has commented Daniell.

he ChemQuest Group has recently announced

development manager for the Chemicals Division of

that it has appointed Wayne Daniell as the

SAES Getters SpA, with responsibility for all business

new director of its operations in the EMEA

development activities for the newly formed unit and

post-doctoral researcher at both the University of Nottingham and the Ludwig Maximilian University of Munich (Germany).

For further information:

“The wide-ranging expertise in specialty chemicals

www.chemquest.com

FORNITURE TECNICHE PER LA VERNICIATURA INDUSTRIALE

Via Fermi, 9 Zelo Buon Persico (LO) Tel. 02 90 66 92 40 r.a.

info@guerrasrl.it www.guerrasrl.it

BRAND-NEW

Outdoor Shot blasting and Coating Booth with ‘FREE Building Permit’ Rimor Camit has designed and installed an outdoor shot blasting and painting system which does not require a building permit.

A

t the Lecofer plant in Alcamo (Sicily - Italy), Rimor Camit has

guarantee the best working conditions for operators while also reducing

installed a shot blasting and painting system treating over

energy consumption.

100 containers per month. The booths have been designed

The health of the personnel inside the oven is safeguarded by the

to operate outdoors, in any season and weather condition. The only

indirect air vein heating solution, that also optimise energy usage.

construction works needed for the installation are related to the

​The adoption of the patented Rimor Camit solution ‘Recube’ allows noise

preparation of the platform, which must have the minimum degree of

to be minimised and the service-life of the motors to be extended by up

inclination to rainwater flow. It is therefore possible to define this type of

to 8 times. The entire system is managed automatically and it even self-

system as a ‘FREE building permit’ plant, since it is totally freed from the

adjusts according to the progressive saturation of the filters.

bureaucratic aspects inherent to its construction.

Inside the booths, the grit recovery and selection system patented

by Rimor-Camit and the design following a fluid dynamic simulation

© Rimor Camit

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N. 84 - NOVEMBER/DECEMBER 2023 - international PAINT&COATING magazine

For further information: www.rimor.eu

eosmarketing.it

Your partner for green chemical processes Chemtec’s mission is to update tradition.

Our revolutionary chemicals are designed to have a very limited environmental impact, to reduce consumption of resources and for a greater operational simplicity.

With Chemtec technologies you can replace zinc&iron phosphate:

PRONORTEC multi-metal surface treatment

TORAN 3® multi-metal pre-treatment process

WASTE WATER TREATMENT SYSTEMS

www.chemtecitalia.it

SUCCESS STORIES

Eurotherm Supplied an Automatic Powder Coating Plant to the British Manufacturer Broxap Original article appeared in Daily Focus - https://daily-focus.co.uk/

Broxap has relied on Eurotherm for the installation of modern, automatic powder coating plant equipped with a pre-treatment area and a power & free overhead conveyor.

T

he British street furniture manufacturer

commitment to put sustainability at the heart

preparation to the following powder coating

Broxap has revolutionised its

of our operations and the new automated

process as well as a power & free system,

production processes by installing a

powder coating system is one of the most

which allows for the manual loading of

new custom-built automated powder coating

significant investments we have made to

products before they travel through the

plant from the Italian company Eurotherm.

reduce our carbon footprint. The system not

processing areas via an automatic overhead

The introduction of this new cutting-edge

only respects the environment, it improves the

conveyor that can handle the wide range of

technology is the latest phase of an extensive

quality and safety of working conditions for

shapes and sizes of Broxap products.

sustainable manufacturing project, which

our production teams, delivers better flexibility

The pre-treatment cycle devised by Chemtec

will allow the Chesterton-based company to

for management and provides excellent

and supplied by its British distributor Metavate

drastically reduce its carbon footprint as well

results for customers,” Matthew Miles,

Ltd, is a 4 stages process which includes

as improve the quality and safety of operators’

Managing Director of Broxap stated.

an alkaline degreasing with SACHE AST 01

working conditions.

combined with no-foam surfactants DNAD

“Maintaining high standards in product

The automatic powder coating plant

quality while reducing the environmental

The newly-installed automated powder

with purified water by a reverse osmosis

impact of operations is a big challenge for

coating system includes a highly innovative

system supplied by Chemtec. Afterwards,

manufacturers. At Broxap we have made a

pre-treatment stage for the workpiece’s

the nanotechnology passivating agent

NOF and three rinsing stages, the last one

PRONORTEC MM-04 is atomised in the final © Eurotherm

spray bar, which creates a 50–nanometre thick hydrophobic coating, improving paint adhesion and corrosion resistance on the metal substrate.

The nanotechnology product PRONORTEC MM-04 can be applied to any degreased, nonoxidised or rinsed metal surface by spraying, dipping or atomising. Moreover, it does not require a final rinse and allows Broxap to automatically dose products to achieve the required pH and conductivity levels. Finally, as it does not contain heavy metals such as zinc, chromium or nickel, it increases the healthiness of the working environment, as well as eliminating disposal and maintenance costs and halving energy consumption.

The new powder coating plant will indeed help the company to reduce waste, save energy

40

N. 84 - NOVEMBER/DECEMBER 2023 - international PAINT&COATING magazine

Efficient and reliable © Eurotherm

solutions for surface coating since 1988.

electrostatic systems for liquid painting

electrostatic systems and spraying booths for powder coating

pneumatic systems for high-, medium-, and low-pressure painting and reduce the environmental impact as well as double the powder coating capacity at its manufacturing facility of 125,000 m2, resulting in fast delivery times and a superior product finish.

“Equipping our factory with smart technologies and innovative

IR and UV drying systems

systems supports operational efficiency, reduced energy consumption and green energy production as we look to identify, and work towards, net zero targets and other environmental management objectives,” Matthew Miles concluded.

robot and reciprocators

About Broxap Broxap is a British company founded back in 1946 and specialised in the design, manufacture and installation of high specification street furniture, litter bins, shelters, playground equipment and outdoor fitness equipment. The company also provides a complete turnkey project management service, from design, through manufacture to installation. The product portfolio of Broxap can enhance any outdoor development and covers a wide range of sectors, including education,

www.cmspray.it

eosmarketing.it

construction, public realm, leisure, tourism and healthcare.

CM SPRAY s.r.l.

ADVANCEMENTS

Electrifying Efficiency: how Insulation Coatings can Enhance EV Design and Sustainability Christoph Lomoschitz Axalta Coating Systems GmbH, Essenbach-Altheim – Germany

Global sales of electric vehicles (EVs) reached 6.6 million in 2021, marking a doubling in sales, but EVs still have a way to go before reaching the same number as internal combustion engine (ICE) vehicles.

To aid in the transition to EVs, Axalta has developed coatings for insulating materials that can improve performance, sustainability, drive efficiency, and battery protection. Thorsten Heinrichs, Product Specialist for e-mobility at Axalta Coating Systems, explains how materials such as dielectric powder coatings, encapsulating resins and electrical steel coatings are critical in helping OEMs overcome challenges in EV design, while driving improvements in range, performance and efficiency.

W

hile alternative energy vehicles are becoming increasingly

accelerating purchasing trends, and consumers demand that this is

popular, they have yet to surpass huge numbers on roads

achieved in a sustainable manner.

globally, with many consumers still harbouring doubts over

One area in which improvements can be made is in motor design. Motors

range, efficiency, and even the safety of these vehicles. As such, OEMs

within EVs are expected to meet a higher set of standards and therefore

are being challenged to not only improve their design processes and

must be designed with enhanced efficiency, better weather and vibration

standards, but to also communicate the value of this to consumers.

resistance, improved integration with the gearbox, and a high degree of

Extracting maximum ROI out of the lifecycle of a vehicle is critical to

reliability for daily usage. To meet these standards, OEMs are increasingly

© Adobe Stock

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ADVANCEMENTS

moving towards insulation materials, specifically designed to protect

the sharp rises of these protrusions, electrical insulation failure is not

against electrical discharge, and ensure the efficient transfer of electrical

uncommon. That’s why Axalta has worked with customers to develop

energy.

unique dielectric powder coatings which can be modified to allow

PET films, paper, sheets, and tapes were traditionally used to strengthen

special coverage of the bumps and therefore address these electrical

these materials, including the prevention of electric short circuits, heat

insulation challenges.

propagation and flame spread. However, application challenges with

Protecting the battery is one requirement, helping to extract more

these materials remain, including adhesion limitation, air gaps and

efficiency from it is another. If EV adoption is ever to reach various

bubbles. As a result, specialist coatings are playing an increasingly

government targets in the next few years, OEMs will have to help

important role.

consumers overcome range anxiety, which is where electrical steel

Axalta provides a wide range of specialist coating solutions for these

coatings play a critical role.

materials, designed to provide dielectric protection, maintain optimal

Improving the electrical insulation of the electric drive itself can

operating temperatures, reduce the risk of fire and corrosion damage

significantly improve overall vehicle efficiency. For example, reducing

and prevent electromagnetic interference. The optimal coating

the occurrence of eddy currents can reduce energy losses and improve

depends on the position of the battery components, in addition to the

efficiency of the system. Eddy currents can be generated in the metal

manufacturing processes involved. However, dielectric powder coatings,

components of a motor and other electrical equipment when the

encapsulating resins and electrical steel coatings are just a few of the

magnetic field changes rapidly, such as high driving speeds, in the

solutions OEMs are turning towards to improve EV performance.

case of an EV. These eddy currents can cause energy losses and heat

Customised coatings to support evolving EV designs

build-up, reducing the efficiency of the system and potentially damaging internal components.

Due to the ever-evolving designs of EVs, it is important that any dielectric

Electrical steel coatings therefore must be specifically formulated to

powder coating remains customisable to the application. One example

provide superior electrical insulation to the drive, corrosion resistance,

is battery enclosures. While these often employ a coating solution,

and adhesion to electrical steel laminations. It is critical that these

they are also designed with protrusions on the surface. These serve

coatings help to improve the performance and reliability of electrical

several purposes, such as providing additional support and structure,

equipment by reducing the risk of electrical shorts, reducing core losses,

or protecting the battery from damage during use. However, due to

and improving the durability of the laminations.

© Axalta Coating Systems GmbH

© Adobe Stock

Thorsten Heinrichs, Product Specialist for e-mobility at Axalta Coating Systems.

international PAINT&COATING magazine - NOVEMBER/DECEMBER 2023 - N. 84

43

© Adobe Stock

A lifecycle approach to sustainability

resins and casting resins (encapsulation resins) starts from around

While the transition towards EVs is an environmental one, it is important

eight percent today and reaches almost 60 percent. One of its most

that OEMs don’t just consider their sustainability impact by measuring

popular impregnating resins for battery powered cars — Voltatex®

tailpipe emissions alone; switched on consumers are increasingly

4200, contains about 10% raw materials based on renewable resources.

expecting more.

Another of Axalta’s encapsulation resin products has almost 60 percent

Imagine you have an electric drive for a vehicle and the insulating

renewables.

materials and coatings make it more efficient because they conduct the heat out of the motor faster than another resin. However, all of these

OEMs should consider emissions and carbon consumption

gains are cancelled out if the materials you used for the coatings are

throughout the entire lifecycle of a vehicle to find ways to reduce their

packed full of volatile organic compounds (VOCs). That’s why concerted

environmental impact. This can include improving design, materials

efforts have been made to reduce VOC emissions in car manufacturing

selection, and manufacturing processes to use resources more

to improve air quality and reduce potential health risks during

efficiently, reduce waste, and comply with regulations. Using low carbon,

manufacture.

low VOC coatings in insulating materials can help meet these goals

Another area in which OEMs can make important strides is through the

and improve brand reputation for environmental responsibility while

use of renewable materials.

enhancing overall vehicle performance – all of which are crucial to

The content of renewable raw materials in Axalta’s impregnating

capturing consumer demand.

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N. 84 - NOVEMBER/DECEMBER 2023 - international PAINT&COATING magazine

Ravarini Castoldi & C. srl ELETTROSPRAY® via E. De Nicola, 18 - I-20090 Cesano Boscone (MI) Italy - tel.+39 0255210608 www.ravarinicastoldi.it - dive@ravarinicastoldi.it

FOCUS ON TECHNOLOGY

Flexible, Customised Production: Pilla Meets the Challenges of the Funerary Art Industry with a New Liquid Coating Plant Ilaria Paolomelo, ipcm®

Pilla Srl is a long-established Italian company active in the design, production, decoration, and coating of high-end cemetery items and funerary products since 1935. It recently turned to Radial Group for the installation of a new liquid coating system to increase the flexibility of its manufacturing department and meet the demand for highly customised products.

F

lexibility and quality are the two cornerstones that best describe

require increasingly customised products.

the production approach of Pilla Srl, a leading European company

On the other hand, investing in quality means devoting valuable

in the funerary art sector. On the one hand, a flexible production

resources, time, and efforts to maintaining excellent quality standards in all areas of production. To this end, since 1935, the year of its

and industry trends. The funerary art market is anything but static, and

foundation, Pilla has been constantly investing in state-of-the-art

continually studying and developing new colours and finishes is essential

processes and technologies to manufacture a wide range of funerary

to anticipate trends and meet the expectations of customers, who

and cemetery items, including planters, lamps, vases, letters, plaques,

© Pilla Sr

l

flow means it can quickly adapt its processes to changes in demand

Pilla has been producing various products for the funerary and cemetery art market since 1935, including planters, plaques, and frames.

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N. 84 - NOVEMBER/DECEMBER 2023 - international PAINT&COATING magazine

FOCUS ON TECHNOLOGY

© ipcm

© Pilla Srl

Overview of the plant designed and installed by Radial Group.

The Carrara marble effect is achieved through a special coating system.

and frames, whose distinguishing features are a high quality level

has a workforce of over 100 employees and it is still led by the Pilla

and extreme attention to detail. The latest investment made by this

family, through the direct commitment of Roberto Pilla and his son

company, located in Carrè (Vicenza, Italy), dates back to a few months

Manuel, who together represent the future of the company as well as an

ago. It entailed the installation of a new liquid coating plant supplied

important link with its history.

by Radial Group (Badia Polesine, Rovigo, Italy) and equipped with two articulated robots provided by Lesta (Dairago, Milan, Italy).

From a workshop to an industrial company: the story of Pilla Srl

The production cycle and the importance of finishing In its factory, Pilla processes different types of metal materials, including brass, aluminium, and bronze, all of which undergo a die-casting phase or, based on the type of product to be manufactured, a lost-wax or sand

Pilla was founded in 1935 by Guido Pilla, who started a photoceramist

casting process, two alternatives to die-casting. “What distinguishes the

business and later opened a bronze foundry in Milan. After World War II,

quality of Pilla’s products is undoubtedly their finishing. Our processes’

during which all activities had been suspended, the workshop reopened

extreme quality has always been recognised by the market, since 1935,”

in Vicenza, devoting itself to both photoceramics and foundry work,

says the company owner. “We perform two different finishing cycles,

with the foundry being moved to its current location in Carrè. In 1969,

which differ in the number of coats to be applied, depending on the

thanks to a continuous increase in production volumes, Pilla evolved

type of substrate to be treated and the finish to be obtained. 95% of

from a workshop to a company, although preserving its craftsmanship

our products undergo a coating operation involving the application of a

approach, and inaugurated a new moulding workshop in Carrè. This was

primer and a two-component top coat. We use the new plant supplied

entrusted to Roberto, the founder’s son and the current president and

by Radial Group for this.”

CEO of the company.

The remaining products are subjected to a special coating process that

In the years that followed, the business expanded further and, through

includes the application of four layers of paint. First, a brushed bronzing

six extensions, the Carrè plant grew from a surface area of 1,000 m2

paint layer is applied to highlight the surfaces’ reliefs and chiaroscuro

to an area of 8,500 m2, no longer housing only die-casting operations

effects; then, three coats of a high-temperature protective clear coat are

but every production stage, including finishing and coating. Today, it

applied for greater thickness and therefore for a high level of protection

international PAINT&COATING magazine - NOVEMBER/DECEMBER 2023 - N. 84

47

against atmospheric agents, since many of these items are intended to be placed outdoors.

The new coating system supplied by Radial Group The system was designed, built, and installed

by Radial Group and started up in July 2023.

It is served by a one-rail conveyor supplied by SE.PO (Olginate, Lecco, Italy) and includes a manual loading area where the operator hangs the different components to be coated on the load bars. These are first taken into the primer application booth and into the flash-off tunnel, where they dwell for 15 minutes at 43 °C. The parts then reach a second booth for the application of the top coat, followed by another flash-off phase.

Finally, they are transported into a bell oven where the coating is dried at around 80-90 °C. The coating phase has always played a crucial role © ipcm

The primer application booth and the first flash-off tunnel.

in Pilla’s production flow: treating every surface properly enables the metal’s performance to be enhanced both functionally and aesthetically. “In order to produce high-end products, it is essential to act on both fronts: on the one hand, protecting the metal from the action of atmospheric agents, including oxidation and corrosion, and improving the durability and reliability of the items; on the other hand, offering attractive products without the slightest surface defect,” says Roberto Zanuso, product manager at Pilla Group. “In particular, one of the flagships of our production is a special coating process that reproduces the veining of Botticino and Carrara marble on metals. Our new Radial Group plant is also used to apply these special colours.”

Optimising paint application with articulated robots “Although both booths were initially designed for manual coating, during the installation phase, we also decided to equip them with two articulated robots and to rely on Lesta for this. Robots are usually employed for high production volumes, but we chose to install them because the products we coat often have a similar geometry and © ipcm

Components entering the first booth for primer application.

48

N. 84 - NOVEMBER/DECEMBER 2023 - international PAINT&COATING magazine

because some steps of our finishing cycle, such as primer application, are standardised. This is why

FOCUS ON TECHNOLOGY

Hooks & CE Hooks

From the in-stock small and thin hook to the special hook Ø30 with EU certification and loading capacity calculation, for both small and heavy parts to be coated.

© ipcm

The inside of the first booth where primer application takes place.

optimise this phase,” states Zanuso.

Pilla’s requirements for the new coating line

The application of the primer in the first booth and

Given the importance of its finishing phase, Pilla

of the top coat in the second one is thus performed

had already been investing in other coating lines

by two Lesta LEBOT MV A6 robots. “Equipped with

over the years. Currently, it has two of them, in

six axes of movement, these articulated robots

addition to a few static booths for manual coating

come with Lesta Production Manager, a system

and post-finishing of small and specially shaped

for managing the production flow and the queue

components. “The most significant issue we

of programmes for the different types of parts to

encountered with our previous plant was related

be coated, and Recipe Manager, which allows the

to contamination from ambient dust. One third

coating parameters to be monitored and organised

of the products we coated every day had surface

into programmes that can be easily recalled via

defects caused by the inclusion of dust particles

the control panel’s touch screen,” explains Lesta

and therefore needed touch-ups, thus increasing

marketing manager Mattia Croce. “Finally, to increase

our coating costs and times,” notes Zanuso.

the booths’ productivity and cleanliness degree, we

“Indeed, the old booth was not pressurised, causing

provided Pilla with two Lesta Cleaning Stations, which

ambient dust to enter the production area and

are automatically activated after a certain number

contaminate the treated parts,” explains Francesco

of coating cycles and clean the robots’ guns by

Soragni, the owner Radial Group. “We designed this

immersion in solvent and the mechanical action of a

new plant for dust-free operation: this is why it has

brush.”

pressurised chambers into which filtered air is fed

an automated coating process can enable us to

HOOKS & CE HOOKS

COMPLETE SOLUTIONS FOR HANGING AND MASKING

www.rostirolla.it

© ipcm

Following paint application, the components dwell in the flash-off tunnel for 15 minutes at 43 °C.

© ipcm

The PLC that controls the entire plant.

to guarantee finished products of the highest quality.”

it is fundamental to invest in technologies and equipment that improve

The system also met another specific need: a plant with a small

our production flow and make it more flexible. We often handle very

footprint. “Unfortunately, we had no way to increase the production

small batches requiring different finishes, which means that several

space within our factory and had limited space available to devote to the

times a day we have to stop the system and prepare it for the following

new coating line. Radial presented us with a very compact concept that

cycle. However, we could no longer afford for so many items to have

met all our requirements,” indicates owner Roberto Pilla.

defects due to dust contamination. The dust-free system supplied

Conclusions

by Radial Group has certainly solved this problem, enabling us to manufacture products with flawless finishes,” adds the owner with

“In our sector, being able to offer a variety of finishes and colours, often

satisfaction.

anticipating market trends, is of the essence to stand out. This is one of

“Developing such a system to be placed within a limited space was a

the reasons for our success,” says Roberto Pilla.

real challenge, but we are happy to have found the right compromise

“However, in order to be able to produce highly customised products,

between space and quality,” concludes Soragni from Radial Group.

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DURABILITY AND HIGH FINISHING QUALITY FOR AGRICULTURAL MACHINERY

Protection

Finishing

Seam sealing

SAMES MANUFACTURES INNOVATIVE PRODUCTS FOR APPLYING PAINT, SEALANT AND BONDING SOLUTIONS Increase your performance Control your production costs Reduce your material and solvent consumption

www.sames.com

WHERE WE HAVE BEEN

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N. 84 - NOVEMBER/DECEMBER 2023 - international PAINT&COATING magazine

© AdobeStock

SPECIAL ISSUE ON ACE & OFF ROAD VEHICLES

54 BRAND NEW STORIES 56 SUCCESS A Record-Sized Booth for Industrial Vehicle Coating

ON TECHNOLOGY 60 FOCUS Water-Based Coatings for Finishing Mining

and Construction Vehicles: Gervasi’s Green Choice Since 2010

ON TECHNOLOGY 68 FOCUS Industry 4.0 and Sustainability: the Two Cornerstones of John Deere Ibérica’s Investment in Paint Mixing and Feeding Equipment for Its Two Transmissions Finishing Lines

STORIES 74 SUCCESS Shot Blasting Pretreatment with AGTOS Technology for Liquid Coating of Agricultural Machinery

STORIES 78 SUCCESS The World's Leading Manufacturer of Agricultural Machinery Chose Tikkurila Paint

STORIES 80 SUCCESS Coatings from HMG Paints Employed for the Red Massey Ferguson 35X Tractor Restoration Project

82 ADVANCEMENTS AQUAMIX WORLD: The New Fast-Hardening System OF THE MONTH 86 HIGHLIGHT Europolveri Renews its Range of Anti-Corrosion Primers ON TECHNOLOGY 88 FOCUS Z3 Verniciatura Strengthens Its Core Business by Installing an Environmentally Friendly, Automatic, Hybrid Coating System Applying Both Liquid and Powder Products

ON TECHNOLOGY 96 FOCUS Seppi: a Pioneer in Mechanised Agricultural Mulching, a Pioneer in Environmentally Friendly Coating

ON TECHNOLOGY 104 FOCUS 2elle-engineering Chose to Electrify Its New Coating Plant for Zero-Emission Production of Forged Wheels

112 ANALYSIS In Search for Competitiveness

international PAINT&COATING magazine - NOVEMBER/DECEMBER 2023 - N. 84

53

BRAND-NEW

SPECIAL ISSUE ON ACE & OFF ROAD VEHICLES

PPG and Dutch University Will Cooperate to Develop the First Off-Road Solar Car The upcoming Stella Terra vehicle will use PPG CORACHAR™ fire protection coatings to safeguard the lithium (Li)-ion battery pack and protect the car from thermal damage.

T

he international paints and coatings manufacturer PPG has

“A risk of Li-ion batteries is that they can experience thermal runaway.

recently announced a partnership with a student organisation

While the probability of this failure occurring is rather slim, we decided

from the Eindhoven University of Technology (Netherlands) to

to partner with PPG to minimize the effects of such a severe accident.

develop Stella Terra, the first solar-powered off-road car that will be

PPG’s cutting-edge innovations on battery coatings make it possible for

coated with PPG CORACHAR™.

Terra’s drivers and its surroundings to evacuate in a worst-case scenario

PPG will provide an amount of $37,000 to the Solar Team Eindhoven

by stalling the spread of a battery fire,” has stated Wisse Bos, team

as part of its recent $5 million commitment to the environmental

manager of Solar Team Eindhoven.

sustainability education. In addition, the company will supply its PPG

“The project supports PPG’s goals of developing sustainably advantaged

CORACHAR fire protection coating to safeguard the lithium (Li)-ion

technologies and supporting sustainability education. Through this

battery pack of Stella Terra, which has been designed to withstand the

investment, we aim to support educational activities related to clean

harsh conditions of off-roading. As a matter of fact, the car was tested in

energy and the future of mobility and help prepare the next generation

the Sahara Desert (Morocco) in October 2023.

of leaders to understand the impacts of climate change,” has concluded

The PPG CORACHAR battery fire protection coatings are intumescent

Thierry Destruhaut, PPG customer sustainability business partner for

solutions that expand in the presence of high heat or fire, providing

the Automotive OEM Coatings.

an insulating layer to protect from thermal damage. Furthermore, they can improve light-weighting, increase battery performance, support

For further information:

passenger and first-responder safety in case of a fire.

www.ppg.com/autocoatings/en-US/segments/electric-vehicles

© STE/Bart van Overbeeke

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Surface coating

BRAND-NEW

SPECIAL ISSUE ON ACE & OFF ROAD VEHICLES

ESTEE Coating Solutions Provided CNH Industrial with New Powder Coating Equipment

of heavy-duty workpieces and large-scale components Made in Germany.

Since

1925.

Hall 3 | Booth 3334

At the CNH Industrial plant in Zedelgem, ESTEE Coating Solutions has installed a new manual powder coating booth with vertical extraction equipped with the powder coating devices from J. Wagner GmbH.

E

STEE Coating Solutions – the exclusive

paint shop, the company has also recently invested

distributor of J. Wagner GmbH – has successfully

€650,000 in the upgrade of its electrocoating process,

installed a new manual powder coating booth

which will allow to increase the corrosion protection of

with vertical extraction, equipped with other powder

the coated products.

coating equipment in the Zedelgem (Belgium) plant of

“It is crucial for our customers to be able to rely on

CNH Industrial Belgium, an international manufacturer

our high-performance equipment, year after year,

of the New Holland brand combines, balers and

during harvesting periods which are often short. World

forage harvesters. With more than 3,000 employees,

harvesting records set with our CR combine, built here

the company has been designing, developing

in Zedelgem, prove that we build the best equipment.

and producing components for agricultural and

With regards to durability, the quality of the paintwork

earthmoving machines for 110 years.

of our equipment is a critical factor. This significant

The new booth (L 6m x W 4m x H 4.7m) is composed

investment further strengthens our role as the

by polypropylene in accordance with DIN 4102 B1 and

leader in the harvesting equipment market in terms

has been specifically designed to meet the European

of paintwork as well,” has stated Werner Ballieu, the

standard EN16985. It also includes a cyclone, a filter

Zedelgem plant manager for CNH Industrial Belgium.

and a fan with an extraction capacity of 26,000m³/h.

Furthermore, the electrical cabinet is equipped with Industry 4.0 energy measuring instrument.

For further information:

In order to further improve the performances in its

www.estee-cs.com

© ESTEE Coating Solutions

When it comes to the surface coating of heavy workpieces or large-scale components, customers worldwide rely on high-performance plant technology and material flow systems from Vollert.

vollert.de

© Linea Eco Air

SUCCESS STORIES

Linea Eco Air has installed for System Car a record-sized coating booth with a height of 7.50 m, width of 10.50 m and length of 24 m.

A Record-Sized Booth for Industrial Vehicle Coating Throughout their long-standing collaboration, coating system manufacturer Linea Eco Air has designed and installed several lines and over 100 booths for System Car, an Italian contract coater of special means of transport such as military, civil, and industrial vehicles. One of their latest projects dates back to 2019, when Linea Eco Air designed, built, and installed a booth that was 7.50 m high, 10.50 m wide, and 24 m long, as well as 3 booths that were 5 m high, 5 m wide, and 20 m long. These can accommodate up to 3 truck cabs painted with three different colours at the same time or 2 vans, which can be even coated in different colours at the same time without any contamination risk, thanks to the special ventilation system.

T

he coating of special vehicles, such as military means of transport

challenges. It is therefore vital to rely on a technological partner that is

and agricultural machinery, calls for outstanding attention and

experienced in this field. An example of this is the successful partnership

expertise to provide products that are corrosion-resistant,

between Linea Eco Air (Sona, Verona, Italy), a manufacturer of coating

compliant with current regulations, and durable. The careful selection

systems and spray booths, and System Car (Chero di Carpaneto

of the paint products and equipment to be used ensures that every

Piacentino, Piacenza, Italy), a coating contractor specialising in industrial

component can withstand any environmental and operational

and military vehicles. Since 2001, System Car has been investing in

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SPECIAL ISSUE ON ACE & OFF ROAD VEHICLES

cutting-edge technology, implementing various

© Linea Eco Air

liquid painting lines and more than 100 coating booths in various sizes and types, which were all designed, built, and installed by Linea Eco Air, including the largest one, dating back to 2019.

A record-sized coating booth The expertise and experience of Linea Eco Air’s technicians led to the design, development, and installation of a booth with truly significant dimensions (10.50 metres in width, 7.50 metres in height, and 24 metres in length), built

P25 column

without any steel columns or structures but

standard or customizable system to hang from the smallest parts to heavy 6-metre long bars

only aluminium. “The peculiarity of this booth is the use of aluminium for its construction.

This is an extremely light, ductile, and versatile metal, which is why we at Linea Eco Air call it the material of the future,” says Gianfranco Soliani, the company’s founder and owner. “We are the

© Linea Eco Air

first company in the world to use this metal in most of our solutions. The booth supplied to System Car is characterised by an impressive aluminium structure without a single welded joint. The roof is composed of a system made of trusses in bent and bolted sheet metal profiles placed every 2 metres, without any welding.

The panels are made of high-intensity rock wool and assembled through a tongue-and-groove jointing system. It was only through the use of aluminium and the high-engineering approach

Overview of the interior and exterior of the coating booth.

of our technicians that we were able to create a booth of impressive dimensions with an ultra light weight,” states Soliani.

The aluminium structure of Linea Eco Air’s

HANGING SYSTEMS

© Linea Eco Air

booths is patented and all their panels are approved as load-bearing structures with an A2 s1 d0 fire resistance rating. This is why all technical elements can be and are placed on their roofs. “In addition, no excavation was required to install this booth at System Car’s factory, which would have been a very expensive process,” indicates the owner.

Finally, this system reduces fuel and electricity consumption by 60% while still meeting the European standards for air velocity through the booth.

COMPLETE SOLUTIONS FOR The installation phase of the coating booth.

HANGING AND MASKING

www.rostirolla.it

SUCCESS STORIES

SPECIAL ISSUE ON ACE & OFF ROAD VEHICLES

© Linea Eco Air

© Linea Eco Air

Internal structure of the panels composing the booth.

Internal reinforcements with thickness from 1,2 to 3 mm according to the heights.

A component painted by System Car.

The coating cycle System Car was established in 1987 as a coating contractor specialising

complete lines and more than 100 liquid coating booths at System Car’s

in a wide range of industrial sectors, from civil to industrial, from nautical

plant, which covers an area of around 100,000 m2, of which around

to oil, and from leisure to military. In particular, due to its large size, this

50,000 are covered.

booth (which remains just one of many Linea Eco Air systems used by

“This long-term partnership testifies to the value of a stable collaboration

this company) is mainly employed to coat large military or industrial

and the trust System Car has placed in Linea Eco Air. It has enabled both

vehicles, such as trucks and agricultural machinery.

of our companies to develop state-of-the-art equipment and provide

The production cycle of these items begins with a shot blasting phase,

high-quality solutions for special vehicles, guaranteeing excellent

a surface treatment process that can give their substrates considerable

corrosion resistance and regulatory compliance but also remarkable

corrosion resistance. Agricultural machines, as well as military or

durability. The decision to rely on an experienced technology partner

civil vehicles, are often exposed to atmospheric agents and extreme

such as Linea Eco Air has proved crucial to System Car’s success in the

environmental conditions, including humidity, rain, UV rays, etc., and

field of special vehicle coating,” concludes Soliani.

it is therefore essential to provide them with a protective barrier that significantly reduces the risk of corrosion and oxidation to preserve

About Linea Eco Air Srl

their structural integrity and prolong their service life. Afterwards, the

Linea Eco Air was established in Sona, in the province of Verona, Italy, in

components enter the Linea Eco Air coating booths for the application

1984, based on a project by Gianfranco Soliani.

of a primer and two or three coats of polyurethane paint, depending on

After many years of work as a technical consultant and designer for

customer requirements. Between the application of one coat and the

two major companies in the coating sector, he decided to set up his

next, the parts can be left dwelling in the booth for drying or taken by

own business with the aim of designing and building a wide range of

special trolleys to the ovens, also designed and installed by Linea Eco

products, including automatic and manual coating booths; vertical

Air, for the drying phase only at a temperature of 80-100 °C.

and semi-vertical oven booths for car, bus, truck, train, and aeroplane

A successful, long-standing partnership

bodies; manual and automatic industrial liquid or powder coating plants; air filtration and purification systems; and cataphoresis and anaphoresis

The partnership between Linea Eco Air and System Car began back in

plants. “Linea Eco Air is the first and only company in the world to use

2001 and has spanned over twenty years of fruitful collaboration. In the

aluminium in most of its plant solutions. Excellence is Italian. Eco Air is

course of this long period, the plant manufacturer has installed several

Italian.” states Soliani.

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HEAVY EQUIPMENT COATING SYSTEMS

LIQUID, POWDER AND E-COAT SOLUTIONS Let Us Be Your Competitive Edge Contact: gi.emeai.marketing@sherwin.com | Visit: industrial.sherwin.eu

FOCUS ON TECHNOLOGY

SPECIAL ISSUE ON ACE & OFF ROAD VEHICLES

Water-Based Coatings for Finishing Mining and Construction Vehicles: Gervasi’s Green Choice Since 2010 Alessia Venturi, ipcm®

Water-based coatings’ technological performance has been consolidating since the 2000s, undermining the reign of solvent-based products by presenting themselves as a green choice, an option that forward-thinking companies could consider to reduce the environmental impact of their finishing operations. This was also the choice of Gervasi Industrial back in 2010 when it decided to replace its solvent-based coating cycle by relying on the expertise of Sherwin-Williams, the multinational corporation specializing in manufacturing liquid paints and powder coatings for the automotive and general industry, and one of the leading technological players in the development of water-based coatings with the Inver1 brand. Today, this Italian company coats up to 1,000 machines per year, intended for heavy-duty applications in the construction and mining industries, with a water-based acrylic system from the Inverpur series.

1

Inver is a brand of The Sherwin-Williams Company.

© ipcm

Gervasi Industrial’s product range extends from semi-trailers to dump boxes, with high levels of customisation.

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FOCUS ON TECHNOLOGY

T

he mining industry (or extractive industry) is the part of the

the Sherwin-Williams Company from Bologna. This has been bringing

primary sector that deals with the extraction and processing of

the profound, long-standing know-how in water-based coatings of its

mineral raw materials – not only iron, copper, and gold but also

own Inver brand to support Gervasi Industrial in the transition from

bauxite, diamonds, and uranium to name but a few. Veins and quarries

a solvent-based cycle and afterwards to develop increasingly high-

are often located in harsh, very hot or very cold areas of the world.

performance coating products while offering a reliable service for

These are particularly severe working environments, with rough terrain

the supply of even very small batches of special colours through its

and extreme exposure to the elements. The machines operating here

Invercolor point for the Piedmont region.

are often large systems such as excavators, dumpers, and wheel loaders that dig, transport material, and even clean the sites after the work is

About Gervasi Industrial

completed. They all must be able to withstand the harshest conditions

“My father Francesco Gervasi founded this company together with his

both inside and outside the mines or quarries themselves.

two brothers in 1973,” recounts Alessandro Gervasi, now a business

Gervasi Industrial (Scalenghe, Turin, Italy) is a leading European

partner and the director of Gervasi Industrial. “That was the period

manufacturer of industrial vehicles, specialising in the production of

of the Italian economic miracle: my father and uncles started from a

semi-trailers and dump boxes for quarrying, construction, mining,

garage in Rivalta and slowly expanded until they settled in the present

and special applications (e.g. material transport in bauxite mines).

location in 1980. The company rode the wave of great economic growth

The company works with all the world’s major players in the industrial

of the 1980s and 1990s by working in the Italian market. Since 2000, it

vehicle segment, such as Iveco, Volvo, Man, Scania, Astra, and Renault.

has been gradually entering the international markets, mainly Eastern

It has been gradually expanding its reach beyond national borders

Europe, the Middle East, and Africa, developing great expertise in the

year after year and gaining significant market shares even in Africa and

production of customised vehicles. In 2003, Gervasi Industrial opened

Eastern Europe. Today the production plant has a capacity of about one

two production sites abroad, one in Poland and the other in Russia,

thousand units per year.

approaching the global market with a clear vision. In 2017, a group of

From Russia to Guinea, Gervasi Industrial’s semi-trailers and dump

international significance, the Cellino Group, active in the metalwork

boxes are designed to withstand extreme temperatures, chemically and

sector, entered the corporate structure. This has enabled Gervasi

mechanically aggressive environments, rough terrains, and demanding

Industrial to elevate both its production development efforts and its

tasks while remaining reliable over time. Needless to say, in addition to

positioning towards new customers, aiming for even greater expansion.”

the robustness of their structures, these vehicles also require coatings that are durable and just as sturdy in terms of chemical and mechanical

A wide production range with many customisation options

resistance, but also aesthetically pleasing, as many customers demand

Gervasi Industrial operates mainly in the construction field, producing

almost “automotive-grade” finishes for their equipment. To this end,

both standard and customised equipment for quarrying, construction,

since the early 2000s, Gervasi Industrial has been working closely with

mining, and general heavy-duty applications.

© ipcm

© ipcm

Thunder, the flagship model of the mining division, was developed for the transport of bauxite.

An example of the extreme finishing customisation of dump boxes offered by Gervasi Industrial.

international PAINT&COATING magazine - NOVEMBER/DECEMBER 2023 - N. 84

61

SPECIAL ISSUE ON ACE & OFF ROAD VEHICLES

© ipcm

The metalwork department and the sand blasting machine supplied by OMSG (Villa Cortese, Milan, Italy): it is one of the largest in Italy, with a maximum part size of ø 5,000 x H 13,000 mm.

TECHNICAL FEATURES OF THE SANDBLASTING MACHINE • Maximum part size: ø 5,000 x H 13,000 mm • 13 7.5-Kw direct-drive turbines • 1 two-beam hoist with a load capacity of 10,000 kg and a length of 18 metres The machine is designed to be able to sandblast: • 3,000x2,600x11,000÷13,000 mm boxes with a maximum weight of 10,000 kg • beds - frames - sides - various parts • Initial condition of parts: dry - degreased • Initial surface grade: A - B • Finishing grade: SA 2½ according to ISO 8501-1

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© ipcm

FOCUS ON TECHNOLOGY

One of its most important product lines is the quarry vehicle one. The

A local, fully integrated production process

wide variety of models with numerous options enables every customer

“Gervasi Industrial has the production capacity to manufacture its

to find the most comprehensive solution to meet their needs. To meet

equipment locally and fully in-house, from sheet metal processing to

the growing demand for mining and heavy-duty vehicles, on the other

end product shipping,” explains Gian Piero Bennardo. “Our oxy-fuel and

hand, Gervasi Industrial has developed a line of specially reinforced

laser cutting machines enable us to process large-sized metal sheets,

semi-trailers and dump boxes for transporting stone blocks and

up to 12,000 x 3,000 mm. This is important especially for semi-trailers,

heavy materials. At the same time, if its customers’ needs go beyond

which have a length of 8 to 12 metres. After cutting, we use two bending

the standard product range, Gervasi Industrial has the design and

machines that can handle sheets up to 16 metres. Afterwards, sheet

manufacturing capacity to produce new, tailor-made equipment strictly

metal processing begins, right up to assembly and finishing. The first

meeting any technical requirement.

surface treatment process is sandblasting with a vertical machine

“Gervasi Industrial has always built products of a certain size but, thanks

designed and installed in 2002 by Carlo Banfi, now a brand of OMSG,

to the experience gained since 2000, our manufacturing capacity and

which is one of the largest of this type installed in Italy. This allows lifting

the machinery available for metalwork operations are ideal for designing

products weighing up to 10 tonnes and with a height of up to 16 m (see

even new and customised equipment,” says plant and production

the Technical Box, Ed.) After mechanical preparation, the parts enter the

manager Gian Piero Bennardo. “From laser cutting to bending and from

liquid coating booth set up by Wagner for the manual application of a

sandblasting to coating, we have the ability to do what other companies

water-based acrylic primer and top coat.

struggle or are unable to do. Just a few days ago, we launched a new

“In most cases, the parts are dried at room temperature,” adds

product called Thunder, our flagship model for our mining division,

Bennardo, “except in the case of very short delivery times, for which we

which is gaining more and more importance within the company.

use the drying oven. Once the coating has dried, the products arrive in

We have already agreed to supply a large number of vehicles for the

department 5, which is the assembly workshop: here, we carry out the

transport of bauxite on the African continent.”

assembly of the electrical, hydraulic, and movement-related elements

EXTREME PROTECTION FOR TOUGH GUYS. Optimum surface quality even under extreme conditions.

With our wide range of liquid & powder coating equipment. wagner-group.com

Contact us for professional advice: https://go.wagner-group.com/power-en

SPECIAL ISSUE ON ACE & OFF ROAD VEHICLES

From left to right: A box at the entrance of the sandblasting machine, which prepares the surfaces to an SA 2½ grade.

The manual application booth for water-based coatings.

The paint management unit installed by Wagner SpA (Valmadrera, Lecco, Italy) for handling two-component coatings.

© ipcm

and then perform the final assembly phase with the placement of the

with regional and provincial regulations: this decision took place in the

boxes or trailers on top of the vehicles. After acceptance, the vehicles

framework of several green investments.

are handed over to the customers. Gervasi Industrial does not only

“Sherwin-Williams presented it with a two-coat, wet-on-wet acrylic

handle the manufacturing but also the design phases in-house, thanks

coating system from its Inverpur series, with a polyacrylic primer and

to its engineering department that takes care of the continuous

top coat. Initially, the cycle involved final baking in an oven; today,

development of products.

thanks to careful production planning, the parts are often dried at room

This expertise is what allows us to also provide models that are instantly

temperature and assembled one day later, unless there is a special

modified according to customer requirements, or customised on both

need for a quick delivery. The implementation of a completely water-

an engineering and practical level. Such a customisation-oriented

based system has allowed Gervasi Industrial to eliminate its controlled

approach applies to coating as well: the colour and finish modification

suction systems with activated carbon: Sherwin-Williams’ water-based

service is also carried out in-house with the support of Sherwin-Williams,

coatings have a co-solvent content of less than 10% and, therefore,

which manages to supply us with small and even very small batches

fall perfectly within the requirements of the Piedmont region and the

within a short time frame.

province of Turin, which are much more restrictive compared with

Water-based coating since 2010

the rest of Italy. The transition to water-based products also called for two major technical investments in coating equipment, namely for an

“Gervasi Industrial applies a two-coat primer + top coat system with

application booth and for a mixing system with a PLC to manage paint

acrylic two-component products,” explains Alessandro Conconi, Sr Sales

flows and generate daily consumption reports.”

Representative at The Sherwin-Williams Company, General Industrial

“From 2010 to the present day, we have been gradually fine-tuning the

Coating, in Bologna. “The switch from solvent-based to water-based

original system, as the market demanded increasingly brighter and

coatings dates back to 2010. At the time, the company applied a solvent-

smoother colours, but its performance degree has remained the same,

based epoxy-polyurethane system. This was not a mandatory transition,

high one. We carried out some tests on metal plates treated with the

as it used charcoal filtration systems that already allowed it to comply

exact coating system used on the company’s boxes and we achieved a

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FOCUS ON TECHNOLOGY

© ipcm

© ipcm

salt spray resistance value of over 600 hours with a mechanical pre-

“We chose Sherwin-Williams because it is among the absolute best in

treatment stage (sandblasting) and the application of 70-80 microns

the water-based coating field,” states Gian Piero Bennardo. “In addition,

of primer and 60-80 microns of top coat, for a total dry film thickness

they offer a service that is essential for us, with very satisfactory delivery

of 160 to 200 microns. In some cases, Gervasi Industrial also applies a

times even for small colour batches. Gervasi Industrial works with

third coat of clear coat to achieve greater saturation, when customer

standard OEM specifications defined at the order of each vehicle, but we

specifications require an automotive-grade or similar quality level,” notes

often have to prove as flexible as possible, as some customers require

Alessandro Conconi. “We serve this customer from both our Italian

colour changes at the last moment. With its Invercolor point, Sherwin-

headquarters in Bologna and the Invercolor point in Rivalta (Turin)

Williams manages to be just as flexible and provide us with the required

because Gervasi Industrial offers numerous customisation options, even

products within 24 hours. We need its support to go the extra mile with

producing 4 or 5 vehicles in non-standard colours per week.”

a production speed that distinguishes us from our competitors.

KNOW-HOW, EXPERIENCE, AND RELIABILITY For decades, Radial has been designing, building and installing tailor-made coating plants for metals, plastics and wood. Our systems are the ideal choice for those who desire a cutting-edge turnkey solution.

w w w. r a d i a l g r o u p s r l . i t

SPECIAL ISSUE ON ACE & OFF ROAD VEHICLES

© ipcm

The final assembly line of the industrial vehicles.

© ipcm

From left to right, Gian Piero Bennardo from Gervasi Industrial, Alessandro Conconi from Sherwin-Williams, and Alessandro Gervasi from Gervasi Industrial in front of the new Thunder model.

Conconi, “which is famous in the USA for having sales centres that

Light-duty industrial products in Gervasi Industrial’s future

mainly deal with the production, distribution and sale of paints and

“For the short-term future, Gervasi Industrial’s goal is definitely to

coatings for companies and professionals, where end users can find

consolidate the market positions it has gained abroad, especially in

everything needed for painting. We are trying to replicate the same

Africa, where we will implement other business partnerships,” says

model in the European market in the general industry sector: the

Alessandro Gervasi. “In addition, we are aiming at consolidating our

Invercolor points can produce as little as 5 kg of a product.”

market share in the Italian market, which has expanded in the space of

“Such a high speed is very important for companies like Gervasi

two years. Finally, as early as 2024, we will focus on the development of

Industrial, along with the quality of the coating products,” emphasises

new products to go back to supplying the range of light-duty industrial

Gian Piero Bennardo. “We have chosen two exclusive partners: one is

products that we are not manufacturing at the moment. The idea

Inver, the other is Würth. We selected them precisely because of their

behind this strategy is to provide an all-round service, offering vehicles

speed and product quality, as they enable us to meet our customers’

from 3.5 tonnes up to 50 tonnes of payload. I am confident that Gervasi

requirements at all times and provide support at an international level.”

Industrial has all the skills and qualities to pursue this objective: over

“Since 2010, Inver has been developing into a global company and

the past fifteen years, we have made significant investments and now

our products are now available in all parts of the world,” indicates

we are reaping the benefits. In brief, we must continue to do what we

Alessandro Conconi. “If one of Gervasi Industrial’s customers needed to

do best.”

“This is the commercial policy of Sherwin-Williams,” confirms Alessandro

touch-up or audit their vehicles, they could do it at best using the same products used by the manufacturer.”

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N. 84 - NOVEMBER/DECEMBER 2023 - international PAINT&COATING magazine

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© John Deere

FOCUS ON TECHNOLOGY

SPECIAL ISSUE ON ACE & OFF ROAD VEHICLES

Industry 4.0 and Sustainability: the Two Cornerstones of John Deere Ibérica’s Investment in Paint Mixing and Feeding Equipment for Its Two Transmissions Finishing Lines Alessia Venturi, ipcm®

The trademark with a deer against a green background is world-famous: who would not immediately associate it with John Deere when seeing it on a tractor? This American multinational specialising in agricultural machinery has offices all over the world and a widespread European presence. Madrid (Spain), in particular, is home to John Deere Ibérica, the Tier 1 plant devoted to the production of power transmissions and their components for the tractors and harvesters assembled at the Group’s other sites. This factory has just completed a major project geared towards Industry 4.0 and sustainability to upgrade its high-solids paint mixing and feeding rooms with Graco’ s state-of-the-art technology.

“W 68

e conduct business essential to life. Running for the people who

John Deere, an American multinational with over 180 years of history in

trust us and the planet that sustains us, we create intelligent

the production of agricultural machinery, summarises its identity with

connected machines that enable lives to leap forward.”

this statement. Integrity, quality, commitment and innovation are the

N. 84 - NOVEMBER/DECEMBER 2023 - international PAINT&COATING magazine

FOCUS ON TECHNOLOGY

values that drive John Deere at all its locations around the world. John Deere Ibérica’s production unit in Getafe (Madrid), in particular, is the Group’s centre of excellence for power transmissions and it is devoted to the design, industrialisation, and production of high-tech, highquality, customised components for John Deere’s agricultural machinery transmissions. In 2018, it celebrated its sixty-fifth anniversary. Initially focused on tractor production, it was converted to manufacturing components in 1986: the transition ended in 1995 with the last tractor rolling off the assembly line.

The production plant in Getafe covers an area of 200,000 m2 on a twohectare plot of land and its activities are organised in four different minifactories for producing engines and assembling and coating complex © ipcm

transmissions through robotic systems. The PV&V Lab is at the core of this centre of excellence: here, all John Deere Ibérica’s projects and products are tested through thousands of hours of equivalent work to validate their functionality and reliability before reaching the fields. With about 1,000 employees, this factory achieves about 400 million dollars in annual sales, exporting 100% of its products to the Group’s other production units.

“We produces components for almost all divisions of the company,” points out Ángel Lara Moreno, Plant&Facilities Engineering Manager at John Deere Ibérica. “This Spanish site was converted to the production of transmissions, axles and gears for internal use or engine assembly.

Since 1986, Getafe’s production unit has acquired more and more responsibility in terms of design, validation, and the added value we provide to our customers, which are John Deere’s divisions primarily

© ipcm

devoted to assembling combine harvesters in the United States.

The main strength of John Deere Ibérica is its vertically integrated production. We receive raw materials in the form of forged elements, we machine and heat-treat them to guarantee the necessary hardness properties, subject them to mechanical finishing processes, preassemble the auxiliary bodies to the central transmission, and then take them directly to the coating department, implementing a lean production approach. We also carry out quality and functionality tests under field-like conditions, in order to ensure that the product meets strict quality requirements.”

The coating process “This factory has two automatic coating lines, one installed in the minifactory devoted to control units and one in the mini-factory devoted to

© ipcm

heavy boxes (for differentials, Ed.) The coating process is the same on both lines. Initially, a conveyor takes the hung workpieces to the pretreatment system linked to the respective line: they are different from each other and the most complete one performs five stages,” says Ángel Lara. “Then, the parts are blown off and dried before the automatic

From the top: The production line of the mini-factory devoted to differential heavy boxes; John Deere’s components are automatically coated with a high-solids two-component product by an articulated robot; One of the two identical paint mixing and feeding rooms set up by Finitec with Graco products at John Deere Ibérica.

application of the primer with a six-axis articulated robot. After flash-off,

international PAINT&COATING magazine - NOVEMBER/DECEMBER 2023 - N. 84

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SPECIAL ISSUE ON ACE & OFF ROAD VEHICLES

the top coat is applied, again with articulated robots. This is followed

and give them high a mechanical and chemical resistance degree. All

by another flash-off phase and an oven-drying one. The final process

our paints are mixed and fed to the spraying robots and manual touch-

stages are cooling, removal of the masking devices, and unloading.

up guns in two identical paint rooms, set up by Graco and recently

“We have been applying two-component, high-solids coatings for

upgraded to the company’s most advanced available technology with a

fourteen years now, ever since companies were asked to reduce their

view to energy saving and digitalisation 4.0.”

liquid painting operations’ environmental impact: some opted for water-based products, others for installing an afterburner. We decided

Investing in sustainability

to go with high-solids coatings – which are currently supplied to us by

Through this investment in new Graco equipment, with its level of

Sherwin-Williams. We only apply primers and top coats in two colours,

automation and interconnection with the factory’s management

green and yellow. For us, our coatings’ value is more functional than

software, John Deere Ibérica relied on the potential of technology 4.0 to

aesthetic, because it must protect the treated surfaces against corrosion

gain more control over its processes and align itself with John Deere’s

© ipcm

© ipcm

An EFLO-DC electric pump from Graco. Behind it, you can see the old pneumatic pump kept as a backup to the electric device.

The Graco Promix Easy 2K mixing unit.

The control panel of a mixing room’s circulation system.

70

© ipcm

N. 84 - NOVEMBER/DECEMBER 2023 - international PAINT&COATING magazine

FOCUS ON TECHNOLOGY

sustainability philosophy, since Graco’s new devices ensure significant energy savings, use cleaner energy, and reduce paint product waste. “This production site was already equipped with Graco pumping devices in its paint mixing rooms, but these were old-generation pneumatic pumps,” explains Casimiro García Nieto, industrial technical engineer at Finitec S.L., Graco’s distributor in the Madrid area. “In 2002, it decided to upgrade its technology with Graco’s latest generation of EFLO-DC electric pumps, with an initial focus on energy savings. In addition to this change, we improved the pumps’ management by setting three different working modes so that they could be adjusted automatically depending on production flows or work interruptions and thus consume as little as possible. Graco also took care of the entire circulation and feeding system and installed its Promix Easy 2K mixing machines. Subsequently, John Deere went a step further: all the monitoring lines in the room were connected the company’s own SCADA lines, linked with its master automaton, to control the coating process even better. The installation of the new equipment began at Christmas 2022 and was completed in spring 2023, whereas this latest

© ipcm

A product coated with a green primer.

Industry 4.0-oriented upgrade is still in progress.”

“In addition to ensuring energy savings, which is what the ROI of the investment is calculated on, John Deere Ibérica has achieved a level of equipment connectivity that gives it absolute control over its coating line at any given time,” emphasises Javier Adell, Key Account Manager Industrial Division EMEA at Graco. “Before Graco’s intervention, the pumps had only two working modes, On and Off, whereas now they have three different modes that guarantee a huge reduction in energy consumption.” These are Productive, when the booth is performing a coating phase, Productive without coating, and Stand-by, when the system is not working.

The pumps operate in one mode rather than another depending on the

EVERYTHING

FROM A SINGLE

SOURCE est.

1987

cycle. “The Stand-by mode is the most important one,” notes Casimiro García. “When the system is switched off, such as at the weekends, the paints must still be kept in circulation to prevent them from degrading: the EFLO-DC pumps are programmed for a minimum operating capacity to allow the coating products to recirculate with the lowest possible energy consumption. The pneumatic pumps could only be set to work or switched off. This was neither sustainable nor efficient, and especially not in line with John Deere’s sustainability goals.”

“The EFLO-DC pumps are the latest evolution of electric pumps and, in

.com www.emptmeyer

addition to the advantage of having electric motors,” says Javier Adell, “they have another added value: the fact that their bases are sealed eliminates the need for maintenance of mechanical seals while preventing any paint loss and soiling in the mixing room. Finally, the use of electric pumps has

HOOKS & S HANGING SYSTEM

MASKING

RACKS

considerably reduced the noise in the paint rooms because the typical pulsations of pneumatic pumps are no longer to be heard.”

MENT

UIP ACCESSORIES & EQ

Investment benefits “As mentioned, all of John Deere’s new lines are aimed at achieving environmental and sustainability goals,” states Ángel Lara. “These project

international PAINT&COATING magazine - NOVEMBER/DECEMBER 2023 - N. 84

71

SPECIAL ISSUE ON ACE & OFF ROAD VEHICLES

objectives are saving energy and raw materials, and reducing emissions.

Graco’s new EFLO-DC pumps contribute to achieve these aims.

In addition, improving digitalisation has enabled us to increase our control over the process and monitor the operational and quality consistency of our coating lines. At John Deere, we live and breathe the Smart Connected Factory strategy, calling for all production machines to be connected to collect and interpret data for continuous process improvement.

“We did not notice a big difference in terms of coating quality, also because it was already in line with our specifications. However, the EFLO-DC pumps certainly enable us to gauge the amount of paint to be dispensed more precisely and to keep the coating products in the best agitation, pumping, and feeding conditions. More than coating quality,

© ipcm

feeding quality has indeed changed, as we no longer experience the fluctuations and pressure peaks that are typical of pneumatic pumps.

With these new electric pumps, the reversal of upward and downward movement has braking and acceleration phases that reduce the pulsating effect, thus providing greater pressure stability.”

“We chose Graco based on the reliability of its components and the technical service it offers,” adds Ángel Lara. “Coating lines are critical plants at John Deere Ibérica because if they stop, no products leave our factory. This is why we need reliable suppliers as well as products that are just as reliable: over the years, Graco has been guaranteeing such a high reliability with the technical support of Finitec, its specialised distributor. Incidentally, its extensive network of specialised distributors is one of Graco’s strengths, because they know all the details of each machine and are always available for technical training and assistance.

© ipcm

We do not have data available on the savings and efficiency results The products of the mini-factory devoted to gear trains for tractor power transmissions.

brought by this investment, yet,” concludes Ángel Lara, “because the devices have only been in operation for a few months. We are still in the process of learning how to use them to their full potential, but we have already verified that they operate consistently and with the quality and cost-saving features we had required. When this learning curve is complete, we will be able to officially confirm all the benefits gained from the installation of the EFLO-DC pumps.”

© ipcm

From left to right, Casimiro García Nieto from Finitec, Ángel Lara from John Deere, Alessia Venturi from ipcm®, Javier Adell from Graco, and Rafael Tarancón from Finitec.

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TIGER Drylac® Digital Finishes

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SUCCESS STORIES

Shot Blasting Pretreatment with AGTOS Technology for Liquid Coating of Agricultural Machinery More than 1,000 parts are needed to assemble the finished products of GÖWEIL and 90% of them have to be blasted in preparation for the subsequent coating process. The company then invested over €27 million in a new surface and assembly centre with a new liquid coating plant completed with AGTOS blasting technology.

T

he surfaces of agricultural machinery are exposed to heavy

increased to about € 50 million. As a unique selling proposition, the

mechanical stress. Therefore, a coating with good adhesion is

products are supplied exclusively for the professional sector, mainly to

required. In addition to the protective function, this also has the

contractors.

task of presenting the value of the machine in a visually appealing way.

The demands on the machines are correspondingly high, which also

This has been recognised by GÖWEIL, and implemented accordingly.

applies to the surfaces.

Since 1988, GÖWEIL has epitomised excellence in the area of baling quality. Originally, the company specialised in the production of

The new surface and assembly centre on the greenfield site

agricultural machines, but now it manufactures also several machines

At the beginning of 2022, a new surface and assembly centre with a

for industrial use and its other core areas of activities include bale

floor space of approx. 16,600 m² in Rainbach im Mühlkreis (Austria)

opening and transport devices, high-lift buckets and blade sharpeners.

was put into operation. Since then, the preliminary products from

Through the extremely high export share, GÖWEIL machines are not

the company’s own plant in nearby Kirchschlag as well as from other

just known in Europe, but rather they are known and used worldwide.

suppliers have been processed and finished here. Herbert Göweil is

So, the number of employees grew to more than 300 and the turnover

pleased with the new production facility: “We are very satisfied with the

and wrapping technology thanks to a product selection of unsurpassed

© AGTOS

© AGTOS

Workpieces for agricultural equipment after the blasting process.

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SPECIAL ISSUE ON ACE & OFF ROAD VEHICLES

  © AGTOS

The parts before the blasting process.

investment. All expectations have been fulfilled. In the original paint shop in Kirchschlag, the plant was prone to breakdowns. Large parts had to be blasted by hand, this was of course very time-consuming.”

Many plans and suggestions from visits by the GÖWEIL project team to similar production tasks in other industries formed the basis for the planning. Thus, the decision for liquid painting instead of powder painting was also quickly made, because wet painting would have been necessary in any case for some parts from the wide GÖWEIL range. Incidentally, an automatic colour change was made possible for the three standard colours blue, yellow and black.

More than 1,000 parts are needed for GÖWEIL’s products and 90% of them have to be blasted in preparation for the subsequent coating process. The parts are cleaned of scale after welding.

The investment sum for the entire complex was over €27 million.

The planning was started backwards according to the production process. The area was determined on the basis of the expected assembly capacity.

The painting system from the manufacturer RIPPERT and the upstream wet-chemical pre-treatment, the double rinsing process with adhesive water dryer and also the AGTOS blasting technology were calculated on the basis of these capacities, too. The treatment processes, which also include masking, were connected by a friction wheel conveyor system from the manufacturer KJ. So, it is possible to produce not only according to the ‘first-in-first-out’ principle. The system makes it possible to determine a modified sequence all the way to the assembly line.





SUCCESS STORIES

SPECIAL ISSUE ON ACE & OFF ROAD VEHICLES

© AGTOS

The respective processing recipes are defined and filed by the production planning. Each product carrier has a data medium on which the specific processing parameters are stored. Moreover, a second painting line has been planned in order to satisfy the future growth and GÖWEIL is considering using a robot painting system here to process standard parts.

AGTOS shot blasting technology The blasting tasks are performed by an AGTOS continuous overhead conveyor blast machine of type DHT 25-25. Various workpieces are suspended from cross beams with a length of 7,000 mm. The blast chamber of the machine can hold workpiece dimensions of W x H max. 2,500 x 2,500 mm.

The maximum workpiece weight is 2,000 kg. Due to the quite different and angled geometries of the workpieces, the system was equipped with 16 high-performance turbines with 11.0 kW each. Frequency converters allow the best setting of diverse processing programmes. Round and angular grain can be used as blasting media. The throughput speed is approx. 1 to 3 m/min.

The abrasive is recirculated and fed back to the turbines after cleaning. Two © AGTOS

AGTOS cartridge filter systems of type PF 4-40 ensure a residual dust content of </= 1 mg/Nm³ in the extracted air. A sound enclosure reduces the noise level to below 80 dB(A), measured according to DIN 45635. The workpieces are blown off after the blasting process and thus freed from dust and remaining blasting media. This ensures that they are optimally cleaned before they are painted.

Mathias Kapfer, the project manager of the new plant, summarises the differences to the previous state as follows: “Today, about 90% of the process is automated. That means we hang the parts on the system, they pass through the shot blast plant fully automatically via the conveyor system. The recipes are assigned directly to the product carrier, so there is no manual manipulation or anything like that. The expectations and the challenges were great. It was the right decision that we did it with AGTOS. The biggest advantage is that we get our largest component through the machine, something that was not possible before because the large base frames were

© AGTOS

blasted by hand.”

The issue of conserving resources is also rated positively. “Especially the throughput time is enormous with this plant. If we think back to the operation in Kirchschlag, we needed about three quarters of an hour for a large base frame by hand. Here, with automatic blasting, we need about 10 minutes. So, the shot blast plant and also that has changed very positively,” has concluded Kapfer.

From top to bottom: View into the wind sifting.

A blasted surface.

Herbert Göweil (CEO - left) and Mathias Kapfer (right project manager) in front of the AGTOS shot blasting machine.

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I N D U S T R I A L C OAT I N G S

www.mirodur.com

SUCCESS STORIES

©Tikkurila

The World's Leading Manufacturer of Agricultural Machinery Chose Tikkurila Paint This article was first published on the Tikkurila website at the following link: https://shorturl.at/lBCRX

Aimo Kortteen Konepaja avoided a complete paint shop renovation with the help of Tikkurila’s time-saving surface treatment solution. In addition to a smoother assembly, Temasilox paint provides a durable surface for heavy wear.

I

n the expanses of Ylivieska (Finland), it is possible to find the world’s

didn’t have. The tone has been very effective in terms of marketing, as

leading manufacturer of agricultural machinery for processing

it stands out at trade fairs and also in traffic, where it is good for large

and preserving feed grain: Aimo Kortteen Konepaja Oy, which has

agricultural machines to be visible as far as possible from the point of

been manufacturing roll mills, feed mixers and feeding systems since 1969. During its 50-year journey, the company has specialised in

view of safety”, has commented Rönni.

product technology that saves energy and the environment, facilitates

Additional capacity with an efficient painting method

agricultural work as well as improves the profitability of farms, not only

Around 2020, the capacity of the paint shop connected to Aimo

in Finland but worldwide.

Kortteen Konepaja production facility was beginning to reach its limits.

“Since the 1980s, most of our agricultural machinery has been exported,

A solution was needed that would provide both a high-quality result and

mainly to Europe and Russia, but also further, for example to Japan,” has

faster throughput of components in the painting line.

stated Jari Rönni, the purchasing director Aimo Kortteen Konepaja.

“We had been thinking about upgrading the paint shop for a long time.

The Cooperation with Tikkurila is also long-standing. Although the company

However, a complete renovation is a big investment, so we considered

has used other paint suppliers over the years, Tikkurila was involved in

other options as well. We noticed that we could affect capacity with the

the start-up of the company – and the recognisable purple colour of the

painting solution. After conducting several test paintings and comparing

equipment manufactured by the workshop was also tinted by Tikkurila.

the costs of alternatives, we ended up with Tikkurila’s Temasilox paint,”

“We conducted a project with the Lahti Design Institute, where we

has explained Rönni.

received suggestions for a new colour to replace the red one used

Temasilox is a two-component, high-gloss polysiloxane topcoat with

earlier. The purple we chose was a special, striking colour that others

excellent colour tone and gloss retention. As a single-coat paint, it

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SPECIAL ISSUE ON ACE & OFF ROAD VEHICLES

Custom-built painting installations Macchine e impianti realizzati su misura

Shot blasting booths Cabine di sabbiatura

©Tikkurila

Washing tunnels provides faster throughput and withstands mechanical stress well

Tunnel di lavaggio

without rusting, fading and scratching.

“Thanks to Temasilox paint, items go through the paint shop much faster, which made production assembly even smoother. The end result is also of high quality: appearance and durability are now better than before. This is important because the service conditions of the machines place heavy demands on surface treatment: the painted surface must withstand varying weather, repeated washing and UV stress,” has added Rönni

Liquid painting installations

Impianti di verniciatura a liquido

“Temasilox allows a harder surface than traditional single-coat paints.

A durable surface minimises scratches from storage, stacking and assembly, which in turn reduces the need for after-treatment. Faster drying time also saves energy,” has clarified Johannes Vähänen, the key account manager of Tikkurila.

A solution also for a healthier working environment

Powder painting booths

Cabine di verniciatura a polvere

As the painting line is located in a large production hall where the equipment is also assembled, it is important that the products used do not release emissions to the surrounding area.

“Unlike most traditional single-coat products, Temasilox does not contain isocyanates. Thanks to its high non-volatile content and low VOC content, Temasilox meets even the most demanding environmental requirements. It also has a milder scent,” has

Curing ovens

Forni di cottura

continued Vähänen.

“Occupational safety is important to us. It is great that, in cooperation with Tikkurila, we found a product that is efficient in terms of technical properties and also low-emission and environmentally friendly,” has concluded Rönni.

Tikkurila has been part of PPG since 2021. PPG develops and delivers paints, coatings and specialty materials. They operate in more than

Eurotherm S.p.A. T +39 011 98 23 500 | M info@eurotherm.eu Eurotherm Oberflächentechnik GmbH T +49-7571-92795-10 | M germany@eurotherm.eu

70 countries serving customers in construction, consumer products, industrial and transportation markets and aftermarkets.

To learn more, visit www.ppg.com.

Eurotherm France S.A.S. T +33 (0) 7 89 37 56 88 | M france@eurotherm.eu Eurotherm Benelux T +33 (0) 6 47 44 96 27 | M dekergorlay@eurotherm.eu

www.eurotherm.eu

SUCCESS STORIES

SPECIAL ISSUE ON ACE & OFF ROAD VEHICLES

Coatings from HMG Paints Employed for the Red Massey Ferguson 35X Tractor Restoration Project HMG Paints provided Acrythane SC601 to ensure that the restored tractor could withstand harsh weather conditions and atmospheric pollution.

C

lassic Vintage Tractor Restorations, known for their exceptional

outstanding properties, including rapid drying and simplicity of use. The

craftsmanship in restoring vintage agricultural machinery, has

striking finish and the exceptional durability of the Red Massey Ferguson

proudly unveiled their latest masterpiece: a stunning restoration

35X were in fact made possible thanks to this popular paint product,

of a Red Massey Ferguson 35X Multi-Power tractor, which was made

which is ideal for the ACE (Agricultural and Construction Equipment) and

possible with the help of the Acrythane SC601 coatings of HMG Paints.

Restoration market places.

James Cardus, the skilled artisan behind Classic Vintage Tractor

As a matter of fact, not only did Acrythane SC601 provide an impeccable

Restorations along with his painter Peter, revived this classic tractor with

finish, but it also offered excellent protection against harsh weather

a rich heritage and a passionate following, breathing new life into an

conditions and atmospheric pollution. Its resilience ensured that the

iconic piece of agricultural history. With a rich history and a passionate

Red Massey Ferguson 35X would retain its beauty and functionality for

following, the Massey Ferguson 35X tractor deserved nothing but the

years to come.

best in its restoration journey.

“It is wonderful to see our paint being used on projects like this and

“We have been using HMG Acrythane SC601 for many years now, we are

brilliant to see the engagement on social media about the project. To

extremely happy with the excellent finish it produces as standard. Even

receive over 7000 likes on the teaser picture of the painted bonnet

more so our customers love the finish and happy customers are the

shows just how amazing this project was and passionate the restoration

most important thing for us,” has commented Cardus.

community is. The work James and his painter Peter have done is

Acrythane SC601 played a pivotal role in restoring the tractor to its

testament to their attention to detail and we’re delighted he chose

former glory. The product from HMG Paints is a high solids 2K acrylic

Acrythane SC601 as his topcoat of choice,” has added Paddy Dyson, the

coating cured with isocyanate hardener which is well-known for its

marketing manager of HMG Paints.

® HMG Paints

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® HMG Paints

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ADVANCEMENTS

SPECIAL ISSUE ON ACE & OFF ROAD VEHICLES

AQUAMIX WORLD: The New Fast-Hardening System Edited by ESTALIA Performance Coatings S.p.A. Castenedolo (Brescia) - Italy

Franchi&Kim brand step into the new era of water-based industrial coatings with the AquaMix Fast, a fast-hardening system.

I

n recent years, there has been a growing demand for coating

than qualitative.

products with “reduced environmental impact” calling for technical

For Franchi&Kim, however, right from the outset (our first formulations

and innovative solutions to reduce emissions and, consequently,

date back to the mid-1980s) water-based industrial coatings have been

pollution by using alternative sources to fossil fuels in the production

a high-tech formulation tool useful to seize new market opportunities

of coating products. Unfortunately, such demand often seems to arise

and meet the needs of users. To date, Franchi&Kim’s water-based

only because of the media’s pressure related to the new EU directives,

product formulations guarantee results on a par with solvent-based

adopting a conforming approach that appears to be more emotional

products and, in fact, in some cases they perform even better. Thanks to

© AdobeStock

ADVANCEMENTS

the growing awareness of ESG issues and the increased political push

unparalleled versatility by allowing adjusting the resistance degrees

for environmental protection, many companies are now fortunately

according to each company’s stacking needs thanks to the use of

moving in this same direction, starting to produce water-based, low-

different hardeners: in its high-performance version, a standard

impact coatings.

isocyanate hardener can be used; for shorter polymerisation times,

A new era

despite a slightly lower anti-corrosive resistance degree, a second, higher-performance hardener can be used.

In the framework of the green deal, Franchi&Kim now offers a new,

Unlike water-based epoxy systems, polyurethane systems are

innovative technology that goes beyond the systems conventionally

not sensitive to temperatures below 10 °C, as they crosslink at

available on the market. Having already reached a new step in water-

temperatures close to 0 °C. The reaction between component A (polyol)

soluble coatings-related research, we are officially in a new era. Due

and component B (isocyanate) takes a medium-long time depending

to the recent geopolitical events that have caused increases in natural

on the types of the two components. To reduce these physiological

gas and electricity prices, as well as the more and more stringent

crosslinking times, hardeners are often called into play to speed up the

scheduling requirements of companies due to inconstant orders and

system, improve hardening quality, and decrease pot life.

ever-shorter delivery times, we have formulated a line designed to

The salt spray and humidity chamber tests carried out show that

reduce drying times, energy consumption, and application times.

such a higher speed does not compromise the final degree of coating

AquaMix Fast is a water-based coating system consisting of a 2K

performance in any way, maintaining anti-corrosive properties on iron,

polyacrylic primer and a 2K polyacrylic quick-air drying topcoat that

sandblasted iron, and galvanised iron that are absolutely in line with

guarantees several advantages over many competitor products

standard products. In addition, this water-based system allows for

especially thanks to the peculiar resin used in the formula. It ensures

maximum customisation as the clear base can be coloured as desired

© ESTALIA

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with water-based colorants, maintaining colourability and compatibility

• possibility of performing wet-on-wet coating systems with the primer

with the tinting systems available on the market.

oven-drying for 10 minutes at 60 °C or air-drying for 20 minutes, thus

The advantages of the new AquaMix Fast line

further reducing coating times; • excellent final aesthetics finish without blooming with an excellent flow

The AquaMix Fast line guarantees the following benefits:

and a high film resistance;

• possibility of lowering the temperature of the drying oven to 50 °C for

• increased hourly productivity with a significant reduction in the time

30-40 minutes for the topcoat, unlike non-fast-hardening products that

taken to stack or package the coated products;

need a temperature of 60-70 °C and solvent-based systems that require

• very high final hardness of the coating system already after final

temperatures around 70-80 °C;

drying in the oven at a temperature of 60 °C (without waiting the usual

• consequent reduction of energy costs (gas and electricity) by 25%

48-72 hours), thus offering the possibility of immediately handling and

compared with solvent- or water-based coatings systems using much

stacking the coated parts after cooling, without the risk of marking and/

higher final drying temperatures;

or indenting their surfaces;

© AdobeStock

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ADVANCEMENTS

• lower emissions thanks to the water-based nature of the system, thus reducing the environmental and health risks for operators without sacrificing the quality of the end product.

Ultimately, AquaMix Fast is a true breakthrough: it guarantees high quality-price ratio, an increase in total plant productivity, significant energy savings, reduced costs, and unrivalled versatility without sacrificing customisability and adaptability to customer requirements. It was well received in the market and highly appreciated in the industry sector. Many manufacturers of earthmoving machinery are currently in the process of converting their solvent-based systems to effectively reduce drying times and enable the handling of the coated parts within a short time before assembly.

A success case In this regard, it is interesting to mention a successful conversion case involving a Franchi&Kim customer. A manufacturer of oil hydraulic cylinders needed to transition to water-based products for its entire production to lower emissions and meet current market and regulatory requirements. Its plant was very compact and “short”, which brought the performance degree of the tested water-based paint products below the required threshold. Stacking times were always too long, making it necessary for the company to slow down production or set up an ad hoc drying area, which required additional space and manpower. Alternatively, the company would have had to rethink its overall line to lengthen its cycle.

Franchi&Kim offered a fast-hardening water-based system with 2 hardener options, so that the customer could choose the combination required by the task at hand from time to time, thus

Benefit from the highest coating results!

always guaranteeing a high degree of customisation. This solution enabled the company to smoothly stack its coated products without having to modify its plant (thus saving a possible revamping investment), while maintaining a high performance degree despite the increased speed, reducing emissions, and increasing its overall productivity.

Our innovative XXL cabins ensure in combination with the dynamic contour detection for constant performance and top quality. You too can your production automation to the next level!

Gema Europe Srl | Via Goldoni, 29 20090 Trezzano s/N | Italy T +39 02 48 400 486 gemapowdercoating.com

HIGHLIGHT OF THE MONTH

© Europolveri

SPECIAL ISSUE ON ACE & OFF ROAD VEHICLES

Europolveri Renews its Range of Anti-Corrosion Primers Edited by Europolveri Spa Sandrigo (Vicenza) – Italy

Europolveri updates its range of epoxy primers and introduces the new product Anticorrosion11 Plus 6L4871113T0C0, a conductive zinc-based primer that combines the presence of zinc phosphates with additives allowing the migration of electric charges through the coating film.

T

he main use of epoxy powders is as primers in two-layer systems

reason for their success and widespread diffusion. Besides the epoxy

to improve corrosion resistance. For the protection of parts

components, a fundamental role is played by the presence of additives

against corrosion, two- or multiple-coat systems are a common

and fillers able to increase the primers’ resistance level with a synergistic

choice in industrial powder coating, especially in sectors such as earth-

effect.

moving or agricultural machinery (ACE), structural elements, urban

Europolveri has been present in this industry with its products for many

furniture, tanks, or fences, where the use of epoxy primers plays a

years, in particular with its powder 6L4800003T002, a high-performance

fundamental role in increasing the resistance against corrosion of the

(HP) primer, and with its zinc phosphate active protection (AP) primer

treated surfaces.

6L2800003T002. The epoxy primer 6L4871153T0C0 was added to them

Indeed, the epoxy resins used in this kind of primer penetrate the

a few years ago: based on the 6L4800003T002 product, it has its same

substrate’s interstices better than any other type of system (if the

corrosion resistance properties and contains an additive that makes it

workpiece has undergone a mechanical, sandblasting pre-treatment)

anti-static, i.e. capable of transferring the electrostatic charges present

or react with the substrate (if the workpiece is subjected to a chemical

on the surface to be coated after the primer’s application and during the

pre-treatment, e.g. phospho-degreasing, chromating, etc.). Their ability

second layer’s application.

to adhere to the surfaces and form a barrier to the passage of humidity

Now, Europolveri has launched its new powder Anticorrosion11 Plus

and environmental agents that can promote corrosion is the main

6L4871113T0C0, a conductive zinc-based primer that combines

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the qualities of the previous powders with the presence of zinc phosphate, with additives that allow the migration of electric charges through the coating film. Generally, with two-layer systems, after primer application, the component is covered with an epoxy film that is particularly effective as an electrical insulator. This makes the following application of the finishing coat more difficult, due to the counter-ionisation phenomenon that makes the powder unable to discharge the excess electric charge received from the

Increase your productivity WITH SELF-LEARNING ROBOT FOR FINISHING

guns. Something similar happens when the part-holding hooks are not clean enough and isolate the components to be coated, thus preventing them from being correctly earthed. In the new anti-static primer Anticorrosion11 Plus 6L4871113T0C0, as well as in the previous product 6L4871153T0C0, the presence of specific additives allowing the transfer of electric charges from the primer surface to the underlying substrate leads to a more effective top coat application, to greater ease in coating (especially of three-dimensional workpieces and those with Faraday cages), to improved aesthetics, and to reduced overspray and powder consumption.

The presence of zinc phosphate fillers improves the barrier effect by increasing the coating’s resistance to oxidation, rust formation, and delamination with reduced maintenance costs and increased service life, even if exposed to particularly severe environmental conditions.

In addition to this, the Anticorrosion11 Plus 6L4871113T0C0 primer has proved to be particularly effective in covering sharp edges with adequate thicknesses (e.g. those created by laser cutting of metal sheets) as well as surface areas where anomalous electric fields are created.

Neutral salt spray tests conducted in compliance with the ISO 9227 standard have demonstrated that the corrosion resistance of a twocoat system combining Anticorrosion11 Plus 6L4871113T0C0 and a polyester or polyurethane-based second coat applied on industrially pre-treated parts (sandblasting to SA grade 2.5) exceeds 1200 hours, with an average delamination of less than 2-3 mm. At the same time, continuous condensation humidity-resistance tests in compliance with the ISO 6270 standard showed similar results exceeding 3000

SELF-LEARNING ROBOT

hours.

1 OPERATOR REQUIRED © Europolveri

EUROPEAN ASSISTANCE

info@Lesta.it

www.Lesta.it

FOCUS ON TECHNOLOGY

Z3 Verniciatura Strengthens Its Core Business by Installing an Environmentally Friendly, Automatic, Hybrid Coating System Applying Both Liquid and Powder Products Federico Melideo, ipcm®

Italian company Z3, specialising in the contract coating of metal parts, has recently embarked on a course of expansion and automation of its production capacity, enlarging its site and investing in an automatic coating plant supplied by Silvi (Peregallo di Lesmo, Monza e Brianza, Italy). The special feature of this new system is the possibility of operating in a hybrid mode, taking advantage of the specific advantages of both liquid and powder coating for greater versatility and adaptability to the needs of end customers.

L

ike many others, the oil hydraulics sector experienced several challenges during the COVID-19 pandemic. However, thanks to the gradual recovery of the global economy, the market has begun to

show signs of recovery and to adapt to the new dynamics. This transitional phase has indeed transformed the industry, presenting it with new opportunities and unique challenges, with a significant impact on the contract coating segment as well. The strong upturn in manufacturing activities has indeed increased the volumes to be coated, pushing companies to offer a faster delivery service and raise the quality of their finishes while also taking into account the growing focus on sustainability.

© ipcm

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Z3 Verniciatura specialises in the finishing of oil hydraulic cylinders for the ACE sector.

FOCUS ON TECHNOLOGY

To meet these demands, many coating contractors have invested in new technologies and adopted more sustainable practices.

Although today’s demand is stabilising after the peak of the last two years, the implementation of modern technologies has certainly had an important result: it has enabled these companies to accelerate their automation and digitalisation processes, fostering growth and increased flexibility, innovation, and above all ability to anticipate market needs, which are all determining factors for success in this new economic scenario.

Providing an impeccable, fast, and environmentally friendly finishing service is also the mission of Z3 Verniciatura, a company founded in the Veneto region (Italy) in 1974 as a car body shop and then gradually evolved until the 2000s, when it launched its first industrial coating services. Over the years, Z3 has been specialising further in this sector. In 2017, it made its first, major investment by taking over a new 3,000 m2-

© ipcm

One of three static oven-booths in the manual finishing department.

wide site in Cittadella (Padua, Italy) to expand its production capacity. Today, the company’s main activity is contract coating of cylinders and tanks, as well as chassis and large parts, for the agricultural and construction machinery markets. The positive trend in these sectors over the past three years, combined with its entrepreneurial spirit, then prompted Z3 to install an automatic plant in addition to its already established manual liquid coating service, while also doubling the staff in its paint shop. The new automatic coating technology has made it possible to meet the increasing number of requests from customers in the oil hydraulics sector, demanding high-quality, durable finishes with excellent anti-corrosion properties.

“We have always applied liquid paints and until recently, no customer had ever required us to use a powder coating. As we did not know this field, an investment of this magnitude could be risky. That is why we opted for a solution

© ipcm

Overview of the automatic line designed by Silvi. The control desk with screens for managing the plant through 4.0 technology is clearly visible.

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© ipcm

© ipcm

that would enable us to continue with liquid coating and, at the same time, allow us to enter the powder coating market and begin gaining new customers in this area,” explains Z3 owner Andrea Zanoni. “We have found the perfect partner in Silvi, able to provide us with a technologically advanced plant, taking care of both its powder and liquid application components and implementing many technical solutions for greater efficiency.”

Z3’s factory layout and the new Silvi automatic system’s features The Z3 factory occupies an area of 3000 m2 and it is structured in two macro-areas devoted to coating operations. The first includes 2 25x12.5 m static manual oven© ipcm

Top left: The loading bay of the automatic system with the Futura Convogliatori Aerei power & free conveyor. Both the loading and unloading stations are equipped with an elevator to facilitate operations.

Top right: The exit of the pre-treatment tunnel. On the left, the automatic powder coating booth with Reind’s powder centre and reciprocators.

Above: The pre-treatment tunnel.

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booths with suction walls and temperature and humidity control systems. These are used to treat large parts such as machine frames and structures or smaller parts requiring longer cycles, such as those intended for marine, offshore, or even military applications.

One station is served by a 10-tonne overhead crane to facilitate the lifting and handling of

FOCUS ON TECHNOLOGY

GLOBAL SOLUTIONS FOR WATER TREATMENT

with a complete service that includes system design manufacturing, installation, technical support and chemicals

components.

The second macro-area accommodates the new automatic, hybrid plant designed and built by Silvi, handling parts with a maximum size of 6x1.2x2.5 m. This line consists of as follows: • a pre-treatment tunnel; • a blowing/masking station; • a drying oven; • 2 liquid coating booths; • 1 powder coating booth: • a heated flash-off chamber; • a common polymerisation oven for liquid and powder coatings; • an overhead power & free conveyor with loading/unloading elevators.

SPRAY BOOTHS WATER SLUDGE REMOVAL RESIN DEMINERALIZATION SYSTEMS REMEDIATION OF CONTAMINATED SITES BIOLOGICAL SYSTEMS BATCH TREATMENTS PHYSICAL-CHEMICAL SYSTEMS ADSORPTION FILTRATION REVERSE OSMOSIS MEMBRANE SYSTEMS EVAPORATORS BIOGAS BIOMASS SYSTEMS OIL SEPARATORS DESANDERS DESALINATION SYSTEMS PYROCHAR OTHER SYSTEMS CHEMICALS

“The pre-treatment tunnel has closed cells with movable spray bars with an alternating back and forth motion for better cleaning effectiveness. The system is equipped with a three-column demineraliser performing anionic, cationic, and activated carbonbased processes,” explains Daniele Fumagalli, Chief Operating Officer at Silvi.

“The two dry booths for liquid coating are pressurised and preheated. The first is devoted to primer application and equipped with a self-learning articulated robot supplied by Lesta, whereas

srl

the second is devoted to top coat application and it is prearranged for the installation of another robot. The powder coating booth

Via Torricelli, 79 - Z.I. Fossatone 40059 MEDICINA (BO) - tel. (+39) 051 856263 info@hydroitalia.com - www.hydroitalia.com

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built by Silvi is made of PVC with a sandwich design. It is equipped with a self-cleaning filter, a cyclone for overspray recovery, and an incoming workpiece detection system.

Wagner supplied the powder application equipment and Reind the reciprocators and the powder centre.

“The new line also features three ovens: one for drying after pre-treatment, one for flash-off (placed between the two liquid booths for primer and top coat application), and one for the final polymerisation phase. All ovens are equipped with air stream burners fuelled by natural gas and operate together for polymerising both types of finishes.” With liquid paints, drying takes place at temperatures between 60 and 70 °C, whereas with powders, curing is carried out in the temperature range of 180 to 200 °C. © ipcm

“The two drying and polymerisation ovens

The drying oven (left) and the polymerisation oven (right) are heated with air stream burners.

are manufactured in high-quality materials, perfectly insulated with a 150 mm thickness, and equipped with inlet pre-gelling chambers, automatic double doors, and a centralised suction system to reduce consumption and heat loss, thus enabling the ideal temperature to be reached quickly and efficiently. The combination of the air stream burners with the construction solutions adopted guarantees a significant reduction in methane gas consumption, around 25-30%,” states Fumagalli.

The workpieces are handled by an overhead power & free conveyor from Futura Convogliatori Aerei (Robecco Pavese, Pavia, Italy) featuring a loading and unloading elevator to facilitate the operators. It is connected with a 6-metre load bar system with a maximum capacity of 1000 kg, equipped with free-sprocket hooks, 15 of which are rotating and 14 are fixed, as well as a motorised rotation system to turn all sprockets simultaneously on the bars.

The conveyor’s route also includes a 9-slot

© ipcm

The primer application booth is equipped with a Lesta articulated robot.

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storage buffer before the cleaning tunnel and a second 4-slot buffer located after the

FOCUS ON TECHNOLOGY

polymerisation oven for cooling the parts before unloading them. The loading bay also accommodates a technical area with all types of hooks suitable for all the different weights and sizes of parts to be hung.

A highly versatile coating process Surface pre-treatment is the first important step in the entire coating process. Indeed, the metal workpieces must be adequately prepared for the subsequent coating application stage to guarantee proper paint adhesion. “The new plant’s structure enables Z3 to offer a technologically advanced pre-treatment service, capable of reducing its environmental impact and energy consumption while lowering production costs and ensuring high-quality surface preparation,” adds Fumagalli. The pre© ipcm

treatment process includes 5 stages: • phosphating

A cylinder at the entrance to the powder application booth.

• first rinse with mains water • second rinse with mains water • rinse with demineralised water • nanotechnology conversion.

At the customer’s request, Z3 also provides a manual sandblasting service using garnet or metal abrasives, as it is equipped with a 5x5x15 metre manual sandblasting system from Vespa Sabbiatrici. Sandblasting is followed by blow-off and cleaning stages.

After pre-treatment, the parts move on to the coating stage, the beating heart of the plant.

The aim is to provide the end customers with products that boast high-quality, durable finishes with excellent anti-corrosion properties. The main coating systems used by Z3 are composed as follows: • a liquid primer and a powder top coat • a liquid primer and a liquid finish • one coat of powder • a powder primer and a powder top coat.

Industry 4.0 and conclusions “The new plant complies with the current Industry 4.0 standards. All machines are

© ipcm

The conveyor’s route before reaching the unloading area.

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interconnected through a computer system that allows a wide variety of parameters to be monitored and tracked, e.g. cleaning temperature and pH concentration of the degreasing bath or the coating. In addition, all systems allow for a remote assistance service, which guarantees direct intervention in case of failure. The technical department manages all production-related activities in-house. Upon receiving the material to be treated, the operators carry out the necessary checks and place the order. Then, the system records all the steps to be performed, which vary depending on the coating system to be applied,” concludes Fumagalli.

There were three reasons why Z3 invested in an automated system. Primarily, the desire to build a new customer base by offering a new service, namely powder coating. “With a

© ipcm

The 9-spot storage buffer before the pre-treatment tunnel.

view to our future development in this market, the implementation of a powder application station has produced very good results in a short period,” states Zanoni. Secondly, Z3’s will to enhance the quality of its existing services to significantly increase productivity and delivery speed. Thirdly, the possibility to equip its new headquarters with a low-consumption, environmentally friendly automated system, which was an indispensable mission for Z3. “We are more than satisfied with this investment, which has met and even exceeded our expectations. The collaboration with Silvi was more than positive. Its team supported us at every step, from the beginning to the end of the project, and I am also very pleased with the choice of all the other suppliers that Silvi coordinated.”

© ipcm

Z3 Verniciatura’s team.

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The right partner in the green transition

FOCUS ON TECHNOLOGY

SPECIAL ISSUE ON ACE & OFF ROAD VEHICLES

Seppi: a Pioneer in Mechanised Agricultural Mulching, a Pioneer in Environmentally Friendly Coating Alessia Venturi, ipcm®

Efficiency and streamlining of production facilities and their energy consumption have been among the hottest topics in the last few years. SEPPI M. (Mezzolombardo, Trento, Italy), a leading company in the production of agricultural mulchers, has recently collaborated with Savim Europe (Arbizzano, Verona, Italy) and a group of industrial partners including CMA Automation, Wagner, and Sherwin-Williams to build a coating plant that would be the heart of the company itself, fuelled with biomass to increase efficiency and reduce environmental impact.

© SEPPI

SEPPI M. is among the leaders in the production of agricultural mulchers.

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T

to a shortage of gas throughout Europe and an excessive rise in

SEPPI M.: from the post-war period to the present day through three generations

the cost of this raw material. These factors have been weighing

Founded in 1939 by Max Seppi, the company is among the leaders in its

he 2020 pandemic and the geopolitical events that followed it led

on the budgets of many companies, especially those with high energy

field worldwide.

consumption rates, for example in the coating sector, notoriously one of

A pioneer in mulching technology, SEPPI M. has been specialising in

the most energy-intensive processes in the industry.

the production of mulchers for professional agriculture, public green

This increase in energy costs went hand in hand with a spike in demand,

maintenance, and forestry for forty-five years now. Flail mulchers,

which exploded in markets around the world after the pandemic.

rotary mowers, solutions for orchards and vineyards, mulchers with

Companies therefore found themselves facing excellent market and

large working widths for use in open fields and large areas such as

growth prospects with the handicap of energy costs.

airports and parks, forestry mulchers for tractors, excavators, or forestry

That is why SEPPI M., a leader in the mulching sector, worked with Savim

equipment carriers, stone crushers, and soil tillers are just some of the

Europe, a company specialising in the design and construction of liquid

70 products included in SEPPI’s range.

and powder coating plants and booths, to turn its newly installed coating

“My grandfather Max set up his own business on the eve of World War

line’s power supply system into a hybrid one, using both methane gas

II, after the company he worked for closed due to the conflict,” recounts

and hot water produced by a biomass boiler to heat the plant.

Lorenz Seppi, the current president of SEPPI M. “His company was

This modification project was ambitious and unexpected. After a design

immediately successful because it produced everything the country

process that had lasted several years, Savim had actually just completed

needed in the post-war period: items for agriculture and waterworks,

the installation at SEPPI of an automatic coating system with a two-rail

bandsaws, and other tools. SEPPI’s portfolio as we know it today was

conveyor designed and supplied by CM Automazione as well as three

introduced in the early 1970s: we were among the first companies in the

static oven-booths for treating large parts, on the occasion of SEPPI’s

world to specialise in mulchers and today we are one of the leaders in

relocation to a new plant in Mezzolombardo (Trento, Italy) specially

our field.”

built around the new coating plant itself as the heart of the production activities.

A vertically integrated production process

Savim’s design and technical capabilities, however, made it possible to

“The Mezzolombardo factory is brand new: we entered it at the end of

carry out the necessary modifications to the line and booths in just a

2021. Previously, we were headquartered in Caldaro, in the province of

few months, so that they could also be powered with hot water: SEPPI’s

Bolzano (Italy), but that space had become too tight, especially for our

coating line has thus been running on energy produced from wood

coating operations, which are the true heart of our production process,”

chips since April.

explains Lorenz Seppi. “We invested around 20 million Euros to better

© SEPPI

The brand-new headquarters of SEPPI M. in Mezzolombardo, Trento, Italy.

© SEPPI

A mulcher by SEPPI M. mounted on a tractor.

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© Savim

Overview of the plant installed by Savim Europe.

organise our production flow, which is fully integrated: we start by

Savim, and then we built the factory around it: the paint shop is the only

subjecting sheet metal to laser cutting, bending, turning, welding, and

department that, once located, can no longer be moved, so we adapted

partial assembly before coating. This is one of the reasons why we have

the entire company to it,” says Lorenz Seppi. “The plant’s development

never considered powder coating: we paint pre-assembled machines

process lasted three years, during which Savim fully supported us with

with bearings, seals, and heat-sensitive components that would not

design studies, estimates, and modifications. In fact, our first contact

withstand the curing temperature of powders. After coating, the systems

with Savim goes back more than ten years: we can say they have

are fully assembled, tested, and shipped. All our products are developed

earned it! The process we have developed together guarantees a very

and industrialised in-house, with such a vertically integrated production

high coating quality in terms of both adhesion and colour. In addition

process.”

to Savim, we also relied on the expertise of Sherwin-Williams for the

Coating at the core of SEPPI M.’s activity

supply of water-based paints, Wagner for the application system with electrostatic technology, and the supplier of pre-treatment products.

“Coating had been a headache,” notes Lorenz Seppi, “since I started

We witnessed great team effort among the various suppliers, which our

working at the company in 2006, as the province of Bolzano had already

engineering department synchronised to have a plant, process, and

banned the use of solvent-based paints. This is why we were among the

application system fully tailored to our products.”

first to switch to water-soluble paints. However, initially, quality was poor and we received numerous complaints from customers as the colour

Main features of the line

faded or flaked off. Although some might think otherwise because

SEPPI’s paint shop consists of two operating units, both featuring

agricultural machinery operates in the fields and thus gets ruined very

equipment from Savim, which acted as the general contractor: an

quickly, finishes are actually a very important part of these products’

automatic line with a two-rail conveyor from CM Automazione with a

quality, since they are the first thing that customers see when buying

capacity of up to 2000 kg, which can coat parts with a maximum cross-

them. Every machine must be aesthetically pleasing and the quality of its

sectional dimension of 1.5x1.5 m and a maximum length of 3.2 m;

colour must be preserved.

2 static oven-booths for finishing oversized parts, each of which can coat

“That is the reason why coating is one of the production steps that

parts up to 6 metres long, served by a cleaning booth with a manual

has been the subject of constant development at SEPPI more than

nozzle and using a pickling product.

any other. First, we defined the layout of the new coating plant with

The pre-treatment phase performed by the automatic line includes 3

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FOCUS ON TECHNOLOGY

stages, i.e. pickling and 2 rinses with mains water. After drying, the parts enter the booth for manual application of the epoxy primer, followed by a 40-minute flash-off in the oven. The workpieces then enter the water-based top coat application booth and finish the cycle in the drying oven at 70 °C. When designing the conveyor, CM Automazione was faced with a plant engineering challenge due to the limited space available and the characteristics (size and weight) of the products to be processed. The choice fell on the robust, flexible, and reliable XD45/59 PF Power&Free. The line develops for approximately 120 metres and the chain moves with a continuous motion at 7 m/1’.

The loading/unloading area is served by a counterweighted elevator/ lowerator for safe part handling. Stop stations located along the line allow for the stationing of the load bars during the coating cycle. The pickling and double rinsing stations are served by tilting systems to ensure optimal pre-treatment. In order to guarantee the correct stationary times, the flash-off and final cooling areas have 2 storage buffers with a sideshift system, again highly compact to optimise the available space.

SEPPI applies Sherwin-Williams two-component water-based paints, namely epoxy primers and polyurethane top coats, fed from a paint

© Savim

The entrance to the pretreatment tunnel.

SPECIAL ISSUE ON ACE & OFF ROAD VEHICLES

management unit set up by Wagner Spa, which is equipped to feed all 4 booths, i.e. the 2 automatic and the 2 static ones, through a high-pressure circulation system for the following products: • 1 two-component water-soluble epoxy primer- 1 hardener for the water-soluble epoxy primer • 2 standard two-component water-soluble polyurethane top coats • 2 wild-card two-component water-soluble polyurethane top coats • 2 hardeners for the two-component water-soluble polyurethane top coats • 2 cleaning mixes for the paint and the hardener. © ipcm

Each feeding unit is composed as follows: • 3 Wagner Leopard 35-70 pumps for the primer and the standard top coats, with a by-pass system between 2 PGR 200 elevators for 200-litre drums equipped with an electric agitator (while one PGR 200 is feeding paint, the other is in preparation) • 2 Wagner Leopard 35-70 pumps for the wild-card top coats • 2 Wagner Leopard 35-70 pumps for the hardener featuring an airtight tank and a by-pass system between 2 PGR 200 elevators for 200-litre drums- 1 Wagner Leopard 35-70 pump for the hardener cleaning mix • 1 Wagner Leopard 35-150 pump for the paint cleaning mix.

All these pumps feed 4 Wagner Intellimix Touch 2k devices positioned in the respective booths of the automatic and manual systems. Each Intellimix Touch device, in turn, feeds an AirCoat GM 4700 manual gun for medium-pressure coating.

The Intellimix Touch devices also control 4 Gun Flash Boxes

© ipcm

to manage the cleaning and colour change operations on the individual guns.

This whole line was built according to the interconnection parameters of Industry 4.0. It is also prearranged for the future use of articulated robots in the automated system.

From top: The interior of one of the two manual liquid paint application booths supplied by Savim.

The loading area of the automatic painting line designed

by Savim with a power&free conveyor supplied by CM Automazione, it is equipped with a counterweighted elevator/lowerator for safe part handling. © ipcm

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A buffer on the power&free conveyor.

FOCUS ON TECHNOLOGY

“With the two main colours we apply, i.e.

© ipcm

black and red, we can quickly switch from one tint to the other using the same pumps,” comments Lorenz Seppi. “With Savim, we chose a Power&Free conveyor to make the individual workstations more independent, although we do not take full advantage of its full potential since we have little storage buffer spaces among the working areas, due to the compactness of the line. Savim did an excellent job on design, construction, and installation and I am also very pleased with the choice of CM Automazione as the conveyor supplier. Savim fully grasped the characteristics of our ideal plant in terms of both size and process, it ensured continuous technical support and advice, and above all it showed that it cared a lot about the project, also considering that our decision-making phase lasted almost ten years! Finally, even

The primer application booth with one of the four Wagner Intellimix Touch 2k devices.

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© ipcm

© WAGNER

© SEPPI

The topcoat application booth; The paint kitchen equipped by Wagner Spa; Lorenz Seppi.

when we asked for a modification to the plant’s power supply system

we could switch to natural gas without having to stop the coating plant.

only a few months after start-up, Savim accepted the challenge.”

It was another big investment, but its ROI is quick because the cost of

From methane gas to biomass

biomass is about 35% of that of gas for the same heat output (based on an annual average). The thermal-hydraulic project was done by Savim in

As mentioned at the beginning of this article, SEPPI installed this new

autumn 2022 and its implementation started in December 2022. By the

coating line in one of the blackest periods for energy supply and its

end of last cold season, the system was up and running: this year, we

related costs. The plant, which started up in April 2022, has an installed

will be able to quantify the savings achieved.”

capacity of 2 MW of methane gas: SEPPI’s immediate concern was its ability to sustain such rising costs for a long time. Last summer, therefore,

A high degree of satisfaction

SEPPI’s owners requested a major plant modification from Savim to power

“I am very satisfied with our investment,” concludes Lorenz Seppi.

the plant with hot water produced by a biomass boiler (wood chips)

“The system is working well and we have achieved a very good colour

instead of methane gas. As a result, the company reduced energy costs

and finishing quality degree, as also confirmed by our customers.

and the environmental impact of its coating process in general.

Productivity has not reached the optimum level we had set, yet, but this

“Savim did a very good job in a very short time,” states Lorenz Seppi.

is due to many different factors including the organisation of work and

“We now have a hybrid power supply system: if one day the biomass

people and the procurement of materials. I am sure that for any further

boiler were to go out of use for maintenance or for any other reason,

plant engineering project, Savim will be at our side.”

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FILTRAZIONE PER IMPIANTI DI VERNICIATURA FILTERING FOR FINISHING LINES

rotoli, pannelli e celle in fibra di vetro

rolls, panels and cells of glass fiber

celle filtranti per alte temperature

filtering cells for high temperatures

rotoli e pannelli in fibra sintetica

rolls and panels of synthetic fiber

accumulatore vernice “Columbus”

paint accumulator “Columbus”

filtri “Andreae”

“Andreae” filters

cartucce filtranti

filtering cartridges

filtri assoluti applicazioni speciali

absolute filters special application

FILTRO ALVEOLARE MAX PAINT distributori esclusivi per l’Italia

massima efficienza massimo accumulo di vernice massima durata

=

minori costi di smaltimento minori costi di manutenzione

L’esclusivo design alveolare permette di trattenere quantità di overspray notevolmente superiori rispetto ai filtri oggi in commercio

www.defil.it

© ipcm

2elle-engineering produces forged aluminium alloy wheels for the aftermarket and original equipment sectors as well as for limited edition vehicles.

FOCUS ON TECHNOLOGY

SPECIAL ISSUE ON ACE & OFF ROAD VEHICLES

2elle-engineering Chose to Electrify Its New Coating Plant for Zero-Emission Production of Forged Wheels Monica Fumagalli ipcm®

The decision to power its new coating system exclusively with electricity is at the core of the environmental vision of 2elle-engineering, a company specialising in the design and production of high-end aluminium alloy forged wheels. To realise its sustainable plant engineering project, the company turned to Tecnofirma, a specialised surface treatments company.

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© ipcm

© ipcm

The loading area of the pre-treatment tunnel’s overhead conveyor.

T

The 13-stage pre-treatment tunnel.

he manufacturing industry is at the heart of the world’s energy

project included the construction of a new hall to accommodate the

issue, which calls for the need to transition to less impactful

pre-treatment and coating phases of forged aluminium alloy and

solutions. Whereas “going electric” is one of the most popular

carbon wheels, which were previously outsourced but are now carried

trends of the moment, from domestic energy to cars, since today

out directly in-house. “The decision to insource the coating operations

electrically powered engines are the most popular alternative to internal

was motivated by the need for greater control of our production

combustion engines, in the industrial sector replacing methane gas

process to achieve the high quality standards that the market

powdered systems with electrically powered alternatives is still a path

increasingly demands,” states Davide Lucaora, the production manager

taken by a limited number of companies, due to the high costs entailed

of 2elle-engineering.

and the necessary changes to made in the plants involved. Methane, the

“Building a plant from scratch requires a huge investment, but it

cost of which has soared in recent times, is a dangerous greenhouse

also offers the possibility of defining its operating conditions without

gas but, at the same time, an almost indispensable fuel. Now, however,

the limitations of existing infrastructure. We had imposed two

the industry has started to look for alternative energy sources to

prerequisites for this system: an all-electric power supply, to eliminate

overcome the health risks that a gas-fired plant can entail in the event of

the need for gas and enable our employees to work in complete safety,

an unforeseen malfunction and the excessive costs associated with its

and maximum flexibility, to easily switch from solvent-based to water-

maintenance.

based liquid top coats and to add or exclude process steps according

2elle-engineering, a young company based in Trebaseleghe (Padua, Italy)

to different programmes. Tecnofirma (Monza, Italy), which has been

and specialising in the design and production of forged wheels for the

active with an international vocation in the pre-treatment and coating

high-end car and motorbike industry, chose electricity as the alternative

fields for over seventy years, especially in the automotive sector, was

energy source for its new coating line. Indeed, a recent factory extension

able to meet all these requirements.

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© ipcm

© ipcm

2elle-engineeering’s wheels are forged to measure

over 50,000 cars are equipped with our rims, which we produce

Founded in 2008 by Davide’s father, Luigi Lucaora, who channelled

in diameters ranging from 13 to 24 inches. We have also recently

many years of personal experience into it, 2elle-engineering is now a

launched some forged aluminium wheels for motorbikes with

benchmark in the sector, especially for companies that require a high

diameters from 16 to 21 inches.”

customisation degree of modular or monoblock rims. “We started

2elle-engineering provides its customers with a complete service, from

by designing and manufacturing our 6061-T6 and 6082-T6 forged

the co-design of the stylistic features to the 3D drawing and structural

aluminium modular wheels.

analysis of the rim. “The safety of the drivers of any vehicle fitted with

Modular wheels differ from monoblock ones in that the former are

our wheels is paramount to us and the reliability of our products is

assembled with other components, such as channels and flanges,

renowned,” adds Lucaora. “The growing reputation of our wheels

whereas the latter consist of a single piece,” explains Davide Lucaora.

has even led some international armoured vehicle manufacturers to

“2elle-engineering’s target market includes high-end aftermarket and

ask us to produce special reinforced wheels using our lightest and

OEM manufacturers as well as producers of cars and motorbikes in

strongest alloys.”

limited editions. As such, it is characterised by very frequent trend

Turning and milling are the two processes for which this company

changes. When the needs of the industry shifted towards an increasing

stands out. “Our latest-generation lathes perform the shortest but

demand for monoblock rims, which guarantee higher performance

most important machining step in our production flow, as this is

degrees thanks to their lower weight and are therefore more suitable

where raw aluminium loses more than 80% of its weight. The flagship

for the sports car sector, we adapted our production by investing in

of our manufacturing process, however, is the milling phase, carried

new machinery to be able to manufacture both types of wheels. Today,

out with 3- to 5-axis milling machines with which the turned blanks

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FOCUS ON TECHNOLOGY

The entrance to the drying oven.

A wheel loaded onto the floor conveyor.

take on the shape and style defined by our engineering department to be transformed into wheels – ready to be coated in the recently installed state-of-the-art plant that adds the final touch of perfection to our products.”

A safe and zero-emission plant Another aspect that makes this company stand out from the rest of the industry is its environmental vision. “When we decided to insource coating to have more control over this fundamental and delicate stage, improve our finishes’ quality, and reduce our delivery times, we knew we wanted a technology that could provide us with an effective energy alternative to the use of methane gas for plant operation. Tecnofirma’s 100% electrically powered coating line was the best-suited solution.

Having eliminated the use of gas ensures we operate in a safer working environment and reduce our carbon dioxide emissions.”

SPECIAL ISSUE ON ACE & OFF ROAD VEHICLES

© ipcm

© ipcm

© ipcm

After machining, the wheels are taken to the recently built hall accommodating the new system. The company’s coating manager, Luca Zampieri, describes the standard rim coating cycle as follows: “The wheels are loaded onto the overhead conveyor that transports them along the 13-stage pre-treatment tunnel.

Afterwards, they are dried at 100 °C. This is followed by a forced cooling stage in a tunnel and a natural air cooling one. An automatic sideshift system then removes the parts from the overhead conveyor’s bars and loads them onto the floor conveyor that takes them to the three automatic coating booths equipped with CMA Robotics robots. One applies powder primers with thicknesses ranging from 100 to 120 microns and it is linked to a WAGNER

From top left clockwise:

powder centre. The second applies liquid base coats with thickness values of 15 to 18

The automatic sideshift system to transfer the parts from the overhead conveyor of the pre-treatment tunnel to the floor conveyor of the coating plant.

microns and the third applies liquid clear

Two of the three booths: the one for applying powder primers (left) and the one for liquid base coats (right).

microns.

The inside of the powder application booth with WAGNER equipment.

cured in an oven at 180 °C for 40 minutes

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coats with a thickness between 20 and 25 “After powder application, the coating is

FOCUS ON TECHNOLOGY

and cooled in a ventilated tunnel for 18 minutes. This is followed by IR

thanks to automation. This initially had a strong impact on the company’s

pre-heating and base coat application. Flash-off between the first and

operators, who were accustomed to manual processes, but it is now

second coat takes place at a temperature of 30-40 °C for 24 minutes;

perfectly understood and managed by all of them.”

after the application of the second coat, flash-off occurs at room

Another technical solution implemented in the pre-treatment phase is

temperature for 16 minutes. The last section of the line includes a

the presence of two deoxidation tanks allowing the most suitable pickling

curing oven for baking the liquid clear coat at 160 °C for 40 minutes and

programme to be selected depending on the type of wheel. “In the

a station where both forced cooling in a ventilated tunnel and natural air

case of raw rims,” indicates Caprino, “the parts can be pre-treated with

cooling take place.” At the end of the coating cycle, both types of wheels,

aggressive oxidants. In the case of diamond-finished wheels, however,

i.e. modular and monoblock, are subjected to strict controls by the

this is not possible because such chemicals could damage their surfaces.

quality department, which tests all parts for conformity to the specified

Therefore, the installed software package allows the second tank to

tolerances. Once a wheel has passed all tests, it is ready to be packed

be chosen, with more suitable oxidants. The same flexibility, which is

and shipped.

truly the strength of 2elle-engineering, also characterises coating. For

The flexibility of the new system

example, as diamond-finished wheels require two layers of clear coat, the powder primer application robot can also apply the powder clear coat,

“Both the overhead conveyor and the floor conveyor are equipped with a

on which the liquid clear coat is then applied in the third booth. Polished

total of 85 load bars and have a speed of 0.5 m/min,” indicates Salvatore

wheels, after pre-treatment, skip the primer and base coat application

Caprino, sales engineer at Tecnofirma.

stages and are sent directly to the third booth for clear coat application.

“The concept behind this new automated coating line is maximised

Finally, when treating carbon wheels, the cycle remains identical, but the

flexibility for handling small batches, down to only 4 wheels, and carrying

oven temperatures can be lowered. In short, this plant allows treating the

out up to 20 colour change operations per shift. The main features

surfaces of all different parts in a versatile manner thanks to its user-

of this plant include an all-electric power supply and ease of handling

friendly management system.”

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Conclusions “Thanks to automation,” confirms Lucaora, “we have been able to increase our production speed so that we can meet increasingly stringent specifications within shorter delivery times, thus fully responding to our customers’ requests as the bar for quality and functional performance is raised higher and higher.

Another important advantage is that can run the plant with only three operators.”

“We also greatly appreciated the speed of installation and commissioning,” emphasises Zampieri. “Installed between March and April this year, the system was already functioning at 100% by September.”

“In addition to higher plant productivity and greater control over coating quality,” concludes

© ipcm

Lucaora, “what makes us most satisfied is the opportunity to improve the safety of the workplace and the impact of our activity on the outside environment. Even when – in 50% of cases – we use solvent-based paints to meet customer specifications, the activated carbon filtration device purifies the air before it is released into the atmosphere. We are aware that the manufacturing industry in general and our sector in particular still have a long way to go for the complete decarbonisation of production processes, but this plant represents an important step forward for us. It is a demonstration that it is possible to fulfil the commitments made at international meetings for future industrial production based on renewable sources.”

The CMA Robotics robots’ control units outside the booths.

The inside of the top coat application booth with Edrizzi filters.

© ipcm

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P

o

w

de

r

i

n

s

i

d

e

There is a strength enclosed in the composition of Europolveri’s products, a formulation that determines their quality and which is reflected in the appearance and resistance of the treated surfaces.

A quality that is never casual, but it is the result of a commitment to product development and industrial processes, that allow to guarantee a great chromatic and application variety.

Europolveri offers either a wide range of powder coatings in different finishes and gloss levels, with a stock of about 1000 always available different colors, and the possibility of formulating and delivering customized products in the short term.

advanced solutions for metal surfaces treatment since 1982

EUROPOLVERI S.p.A. - Sandrigo (VI) Italy - Ph. +39.0444.750643 - Fax +39.0444.750653 FILIALI/Branch Office: Cernusco sul Naviglio (MI) Ph.+39.02.92148001 - Erbusco (BS) Ph.+39.030.7704158 DEPOSITO/Depot: Iori Colori, Reggio Emilia Ph.+39.0522.327248

info@europolveri.it - www.europolveri.it

© HangOn

ANALYSIS

SPECIAL ISSUE ON ACE & OFF ROAD VEHICLES

In Search for Competitiveness Adriano Antonelli Tecno Supply - Ibix Srl, Lugo (Ravenna) – Italy

adriano.antonelli@tecnosupply.com

Masking as a strategic operation to reduce handling times and eliminate the need for touch-ups after coating: once again, Adriano Antonelli’s analysis starts from the general economic situation to get to the heart of the paint shop and suggest effective solutions to optimise processes.

W

e find ourselves in a phase of change where instability

past. More in detail, the reduction in inflation, so far not as significant

is a variable that is difficult to manage. Although some

as had been hoped for, has certainly helped households partially regain

factors such as falling inflation and lower energy costs are

their purchasing power. The reduction in energy costs, which weighed

positive, some issues remain unresolved, such as rising interest rates,

heavily on inflation, has been a relief for many families and even more

sustainability-related problems, climate change, and a globalisation

so for energy-intensive companies. On the other hand, the rising cost of

paradigm that no longer equals the free market as conceived in the

money and the consequent falling stock markets, as well as a weather

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ANALYSIS

situation that has caused severe damage, at least in Italy, especially in

EU instrument to boost infrastructure and modernisation. The green

the Emilia Romagna and Friuli Venezia Giulia region, make the outlook

revolution will have to be considered an opportunity.

less than positive. New European regulations will have to address these

Private companies will have to search for renewed competitiveness as a

issues.

focal point for staying in the market and expanding their shares against

What is the state of the art of SMEs in this framework?

emerging countries (which perhaps we should no longer call emerging:

At the macroeconomic level, compared to a positive first quarter thanks

countries such as India are going to overtake their former colonisers,

to the GDP growth that occurred in 2022, the second quarter of 2023

such as the United Kingdom, in terms of GDP). To do so in the surface

saw a not-so-worrying contraction, closer to a cooling of the economy.

coating sector, what can be implemented in the immediate future to

Growth has certainly lost momentum. It remains to be seen whether

increase process efficiency? A key aspect is surely hanging density, which

this is a slowdown or a real stop that could lead to recession, at least

can contribute to reducing a number of costs such as, first and foremost,

from a technical point of view. The large European countries, including

energy costs. A useful tool available at https://www.hangon.com is the CCC

Germany, are coming to a standstill. What can we expect? Definitely not

spreadsheet, which allows comparing the consumption degrees and

a cut in interest rates, a drastic decrease in energy costs, or state aid.

savings achievable with different hanging systems. Another key factor is

Italy, in particular, will have to take full advantage of the Next Generation

masking, which Ibix addresses with the support of HangOn, for which it

© HangOn

Technical comparison between GA caps and GAQ caps: time saving is significant.

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is a distributor. Reducing handling times and avoiding post-finishing are

and prevent grit from entering holes and cavities to prevent the

the objectives on which the company focuses.

workpiece from being rejected for this non-conformity. In the case

Below are some ideas for protecting the parts that do not need to be

of phosphodegreasing or similar processes, they must be watertight;

coated, which of course can be explored further according to each

otherwise, functional parts of the machine could be damaged. Finally,

customer’s production complexity.

if cataphoresis coating is performed for corrosion protection, sealing masking devices are of the essence.

Masking as a strategic step Masking is an important production step to avoid transferring

HangOn’s masking tools

inefficiencies to downstream departments, particularly the assembly

Many of the ready-to-use products in the HangOn portfolio have

one, whose line cannot be stopped because of a pin that does not

already successfully enabled production targets to be met in terms of

screw in smoothly. The parts must therefore leave the coating phase in

time and methods, easy pre- and post-use masking management to

optimum condition. For this to be possible, if any components need to

be implemented, and hence the required results to be achieved. The

be protected, it is essential to do so carefully. Crucial to this is masking

silicone range certainly falls into the group of these high-performance

speed, the certainty that the treatment product will not seep into the

products. All the devices in this range are coloured and tint consistency

protected surfaces, the ease of insertion of the masking devices, and the

is guaranteed for each batch. For example, the M4 size is white in all its

possibility of removing and reclassifying them for later use. Sometimes,

various configurations, so that operators can recognise and classify it

a single part might call for 50 or 60 masking devices to be used, some

easily and quickly. In any case, colours can be changed and customised

of them very similar to each other. The ability to distinguish and select

to match each product to a specific colour.

them at a glance is therefore of paramount importance.

Here are a few examples of products included. The GDM caps allow

Another aspect to consider is pre-treatment. Indeed, masking devices

hermetically sealing through holes. The cylinder terminal part enables to

must sometimes be inserted before the pre-treatment phase. In the

tighten the nut’s flaring. This series currently includes caps up to 83 mm

case of a shot blasting operation, they also must be abrasion-resistant

in size. These caps are hollow for easier insertion.

© HangOn

A DSG special assembled masking device in solid silicone.

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ANALYSIS

The QB caps are screw caps for blind holes, i.e. parts where depth is minimal and it is necessary to close a hole hermetically and guarantee the masking device stays still even during handling.

In the case of bushings with large through holes, good results have been obtained with expanded silicone. The SP expanded silicone tubes, which can be cut to measure, expand into the hole, thus preventing any shading and build-up effects. Their maximum diameter is 60 mm.

The GBH caps also allow masking large holes, up to 110 mm. The GDM H cylindrical caps can also mask largesized through holes up to 83 mm. These allow for proper masking and, more importantly, protection of the holes during shot blasting.

For pins, HangOn has designed some non-standard caps, such as the GAP and GAQ ones, which allow protecting pins up to 50 mm and with variable lengths. The GAP caps feature a ventilation valve to insert and remove the masking device without air resistance. The GAQ caps, on the other hand, allow significantly reducing masking times

© HangOn

A DSS special assembled masking device in silicone foam with a pull handle.

eosmarketing.it

AC E

cataphoresis and liquid spray applications

70 years of experience and innovation in surface finishing lines pre-treatment | spray applications | electroplating | vertical & horizontal plants | enameling | aluminium | white goods | automotive | general industry

FINISHING SYSTEMS

www.trasmetal.com www.varnishtech.it

SPECIAL ISSUE ON ACE & OFF ROAD VEHICLES

© HangOn

thanks to their particular configuration.

that can be die-cut to measure. These can be glued on top of each other

For all non-standard products, HangOn (distributed by Ibix) can produce

to increase thickness and pull handles can be applied to them. The

specially moulded products. Indeed, it can design and manufacture

masking devices obtained can be cleaned like conical caps;

products meeting any special needs by taking into consideration

• Silicone foam from 2 to 20 mm: it looks like a sponge. Thanks to

production issues, tolerances, friction degrees, treatment processes,

its silicone nature, it can withstand high temperatures and it is also

and so on.

cleanable. Its softness allows inserting the caps easily and provides an

Effective masking in the ACE sector

efficient grip. It can be glued to solid silicone when required; • EPDM from 1 to 6 mm: it is rigid and resistant to the abrasive action of

In the agricultural and construction machinery sector, components often

mechanical pre-treatment processes. It has a maximum heat resistance

feature many surface areas to be masked that have completely different

of 170 °C;

characteristics, so that several different masking devices are required,

• Magnetic silicone from 1 to 2 mm: it has a magnetic power that

each one in minimum quantities. Producing a mould for each of them

enables it to stick to ferrous material, thus eliminating the need for

would become too costly. An immediate, flexible solution with short

disposable taping systems. It withstands temperatures up to 250 °C and

lead times and no minimum required quantities is the use of assembled

it can be easily cleaned and glued to the above materials;

masking devices. With this type of product, it is also possible to mix

• MDF: it has a few limits compared with the previous materials. It can

various materials and thus make the masking rigid on the outside and

be applied before mechanical pre-treatment, but not before chemical

soft on the inside.

pre-treatment because it would soak up water. It is less flexible and

The materials that can be used include as follows:

therefore more difficult to clean. On the other hand, however, it is more

• Solid silicone from 1 to 6 mm: it has the same characteristics as the

economical and it withstands temperatures up to 200 °C, which makes it

silicone used in plugs and caps for coating plants. It comes in sheets

also suitable for powder applications;

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ANALYSIS

© HangOn

© HangOn

• Cork from 2 to 25 mm: compressed cork is an inexpensive material

low cost of polyester tape for powder coating or crepe paper for liquid

designed for liquid applications. It withstands temperatures up to

coating is fully recovered, if one also considers the ease of removal

150 °C and it can be glued to other materials. Magnets can be added to

at the end of the process. This also minimises potential errors of

this type of device to provide more stability and a better grip on parts. It

interpretation by the operator who might mask the wrong surface areas.

is also possible to add caps to improve grip.

The flexibility of these masking devices, however, lies mainly in quantity.

Since there are no minimum required amounts, we can produce exactly

Such a wide variety of materials and options enables every company

the number of items needed by each customer. Furthermore, if the

to select the best masking system according to its production times

technical department changes the dimensions of the part to be masked,

and methods. Masking devices must be chosen by considering the

a new device can be produced without fixed costs being incurred,

characteristics of the workpieces to be protected, the acceptable

whereas if some products are damaged or worn, they can be replaced

tolerance rates, the hanging system used, the level of simplicity required

at no extra cost.

in the masking operation, the product type, the durability performance required, the budget, and so on. Based on this assessment, HangOn/ Ibix’s technical department can design the most suitable products and afterwards supply the prototypes to verify their coverage and performance degree.

From the left:

Conclusions

Examples of magnetic masking devices: a DSM 10 special magnetic silicone mask and, bottom left, a standard silicone mask with an embedded magnet.

Proper positioning of masking devices means that there are no errors or uncovered surfaces. The higher initial investment compared with the

Special MDF masking devices with embedded magnets.

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HIGHLIGHT OF THE MONTH

Sweet Embrace: Interpon Colour of the Year 2024.

Sweet on Colour, Strong on Design Performance Alessia Venturi ipcm®

In today’s ever-changing world, people are seeking precious moments of joy and a feeling of stability.

The colour experts from AkzoNobel’s Global Aesthetic Centre exploring current global social, design and consumer trends discovered a desire to belong, to feel grounded in memories and personal relationships. In this context AkzoNobel introduced “Sweet Embrace” the Colour of the Year 2024, a delicate shade of soft grey with a hint of violet, and a subtle metallic effect. A colour with a gentle optimism that is both understated yet liberating, that brings a sense of stability and peace to our living and working spaces.

It was imagined by an international team of colour experts, designers, and architects from around the world and within AkzoNobel’s Global Aesthetic Centre.

C

olourFutures™ is at the heart of AkzoNobel’s Global Aesthetic Centre, located in Sassenheim, The Netherlands. This global trend research, conducted annually, lays the foundation for

Colour of the Year and its supporting colour palettes to provide customers and consumers with the colours they need for the future.

AkzoNobel’s Global Aesthetic Centre has been responsible for trend analysis, colour research, colour design and art direction for three decades, continuously monitoring global social, design and consumer trends as they emerge to ensure AkzoNobel is always one step ahead of consumers’ needs. Each year since 2003, the team engages leading design professionals from all over the world in identifying the trends and capturing the mood of the moment. A research which is then translated into colour, products and inspiring trend collections.

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© AkzoNobel

HIGHLIGHT OF THE MONTH

Trend Forecast 2023 Every year, ColourFutures™ begins with a trend brainstorm. Together with top international design experts, AkzoNobel colour specialists carried out extensive research that showed people want to create their own ‘special somewhere’. What come out from this brainstorming in in 2023 was the sense that, although we are better informed than ever before, we are still searching for something – for peace of mind, for clarity, for moments of joy. When the world feels fragile and complicated, we need a space where we can find ourselves, regroup and face the future. That is the place where we belong.

Three different trends were identified by the Trend Forecast 2023: • Quest for Belonging: a sense of belonging anchors us and gives us the feeling that we are part of something bigger than ourselves. In times of changes and instability, it is important to create a space where we feel completely at home.

• Quest for Calm: when life is complex and we are experiencing information overload, we need a space to clear our minds, decompress and understand the things we really need. At home we can focus on these simple treasures, like ir, light, nature, and love.

• Quest for Joy: in a stressful world, we need all the joy we can get. Our homes can be somewhere to celebrate the everyday moments that gives us pleasure.

In this context Sweet Embrace™ originated as the Colour of the Year 2024.

Sweet Embrace™ and its three colour palettes Inspired by soft feathers and evening clouds, Sweet Embrace™ brings a sense of calm and a feeling of joy to our spaces. Together with three complementary palettes, it brings a sense of constancy, tranquillity and friendliness to our living and working environments. The delicate shade changes tone with the light, filling every space with warmth. Iti s a subtle, sophisticated stand-alone hue that also adds life and personality to other shades. Each of the three different colour palettes are built around it and it brings a different personality to each of them.

“Sweet Embrace™ provides a delicate and positive foundation for all the colour palettes” Helen Van Geent, creative director of the Global Aesthetic Centre says. “The three colour palettes are Warm Colours with global, earthy tones to bring a sense of belonging for a personal space and answering to the quest for Belonging; Calm Colours with soft, fluid green and blues bringing clarity and peace of mind for a simplified space answering the quest for Calm; Uplifting Colours with dreamy lilacs and modern yellows to bring fun and light heartedness for a friendly space answering the quest for Joy.” “Our snapshot of the ColourFutures™ palettes from 2004 to 2023 tells the story of the changing tastes and priorities of our consumer.

While each individual colour captures a moment in time, together they create a colour map of our age. Over the past 20 years, we have seen a

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© AkzoNobel

© AkzoNobel

The ColourFutures™ 2024 International Colour Trends by Sikkens & Interpon presentation in Milan last October 18.

© AkzoNobel

The Colour of the Year 2024 powder coating palette features a number of blues, greens and natural browns in metallic, smooth and fine texture effects.

The Colour of the Year 2024 decorative paint palette by Sikkens.

dramatic shift from a concentration on brighter tones to an emphasis on

These shades have a natural calming and clarifying effect and will help

neutrals, back towards more colour. Vibrant colours and light tones are

a building be at home in the surrounding landscapes allowing even

re-emerging – a reflection, perhaps of our need for positivity and a fresh

modern, high-tech buildings to blend with the natural environment.

approach.”

With 10 colours to choose from, mixing darker shades with lighter

Sweet Embrace™ in the powder coatings industry

neutrals, this palette offers the potential for architects and designers to create subtle coordination or contrast with the objects and buildings

Based on this work, the Interpon Colour of the Year 2024 powder

they design that will impress and delight for many years to come.

coating palette is perfect for transforming interiors and exteriors across

Interpon powder coatings are designed to enable surfaces to retain

a wide range of sectors.

their colour integrity for longer, thanks to their exceptional levels of

Within the palette are a number of blues, greens and natural browns

durability and performance. Interpon new Colour of the Year 2024

in metallic, smooth and fine textures effects that recall shades of

is part of the Futura 2022-2025 colour family, a family with a proven

seascapes and woodlands.

heritage and globally renowned.

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Since 1964

s i l v i srl.it info@silvisrl.it

design and manufacture of complete lines for painting, e-coat, cleaning and thermal stripping

© Feltani Reti

FOCUS ON TECHNOLOGY

VIV Group Continues to Upgrade Its Powder Coating Lines with Custom-Designed Hooks Gabriele Lazzari, ipcm®

As a powder coating contractor, VIV Group needs to meet the most diverse requirements from very different markets. This is why it constantly updates its lines and equipment, down to the hooks of the hanging system, produced through a collaboration with Feltani Reti geared towards identifying customised solutions for increasingly high finishing quality.

V

IV Group is a powder coating contractor specialising in large

parts. Founded and managed by the Bertipaglia brothers in Bagnoli di

iron, galvanised iron, steel, aluminium, and cast iron parts for the

Sopra (Padua, Italy), in recent years this company has experienced solid

interior and exterior furnishing sector, but also able to handle

and steady growth thanks to the new skills acquired by its operators

components for agricultural and earthmoving machinery, cars, and small

and the innovative spirit of its management. As a result, its production

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cycle has been gradually requiring upgrades to meet the growing demands of new customers and keep up with market developments.

In 2016, in particular, it increased its output by implementing a second shift. In 2019, it installed a new manual coating plant designed

by Eurotherm (Volpiano, Turin, Italy) for large parts (9,000 x 2,500 x 3,500 millimetres). In 2020, it developed a new pre-treatment cycle in cooperation with Chemtec, which was the subject of an ipcm® report1. More recently, finally, VIV Group also invested in the upgrade of the technologies supporting its coating phase, including the parts hanging system supplied by Feltani Reti (Campodarsego, Padua, Italy), which has enabled it to achieve greater production flexibility and thus quickly meet the diverse requirements of the different sectors in which it operates.

© ipcm

“VIV Group has always distinguished itself as an energetic company that approaches the

order with Feltani Reti: we indicate the number

optimal service through its internal resources

The new, growing needs of VIV Group

and acquired skills. Indeed, we have also

As VIV Group treats the most diverse

their standard products to make sure we can

invested in staff training, in order to expand

components for the office and home interior

handle any type of part.”

our employees’ skills in surface treatment

sectors, aesthetics play a significant role

technology and open up new markets, and

in its production. At the same time, it also

upgraded our in-house enterprise resource

coats parts for fences and gates, as well as

A supply of high-quality hooks tailored to every need

planning (ERP) software programme Chebora,

tractors and other agricultural machinery:

The relationship between VIV Group and

to make our workflow smoother. As this is

therefore, resistance to corrosion, scratches,

Feltani Reti, therefore, goes beyond the simple

interconnected to all our systems, it enables

and chemicals is also essential. “In addition

customer-supplier relation, but it has rather

us to control not only our production

to increased business volumes, resulting in a

taken the form of a joint project in which

processes but also our consumption efficiency,

higher number of hooks utilised, we are also

both parties constantly interface with each

including for example the amount of powder

required higher powder application precision

other to identify the most suitable solution

coating used for each load bar and the

for better film distension over the parts’ entire

for every specific requirement. “For about

quantity of hooks needed depending on the

surfaces, without any halos. This means that

80% of the material it treats, the company

type of parts to be treated. Speaking of which,

we cannot reuse our hooks, since the paint

uses conventional, 260 mm long, 3 mm

we have also been collaborating with Feltani

that is deposited on them during a finishing

thick, V-shaped hooks capable of holding 30

Reti to develop new hooks that meet the ever-

cycle can compromise the electrostatic charge

kilograms each. However, it also requires

changing needs of our customers and foster

required to coat the next workpieces. At

hooks with a thickness of 2 mm for exposed

consistent paint adhesion,” says Leonardo

the same time, we cannot paint strip them,

components, which therefore have smaller

Bertipaglia, Strategy Manager at VIV Group.

although we have a pyrolytic paint stripping

holes, U-shaped hooks with a length of

oven mainly devoted to our load bars, because

only 180 mm and a thickness of 3 mm, and

the process temperature (800 °C) would

V-shaped hooks with a thickness of 6 mm that

compromise their endurance and even deform

can hold up to 140 kg. Additionally, over the

them,” explains VIV Group coating manager

years we have developed many other specific

Alessio Ronca. “That is why we place a monthly

solutions: 50 mm long, 2 mm thick hooks for

market with innovative drive and offers an

“A pioneering nanotechnology process based on phosphorus compounds for higher corrosion resistance. A innovative process creates a new payoff for VIV Group: Grow Up”, by B. Pennati in ipcm®_International Paint&Coating Magazine no. 76.

1

of hooks we need and request any changes to

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© Feltani Reti

© ipcm

From left to right: Leonardo Bertipaglia, Strategy Manager of VIV Group, Alessio Ronca, Coating Manager of VIV Group and Isabella Feltani.

small parts; 8 mm thick hooks to hold up to 300 kg; Z-shaped hooks; and

always carries out quality control operations even on the raw material it

even hooks with a 90° and 45° bend.

receives (i.e. certified carbon steel) and on the packaged hooks, through

“VIV Group tells us about its needs and the issues it encounters in

visual inspections and control lines for bending angles. An operator

coating its parts, and we design a hook that overcomes these problems.

puts a stamp on each box to be sent to customers, so that it is possible

For example, in the case of a particular welded fence panel, the

to track effectively not only the material used and the processing cycle

standard hook was too thick and compromised the coating operation.

carried out but also the operator who took care of it.

We analysed the ideal bend and load capacity and we developed a new

“We always check test certificates and, of course, our entire production

type of hook with a thinner diameter and a 90° bend,” illustrates Isabella

process. In this way, we can identify any defects in advance and create a

Feltani, the owner of Feltani Reti. “This process takes place whenever a

track record. The high quality of our products is logically a prerequisite,

change to our standard products is required, both in terms of thickness

but our strength also lies in the traceability we are able to guarantee,

and bending angles (e.g. 90°, 30°, 20°, or double bends). Indeed, we have

in the flexibility with which we respond to customer requirements,

twenty machines at our disposal that enable us to produce hooks with

and in the speed with which we can provide standard and customised

any bending angle and radius and diameters ranging from 15 to 1.5 mm.”

solutions,” indicates Isabella Feltani. “In fact, we have recently built a

Feltani Reti’s added values: traceability, flexibility, and speed

new 500 m2-wide hall to expand the warehouse where we store both the finished products and the raw materials, which we order monthly so that we can quickly produce hooks for intended uses ranging from small

These new joint projects revolving around hanging hooks coincided

parts to heavy components and send them to our customers in just

with the upgrade of the powder coating plant’s application equipment

three days.”

and of the Chebora management system developed by an in-house

“We chose Feltani Reti as a supplier based on the positive feedback of

software engineer. Quality control and product traceability are indeed

countless professionals in the surface treatment industry. Indeed, its

two essential factors for VIV Group. And its collaboration with Feltani

professionalism and helpfulness have always enabled us to overcome all

Reti brings a further advantage in this area as well, since this company

the challenges we have faced,” concluded Bertipaglia.

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Magnify your efficiency with our automation solutions HUBO Automation has always focused the attention to the market needs and to the technological evolution. This allowed the company to establish itself as a leader for the industrial

ROBOTISED PAINTING SYSTEMS

STANDARD AND CUSTOMISED RECIPROCATORS

automation and painting. Thanks to the experience of the technical staff and to the continuous investment in new technologies, HUBO is able to satisfy dynamically the requests of a wide range of industries.

HUBO core business is the painting division. The wide range of automation solutions fully meets any need of automatic painting; in addition, the combination of special systems can satisfy particular requests and can guarantee a flexible and reliable painting system from all points of view.

www.hubo.it

AUTOMATIC FEEDING SYSTEMS FOR PAINTING PLANTS

SUCCESS STORIES

Dürr Developed and Installed a Smart and Sustainable Coating Plant for Electric Cars In just nine months, Dürr built a new smart and eco-friendly paint shop for the Chinese electric vehicles manufacturer SERES.

T

he high-end new energy vehicle manufacturer SERES not only

“To meet the requirements of a production process that saves both

focuses on intelligent electric drive technology, but also on

resources and energy, we used especially sustainable products from

sustainable production processes. The company therefore

plant and environmental engineering and installed our DXQ energy

commissioned Dürr to equip a new paint shop in the Liangjiang

management solution,” has explained Yu Lin, the vice-president of the

plant in Chongqing (southwestern) China, in order to optimise the

paint and final assembly business of Dürr China.

production process for energy and resource efficiency. Just nine months after receiving the contract, Dürr installed the plant and exhaust air

Savings with smaller tanks

purification technology as well as the software.

The RoDip® M mechanical rotational process is well-known for

SERES electric cars have been on the market since 2016, and the

conserving energy and resources during the pretreatment and

company has shipped vehicles to over 70 countries since then, aiming to

cathodic electrocoating of vehicle bodies. While RoDip is a classic in

become a major player in the European electric vehicle industry thanks

the market, its sustainability benefits remain remarkable: its 360°

the new paint shop in the Liangjiang plant in Chongqing, which can

rotational movement, which spins the bodies around their own axes,

complete 60 jobs/hour.

eliminates the need for an inclined exit section in the immersion tanks.

© Dürr Systems AG

The RoDip® M rotational process of Dürr for the pretreatment and cathodic electrocoating of the electric vehicles of SERES.

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SUCCESS STORIES

This innovation saves up to six meters in length per tank compared to

Smart factory thanks to DXQ software

pendulum conveyor technology, reducing water, chemical and energy

Furthermore, the DXQ software products of Dürr play a significant

usage.

role in enhancing the sustainability of the new paint shop of SERES:

Cardboard instead of water and chemicals

DXQcontrol is employed for higher-level plant control, seamlessly tracking the life cycle of each body part, while the DXQenergy.

In the future, SERES will use the EcoDry X dry separation system for

management tool provides a transparent overview of energy and

overspray removal, a solution that saves energy: as a matter of fact, the

media consumption across the entire production plant or for specific

cost-effective system relies on easily replaceable disposable cardboard

areas like individual process lines. So, it is possible to quickly identify

filters, eliminating the need for water and chemicals. Dry separation

primary energy consumers at the plant level. Moreover, DXQequipment.

minimises fresh air requirements by recirculating nearly 90% of the air,

maintenance monitors when individual components such as pumps,

so the substantial reduction in energy consumption within the paint

valves or filters need to be maintained.

booth sets it apart from traditional wet scrubbing methods.

Heating ovens with exhaust air

Modular design The plant technology of Dürr is designed with a modular structure,

SERES is also decisively focusing emissions control: in order to eliminate

which allowed to efficiently complete the SERES project in just nine

solvents and the related Volatile Organic Compounds (VOCs) from the

months – from the receipt of the contract to the start of the production.

exhaust air, the paint booths have been equipped with a compact air

However, the modular approach offered several advantages also to

pollution control system developed Dürr. The exhaust air from the paint

the customer: the ideal layout of the individual modules, from the

booths, which has already undergone adsorptive concentration through

pretreatment to the sealing processes, the paint booths and the ovens,

the recirculation process, undergoes a further purification process using

makes the production more flexible and eliminates unused space within

a highly-efficient VOC concentration system in combination with the

the paint shop.

downstream Oxi.X TR TAR recuperative thermal oxidizer.

Finally, in response to a specific request from SERES, Dürr also factored

The result is a 15% reduction in energy consumption. Additionally, the

in space for a future primer line within the layout.

exhaust air from the ovens is purified via the integrated Oxi.X TR TAR

“We are very happy that we were able to impress SERES with our

afterburning system with heat recovery and then reintroduced into the

modular equipment and fast completion time, and look forward to a

oven heating system.

long-term partnership,” has conclude Lin.

The EcoDry X separation system, based on easily replaceable and disposable cardboard filters.

© Dürr Systems AG

© Dürr Systems AG

The screen showing the DXQenergy. management software, the certified energy management solution of Dürr.

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127

© Mival

Mival specialises in the production of bellows valves, which guarantee maintenance-free operation and a long service life.

FOCUS ON TECHNOLOGY

Mival Intensifies Automation with a Customised Self-Learning Robot and a New Water-Based Paint Dosing System Monica Fumagalli ipcm®

Mival, which has been specialising in the production of industrial valves for the most diverse sectors for over fifty-five years, has further improved the automation degree that has always characterised its production plant. It has invested in a new robot designed and installed by Epistolio Srl combined with a new Sames mixing and dosing system for two-component water-based coatings to relieve its paint shop’s operators of the most burdensome operations and reduce its carbon footprint.

V

alves are mechanical components used as connecting elements

steel to PVC, up to the latest Additive Manufacturing moulded types.

in various applications. They allow intercepting or regulating

In industrial applications, the most commonly used valves are made of

fluids flowing in pipelines, be they liquid or gaseous, to guarantee

metal and used to regulate the flow of steam or thermal oil.

specific pressure or flow rate values. Varying in size and weight, they can

Steam, in particular, is one of the most widely used elements for

be made in a variety of materials, from cast iron to plastic, from stainless

transporting thermal energy: in the industrial sector, it fulfils a wide

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FOCUS ON TECHNOLOGY

range of functions, from mechanical power generation to space

“However, our company’s management has always strived to lighten

heating. Specialising in the production of valves for this sector requires

it by implementing the most innovative, safe, automated, and

a solid structure based on the processing of different, sometimes

environmentally friendly machinery: the focus on innovations that can

difficult-to-machine materials, such as cast iron, and high attention to

improve our working environment and the surrounding environment

detail to comply with stringent and ever-changing regulations.

alike has always been one of the cornerstones of Mival’s philosophy.

Since 1967, Mival Srl has been producing different types of highly

One of the latest innovations implemented concerned our coating

specialised industrial valves in its factory in Serravalle Sesia (Vercelli,

department, where we recently installed a six-axis robot designed and

Italy). “Our valves are mainly intended for steam and thermal oil boiler

manufactured by Epistolio Srl (Casciago, Varese, Italy) for the application

systems for the chemical, pharmaceutical, petrochemical, and food

of two-component water-based paints delivered by a new Cyclomix® Evo

industries,” illustrates Purchasing, Quality & Reach Manager Paolo

dosing and mixing device supplied by Sames.”

Rossi, who is at the helm of Mival together with his father Roberto, the and Andrea.

Mival: the perfect symbiosis between human and machine

company’s founder, his mother Carla Minisio and his siblings Sabina “Their main applications are with steam, oil, gas, air, water, superheated

“Our employees have always been at the centre of our corporate

water, and similar fluids, including volatile, poisonous, and diathermic

strategy,” emphasises Rossi. “From the early 1990s to the early 2000s,

ones. They comply with EN and ANSI standards. They also entail a

we gradually replaced our traditional manual lathes with CNC lathes,

complex and heavy processing flow, as we are talking about valves with

which are closed-loop and therefore safer systems, and in the 2000s,

a weight ranging from 3 to 200 kg.

we started to automate loading and unloading with collaborative robots

© Mival

The valves reach Mival’s production department already coated with a red primer to prevent flash rust and ensure better adhesion of the subsequently applied water-based paint.

© Mival

The manual application booth for coating oversized parts with the jib hoist that helps the operator handle the heaviest valves.

international PAINT&COATING magazine - NOVEMBER/DECEMBER 2023 - N. 84

129

to improve part handling. We carried out all these changes without

particular system prevents the fluid, be it steam or diathermic oil, from

cutting our human resources, but rather by training our staff to operate

compromising the tightness of the valve itself. Whereas conventional

the new machines independently. This is confirmed by the fact that the

stuffing box valves require constant maintenance and have a life cycle

number of our employees, which amounts to 30 people, has remained

that is directly proportional to the severity of their operating conditions,

unchanged since then.”

bellows valves have an almost unlimited service life regardless of the

Mival’s production capacity exceeds 50,000 valves per year, made of

temperature and pressure of the intercepted fluid, up to about fifteen

lamellar and spheroidal cast iron, carbon steel, and stainless steel and

years. Mival performs a specific test on each bellow in three steps, i.e.

distributed in both the Italian ((80%) and foreign markets (20%). “We

under pneumatic pressure at 6 bar, under vacuum, and with helium,

do not work to order but according to the Make to Stock method: we

which is the smallest chemical particle after hydrogen: the leak test

produce and stock our valves based on the previous year’s demand

carried out with this inert gas guarantees better than any other that no

integrated with the forecasts for the following year. This enables us

fluid escapes from the valve.”

to manage our batches smoothly and be prepared for any customer

The two other aspects that have made Mival a benchmark company in

request.”

the industrial valve market are its widespread presence, both through distributors and directly, and the reliability of its technical support

Bellows valves, Mival’s core business

service. “We have in-house personnel specialising in tackling all types

“Over the years, we have been specialising in the production of a

of problems, from finding the most suitable type of valve for a specific

specific, maintenance-free type of valve called bellows valve. This

project to solving installation issues,” indicates Sales Manager Sabina

© Epistolio

The MRK 6.1 series robot designed and installed by Epistolio.

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© Mival

A stage in the application of the two-component water-based epoxy coating by the self-learning robot.

FOCUS ON TECHNOLOGY

Rossi. “We have a strong presence in the food & beverage industry, but we also serve the chemical sector and, in particular, the industrial coating segment, where we have numerous important customers. Especially in the paint production and coating plant engineering fields, our bellows valves are highly appreciated because they are TA-Luft certified to guarantee zero emissions and can be opened and closed countless times.”

Coating as an increasingly important step The production process starts with the raw materials, namely stainless steel bars for the valves’ inside parts and bellows systems and lamellar cast iron, spheroidal cast iron, carbon steel, and stainless steel castings for the valves’ bodies and trestles. “We have remained among the few valve manufacturers to process cast iron because it is a humble and difficult-to-machine material and because the core of a cast iron valve, made up of stainless steel components, must have a perfect seal,” confirms Paolo Rossi.

After machining, the valve components are assembled and only after having passed all the acceptance tests, do they reach the paint shop. “Coating has always been a key step in our production cycle,” says Paolo. “Towards the end of the 1990s, we began implementing some automation solutions in this department by integrating an overhead conveyor and a reciprocator for the application of paints, which at the time were solvent-based. When we switched to onecomponent water-based coatings in 2010, our consumption levels

www.cmautomazione.com

© ipcm

CM AUTOMAZIONE s.r.l.

Via Monte Bianco 20, 20833 Giussano (MB), IT - p.+39.0362.314075 - f.+39.0362.861222 - info@cmautomazione.it

The touch screen for robot control.

© ipcm

Sames’ Cyclomix® Evo management system interfaces perfectly with the robot’s control PLC.

© ipcm

Sames’ paint management unit.

thirteen years, however, we started a new process automation project

Mival’s paint shop automated with a customised self-learning robot

that involved Epistolio for the robotic elements, Sames for the dosing

The company’s coating plant is equipped with two application booths, a

and mixing device of two-component water-based paints supplied by

robotic one treating 90% of the valves produced by Mival and a manual

Alcea, and Varco for the plant engineering aspects.”

one for oversized and special valves. Its conveyor has a maximum load

“Our customers have become increasingly demanding in terms of both

capacity of 200 kg and a 400-800 mm pitch. The operator loads the

functionality and aesthetics,” explains Sabina. “Heating systems, for

heaviest valves with the help of a jib hoist.

example, used to be insulated and their valves were not in sight; today,

“The robot we installed at Mival belongs to our MRK 6.1 series,” indicates

the trend has changed and many systems are left in plain sight, which

Luca Venturini, Area Sales Manager at Epistolio. “It is equipped with

results in greater exposure of the valves’ surfaces to external agents

a six-axis self-learning system, as well as an interpolated axis that

and, at the same time, in increased demand for a higher aesthetic yield.

manages the rotation of the workpiece-turning device and that is the

Since the introduction of water-based paints, we have been buying raw

element that we customised to Mival’s requirements. The operator

castings already coated with a red primer for greater protection during

‘teaches’ the robot using a specially designed ergonomic joystick,

transport (especially when it comes to steel transported by sea) but

complete with programmable buttons, including one that controls

also to prevent flash rust on cast iron, facilitate the application of the

the rotation of the treated valve in terms of both angle and speed

subsequent layer of paint, and ensure better adhesion.”

depending on the coating cycle to be performed. Before entering the

became so high that we preferred to revert to manual application. After

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FOCUS ON TECHNOLOGY

booth, two optical scanners check whether the valve is positioned

Manager Michele Troilo, “include its very low application flow rate of

correctly at 0° or 180°: the system can detect any incorrect positioning

around 20-25 cc/min, which is specific for water-based paints, and

by comparing the incoming workpiece with the images loaded into

the vortex created at the coating inlet that, together with the catalyst

the software package and, if required, bring the valve back to the right

atomised through the Airmix® nozzle, creates a sort of pre-mixing

position through the turning device.

action. In addition, the device is designed to spray the entire quantity

“The robot is also equipped with several accessories that are typical of

of paint mix down to the last drop and the ‘push colour’ system allows

all our machines, such as, for example, proportional valves to manage

colours to be changed quickly. This guarantees considerable paint

atomisation, spray fan width, and paint flow rate. Depending on Mival’s

product savings.

requirements, the software package communicates with the plant to

“So far, we have applied one-component water-based paints,” says

manage the queue of programmes to be executed, determines the

Rossi. “However, using two-component paints enables us to also apply

number of cycles required for gun cleaning, and interfaces with the

epoxy products and, as a result, insource the coating of drinking water

latest-generation paint dosing and mixing control unit supplied by

valves, a market in which we would like to expand our offer since we

Sames, one of the first systems of this kind installed in Italy and with

expect the demand for diathermic oil valves to increasingly decline, as

which our plant also interfaced for the first time.”

this is a polluting energy source. After flash-off, the valves can be dried

The new mixing and dosing device

up to a temperature of 65 °C in the electric oven that Mival chose as a green solution since it is powered by the company’s 1,000-panel

The device installed by Sames is a 2K mixing system for water-based

photovoltaic system, producing about 190,000 kWh per year with a

coatings composed of a Cyclomix Evo dosing unit (two colours,

consequent significant reduction in CO2 emissions.

®

i.e. blue and grey, a catalyst and a flushing product), four 04D140

“Currently, our cycle times are 3 minutes for smaller valves and 6

diaphragm pumps in 316 stainless steel designed for high-pressure

minutes for larger ones. We need higher drying temperatures to dry

recirculation circuits with a ratio of 3.5:1 to guarantee remarkable

the bicomponent coatings compared with monocomponent ones, but

performance and durability, and an automatic air spray low-pressure

thanks to the new robotised plant and the new mixing system, we are

A35 HPA gun with modular design that is ideal for high production

going to be able to paint in two shifts, producing up to 150 more valves

volumes. “The main features of this unit,” emphasises Sames Technical

than today.”

© ipcm

The coating plant installed at Mival: on the left, the entrance to the robotised booth and, on the right, the entrance to the electrically powered oven.

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133

© ipcm

Mival produces an average of 50,000 valves/year, which are stored according to the Make to Stock method.

Automation: Mival’s present and future

process and, in addition, our new robot can work autonomously and

“Thanks to the continuous integration of robotic devices,” comments

unattended, any malfunction being notified to us via a mobile phone

Paolo Rossi, “we were already familiar with the functions and

messaging system at any time of the day or night. This is what the

parameters of offline point-to-point programming. The self-learning

implementation of Industry 4.0 parameters and integration between

programming technology proposed by Epistolio, however, represented

machines and humans really mean to me.

a breakthrough for our production, which was tied to the longer

“Epistolio’s customer service was also perfect, always ready to respond to

times of point-to-point decimal programming. With self-learning,

our requests. We could not have made a better choice to create a more

software setting times are reduced to a few minutes. Moreover, the

comfortable and safer working environment for our operators while

proportional valves provided make any adjustment easy, since it is

increasing productivity. The same applies to the Sames team: as with our

sufficient to change a few parameters such as atomisation, spray fan

employees, we place great importance on our personal relationships

width, and flow rate, even only in some parts of the programmes. One

with suppliers. Innovation, focus on human resources, and attention to

of the aspects that impressed us most about Epistolio’s solution was

the environment are the three pillars on which Mival has based its history

its high customisation degree: we wanted to gain full control of the

and on which it is laying the foundations of its future.”

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Save your money with the new

FASTRIP T5 MULTITANK The brand-new modular system consists of a FASTRIP T5 stripping tank, and a series of accessories that can be tailored to specific customer requirements for the maximum efficiency. The items to be stripped are loaded into specially designed baskets, lifted with the overhead crane to be transferred into the T5 stripping tank. From here the pieces go into the rinsing tank and finally to the dripping tank, where they can also be spray rinsed if required, thanks to a multifunctional wheeled pump.

Thanks to its low process temperatures FASTRIP T5 MULTITANK allows you to achieve considerable savings of energy and thus optimize costs.

ALIT Technologies Srl - San Bonifacio, Italy +39 045.245.6638 - info@alit-tech.com

www.alit-tech.com

HIGHLIGHT OF THE MONTH

Nuova Catena: High Quality and Attention to Detail in the Production of a Wide Range of Conveyor Chains Ilaria Paolomelo, ipcm®

In common parlance, the word “chain” often refers to negative concepts linked to constraint, imprisonment, and restraint. However, it can take on a positive meaning as well. This is the case, for example, in the coating and surface treatment sector, where the chain is an element of connection and continuity between the various stages that make up a finishing cycle. Nuova Catena has made it its core business.

A

leading manufacturer of conveyor chains, chain wheels,

Customer-oriented production

conveyors, sprockets, contrast rollers, and components for

Nuova Catena’s entire product range is characterised by high Italian

coating and sandblasting plants, Nuova Catena boasts over

quality in terms of both raw materials and manufacturing processes.

seventy years of experience and expertise in this field. The more than

“These two aspects are extremely important to our company and are

one thousand systems it has already designed and installed are tangible

the true added value of our offer: we are aware that the origin of the

proof of the success of a company that started from its headquarters

raw materials we use and the care we pay to each manufacturing stage

in Uboldo (Varese, Italy) to first conquer the European, Asian, and

can have a significant impact on the quality of our end products,” states

American markets and finally reach the Arabian Peninsula, where it is

Mauro La Guzza, production manager at Nuova Catena. The company’s

now an authoritative player in the sector.

factory in Uboldo has an in-house metalwork and mechanical workshop

© Nuova Catena

Nuova Catena is a leading manufacturer of conveyor chains, chain wheels, conveyors, sprockets, contrast rollers, and components for coating and sandblasting plants.

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HIGHLIGHT OF THE MONTH

equipped with traditional machine tools, numerical control

© Nuova Catena

machines, laser cutting systems, and state-of-the-art technology: this enables Nuova Catena to retain complete control over both the incoming materials and the entire production flow, as well as to meet its customers’ needs with extreme flexibility. “For a manufacturer of components for coating systems, the range of potential customers is very broad. Nuova Catena works closely with many leading plant design and production companies, but also directly with firms that already have coating departments and, for example, need to revamp or modify their conveyors to make their systems more efficient or to create special lines,” says the production manager.

Made-to-order production Nuova Catena’s core business is the production of Morris chains, which are used in overhead conveyors with a high load capacity.

Gears, scraper chains, made-to-drawing special conveyor chains, and one-rail and two-rail conveyors account for the remaining 50%

Nuova Catena’s headquarters.

of its business.

Dedication leads to innovation.

Quality creates value

Don’t hesitate to join us if you think this will be your future

Tel. +(34) 936 305 050 - spray@spray-sa.com - www.spray-sa.com

© Nuova Catena

The chains produced by Nuova Catena are completely Italian-made.

© ipcm

Nuova Catena’s production manager Mauro La Guzza (left) and owner Fausto Albini.

“We have diversified not only our production, but also the industries

decision to use only materials of Italian origin is a testament to the

we serve: coating is an extremely important target sector for us, but we

importance attached to the Made in Italy concept. “This core value

are active in many other markets, from foundry to sandblasting, up to

reflects our company’s commitment to carry out every production step

assembly lines and systems,” adds La Guzza. “Within the finishing sector,

with extreme care and strive for excellence in everything we do,” notes

whether we are supplying a new system or modifying an existing one,

the production manager. “Our chains are machined and assembled

we always tailor the most suitable solution to our customers’ needs: the

in-house, with the utmost attention paid to every detail. This level of

chain is a key element on which the flexibility, speed, and efficiency of a

care and precision is often absent in foreign components. Indeed, we

coating system depend and it is therefore essential that it is optimally

have noticed that in some systems made with components procured

designed and installed.”

from outside Europe, especially with wheel drive units, the chain

The design and development process of a chain begins with an in-depth

often does not keep the correct pitch, jumping on the wheel and thus

check by Nuova Catena’s engineers to determine whether the layout

compromising the functioning of the whole system. On the contrary,

provided by the customer is compatible with specifications, especially in

our chains are designed to reliably keep the pitch and offer superior

terms of curvature radius and load capacity. Then, the chain length, link

performance through the use of high-quality materials and impeccable

conformation, and the size of the ideal supports are determined. Finally,

craftsmanship.”

the type of drive system to be used is identified between a Caterpillar-type

“Choosing cheaper products may seem tempting, but it is essential

drive unit, which is suitable for longer distances and heavier loads, and a

to consider every risk related to potential downtime and personnel

wheel drive unit, which is ideal for shorter distances. “Our aim is to provide

safety before making a purchase. Investing in Italian-made, high-quality

tailor-made solutions that meet our customers’ specific needs while

components ensures durability, safety, and optimal performance, while

guaranteeing the highest quality, safety, and durability,” explains La Guzza.

reducing the long-term costs associated with failures and replacements.

100% Italian production

Nuova Catena’s product quality is synonymous with trust and reliability, and it is a wise choice for companies wishing to achieve the best results

The Made in Italy label is closely related to productions that adopt high

and ensure smooth operation of their plants,” summarises Mauro La

quality standards and embrace craftsmanship. For Nuova Catena, the

Guzza.

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CUSTOM MADE FINISHING PLANTS FOR

®

COSMETIC PACKAGING

GLASS

AUTOMOTIVE

50 YEARS

eosmarketing.it

PLASTICS

OF EXPERIENCE IN INDUSTRIAL FINISHING PLANTS.

www.midue.it

HIGHLIGHT OF THE MONTH

The Brand-New PVC Cyclone Powder Booth Is a Game Changer for the US Powder Coating Market From an interview with Ty T. Crowder, President and owner of Total Finishing Solutions LCC & Total Finishing Systems

During the latest edition of Fabtech Chicago, the leading trade fair for the surface treatment industry in North America, the ipcm® team interviewed Ty T. Crowder, President and Owner of Total Finishing Systems, to present the new PVC Cyclone Powder Booth, a system which will allow American companies to have a cutting-edge painting booth for quick colour changes at a more competitive price. © ipcm

D

uring the latest edition of Fabtech, the leading event in North America dedicated to metal forming,

machining, welding and finishing, which took place from 11 to 14 September 2023 at McCormick Place in Chicago, Illinois, the ipcm® team had the opportunity to interview Ty T. Crowder, President and Owner of Total Finishing Systems, to delve deeper into the state of the art of powder coating in the US and present the latest innovations developed by the Riverside, CA-based company. Among these, the new PVC Cyclone Powder Booth, presented in collaboration with the Brazilian coating system manufacturer, Erzinger, stands out. Regarding the application of powder coatings, in recent decades PVC has forcefully entered the sector as it is a non-conductive material which prevents the electrostatic attraction of powder towards internal surfaces of the booth. This is crucial to avoid the accumulation of powder on the walls, ensuring a cleaner and more efficient working environment. The new solution proposed

by Total Finishing Systems is positioned as an alternative to the booths designed and marketed by the main players on the market, aiming to offer customers a high-quality solution at a competitive price.

The New PVC Cyclone Powder Booth presented at Fabtech US.

HIGHLIGHT OF THE MONTH

© ipcm

© ipcm

The robot supplied by Epistolio with its PLC.

Detail of the PVC cyclone.

ipcm®: Which are the technical peculiarities of this technology?

density of the line using artificial intelligence. This is useful for providing

It is an innovative quick color change PVC Cyclone Powder Booth,

suggestions on trends, maintenance as well as communicating the

meaning it enables fast color changes, better finishing quality, more

percentage of material that is being loaded onto the line. It features an

savings and greater application efficiency. The color can in fact be

interactive touch screen monitor that shows everything happening on a

changed quickly in around five minutes, unlike a traditional manual

given line in real time.

cartridge booth – still in use in the US market – which generally requires about an hour to change it.

ipcm®: Which are the competitive advantages that this system

Along with the Cyclone booth, the booth features the state-of-the-art

offers to companies?

Smart In-Line Control System, Application Automation and Powder

Total Finishing Systems will be the exclusive distributor of this new quick

Distribution Centers.

color change PVC Cyclone Powder Booth in North America, where the

The Smart In-Line Control System is an Industry 4.0 control system,

market is undergoing a deep change. The powder coating industry in the

which thanks to the sensors positioned along the booth, can provide

US is definitely growing: until a few years ago many thought the situation

important information on the consumption of gas, air, powder and

was stabilizing, but now we are witnessing a transition, where larger and

electrical kilowatts, as well as alarms that allow to understand the status

fast-growing companies want to move away from liquid paints to powder

of the components allowing both maintenance planning and prevention.

coatings. Especially the medium-large ones, which are investing in new

Furthermore, the Smart In-Line system allows coaters to control the

powder coating systems.

international PAINT&COATING magazine - NOVEMBER/DECEMBER 2023 - N. 84

141

The shift from liquid paints to powder paints in the US has been a noticeable trend in several industrial sectors. This change is driven by several factors that include environmental aspects and technical performance, such as durability and increased corrosion resistance.

Thanks to the partnership with Erzinger, our system is the ideal solution for small and medium companies working in the powder coating sector that are looking for an alternative to the powder paint application booths produced by the main players on the market, which are marketed at generally much higher prices with lesser control features. ipcm®: Which sector is this solution mainly aimed at?

The primary end-users of this powder application booth are expected to be small and medium size Original Equipment Manufacturers (OEMs) and subcontractor powder coaters equipped with an automatic coating system with overhead conveyor that performs color changes, while businesses like repair shops would not be our ideal customers for this technology. Furthermore, this solution is compatible with anyone’s application equipment of any kind and brand. ipcm®: What is your target market for this type of booth?

The booth can be sold not only in the United States, but also in the rest of the world. It is important for us to also be able to supply this innovative system in Mexico and Canada. At present, the booth meets US and Canadian standards and every component is UL, CE and ETL approved”.

© ipcm

Ty T. Crowder, President of Total Finishing Systems, and Sandro Ivan Erzinger, Technical Manager of Erzinger.

Scan or click the QR code to learn more!

About TOTAL FINISHING SYSTEMS The Total Finishing family was founded as a group of companies aiming at bringing together the skills, knowledge, and resources needed to devise, design, and maintain finishing and painting plants and equipment for the general industry: Total Finishing Solutions is specialized in the supply of spray booths, UV and IR ovens, abrasive blasting equipment, and industrial automation solutions such as flatlines reciprocators and coating robots, with the latter being built by its partners VD Finishing Solutions, Epistolio, and ABB Robotics.

Total Finishing Systems deals with the design and integration of complex, high-quality painting systems. It supplies customized powder and liquid coating plants mainly for the automotive (Tier 1 and Tier 2), aerospace, and defence industries.

Total Finishing Supplies is the division devoted to the supply of all consumable materials and equipment necessary to maintain the operation and efficiency of plants, such as spray guns, paint pumps and spray booth components.

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HIGHLIGHT OF THE MONTH

Pulverit Celebrates Its 50th Anniversary with Huge Investments in Innovation Edited by the ipcm® editorial team

The 50 years milestone is an important, prestigious one for a company. It means having a long-standing history, a wealth of skills, and experience gained in ever-changing socio-economic and technological contexts over many decades. 2023 marks the 50th anniversary year of Pulverit, a well-established Italian powder production company, which is internationally active in both sales and production. Here, we would like to retrace its history.

I

t was 1973. For some time, there had been talk of a new type

addition to subsequent replacements and investments in increasingly

of paint, powder coatings, which did not require solvents unlike

sophisticated equipment for the control and research laboratories and

traditional liquid products. Three leading figures from the Italian

the production department.

coatings world, Mr. Parodi, Mr. Prando, and Mr. Stoppani, were

On the occasion of Pulverit’s 25th anniversary, Mario Parodi, one of

particularly interested in this new technology and decided to acquire a

the three founders, wrote: “Means matter, but companies are made

production licence from IG Pulvertechnik, which would also become a

by people. Pulverit’s deus ex machina has always been Mr. Riva and I

partner in the new company.

would like to state in all honesty that without him, we would not have

This took the name IG Pulver Italia SpA. With an 800 m²-wide

achieved these results in terms of both quantity and quality, but also

warehouse on the outskirts of Milan, three small rooms for the offices

of professionalism and corporate image, which everyone in Italy and

and the laboratory, a shed for storing a few raw materials, a mixer, and

abroad recognises and appreciates. He was involved in everything:

an extruder, the company started business with the support of Mr.

purchasing, new product development, production, testing, sales,

Riva, the leading expert in powder coatings at the time. In 1994, the

and customer service. He did not care about the administrative and

company changed its name to Pulverit after IG Pulvertechnik left the

financial side alone. He was interested in producing more and better

shareholders’ group. This year, it turns 50: this prestigious anniversary

than others, in selling (but only if he had earned the esteem and trust

was celebrated on 21st October with an event at Villa Magnolie in Milan,

of the customer), in creating an image for this company that would

open to all employees and partners.

make it excel over others. And he succeeded. He succeeded with his

Since the beginning, Pulverit has been one of the most important

enthusiasm, his tenacity, his dedication, even his sacrifices. He was

international players in the powder market, but with its roots (and

tough – more so with himself but also with others if necessary. This is

capital) still firmly planted in Italy. It started immediately with very good

the past. Now, we must also look ahead and try to anticipate what the

prospects: it implemented a second powder production line in 1977,

future will be. We need to be ever more dynamic and ready to innovate,

a third one in 1979, and so on until the sixth one installed in 1988, in

without forgetting what our past experience has taught us.”

© Pulverit

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HIGHLIGHT OF THE MONTH

Pulverit’s present with an eye on the future Pulverit’s employees have certainly heeded Parodi’s words: the current management is firmly convinced that it is the people who make the difference in the company, so much so that the shared goal at all levels is that the staff is motivated and ready to embrace a project that has been going on for 50 years, aimed at innovating

EQUIPMENT FOR

powder coating

products and expanding the use of powders to new markets.Today, Pulverit has more than 170 employees and it is eager to operate in increasingly competitive markets, honouring its history and expertise with two production sites, one in Italy and one in Poland (that will double the production capacity), two sales companies in Germany and Spain, and several distributors and agents throughout Europe.

With a consolidated turnover of more than €50 million, it has finally grown from a SME to a large-size company.

© ipcm

DESIGN Our powder coating systems and accessories are designed and manufactured with the utmost attention to details

RESPONSIBILITY We are loyal to the customer and to the product: we build a real relationship of trust and responsibility day by day

PROFESSIONALISM We follow each customer from design to implementation, from installation to after-sales training

MADE IN ITALY Booths, machines, guns and accessories for powder coating designed in Italy with rigorously selected suppliers in the Italian territory and in EU countries

Find out more about ZEUS © ipcm

www.zeus-el.it

ASK JOE POWDER

The “Ask an Expert” Column Kevin Biller

kbiller@chemquest.com

I would love to be able to do the coating etc. in-house with the most affordable but lasting option. I’d like to lose the zinc plating all together because this is, in my opinion the root of all my evils.

If I were to just powder coat, what in your opinion would be the best cost to quality option? I’ve been looking up thermoplastic coating with great interest. Please advise on surface preparation too. I’d like to cut out as many service providers as possible and have greater control and certainty regarding the accuracy the coating process. Perhaps your solution may be worth spending on a small home setup if it’s affordable. I make standard size door gates which are installed both indoors and outdoors. From indoor up to 100 km from the coast to outdoor 100m from the sea.

Kind regards, Barry Lottering Port Elizabeth, South Africa The two years of our “Ask an Expert” column end with increasingly challenging questions about the powder coating. And this time too our Joe Powder does

Hi Barry,

not disappoint us with his always punctual and detailed answers.

Thanks for the question. I took a look at your website and, wow, you do amazing work. You turn simple gates and railings into exquisite artistry.

I think you probably already know the source of the inconsistency in

Hi Joe,

your coatings, it’s the zinc plating. Undoubtedly it is wise to use a two-

I came across your blog whilst looking for solutions to an

coat process to ensure a good combination of corrosion resistance and

ongoing problem I’ve had. I design and manufacture designer

outdoor durability. This is definitely a must for hardware that has to

gates cut from 3mm mild steel. When I get the raw steel back

endure a coastal environment. But zinc plating can be inconsistent.

from laser cutting it is still covered with mill scale. I install all of

Here is what I recommend. Take the finishing process in-house. This will

my gates in a coastal region and because my gates are bespoke

involve not only coating process, but also the metal preparation as well.

boutique pieces I’d like them to last as long as possible while

Since you are laser cutting some of the ware and the parts have residual

exposed to the elements.

mill scale you should blast them with a decent media to lose the mill

I’ve been zinc plating and powder coating them with various

scale and clean the laser cut edges. I suggest aluminum oxide. Next step

service providers but this is hit and miss. It’s incredibly

is a three stage phosphate pretreatment. Google “metal pretreatment

frustrating to hear the powder coater call and say the powder

companies” in South Africa and ask them for recommendations. After

has come out of the oven full of pinholes and usually they say

pretreatment, thoroughly dry the parts with a convection type oven. The

they have no idea what happened. Worse still the zinc plater

air movement will help to completely dry the metal surface.

will also claim ignorance. I’ve had good results but it’s touch and

The next step is to completely cover the metal with an epoxy powder

go and when things go wrong it’s very expensive to fix and I’m

coating primer. If you have tight areas inside of channels, you should

usually left carrying the cost. I’ve tried everything from baking

pre-heat the metal and spray those areas whilst it is still hot. After

before coating to cleaning the gates before with degreaser and

the parts are completely coated, bake the primer for about 5-10

etching solutions, leaving them for a few days to off gas. I also

minutes (see the supplier’s technical data sheet for the correct

have some channels in the gate and where the radius is tight the

temperature). Make sure the coating has flowed out adequately to form

zinc doesn’t deposit too well and often I prime it which is time

a smooth surface. The 5-10 minutes should represent a deliberate

consuming and I’m never sure whether this is good to powder

underbake. This provides optimum adhesion of the next coat. After

coat over.

the part has cooled, lightly sand the primer with a 220 grit sandpaper.

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ASK JOE POWDER

Reheat the part to about 110-125⁰C and then apply a polyester powder

liquid look in powder, or a new type of gun, or maybe both? …or

topcoat. I recommend a “superdurable” grade for good UV durability.

are we all just a little to “pie in the sky” to think it’s possible.

Place the coated part in the oven for a full cure cycle. This process and

Thanks, Tenacious K.

these materials will ensure an excellent coating that should provide 10

Somewhere in Massachusetts

years durability with only moderate fade and chalking. And as long as the part is completely coated and has not been breached it will resist

Hey Karen,

corrosion as well. Furthermore by taking the finishing process in-house,

Yep, this is a problem and has to do with rheology, viscosity and open

you will have complete control of the final quality. I hope this helps and

time of a curing binder system. Metallics tend to orient themselves

I sure would love to visit Port Elizabeth someday. South Africa is on my

randomly in a viscous powder binder. The metal flakes are distributed

bucket list and I need a good excuse/reason to visit.

onto particles via bonding or worse, just mixed into the bulk powder.

Best regards, Joe Powder

Electrostatic application doesn’t help either. The charging characteristics of a metal flake are vastly different than a nodular organic particle.

Dear Joe,

Consequently the “lay-down” of the flakes is indeed random. Then the

A question….Is it possible to create that liquid look with a

only time the flakes can “lay down” to establish any degree of regular

metallic pigment in a powder coating? I’ve heard a lot of

orientation is in the oven after the powder melts, coalesces and is

grumbling among powder coat companies that it’s just not

fluid. The vast majority of powders are thermosetting so soon after the

possible. What research has your lab completed on the topic,

powder melts it starts to build molecular weight and therefore increased

if any, and do you have any positive results you can share

viscosity. Low viscosity binders (some epoxies and polyurethanes) are

with your beloved fans? If not, do you think it will take new

somewhat better but never approach the low viscosity of a solventborne

technology on the resin/pigment suppliers part to achieve the

paint.

Painting for all industries

Bringing your surface to perfection.

Dürr offers painting solutions from manual to automatic application, high-quality and easy to integrate. www.verind.it

ASK JOE POWDER

Schlenk SE

A micrograph of metallic liquid paint.

Schlenk SE

A micrograph of metallic powder coating.

Hence a powder technologist’s tale of woe regarding metallic flake

It is very important to note that polyesters in the US are rather different

orientation and matching a liquid metallic coating’s appearance.

than polyesters in the EU. It’s all about the curing agent used. In the EU,

Peace, Joe Powder

TGIC is considered a genetically harmful chemical and requires special labeling that includes a skull and crossbones. In the US we understand

Hi Joe Powder,

that it is an industrial chemical and handle it accordingly - N95 dust

I am one step closer to spraying powder everywhere... If all

mask and good exhaust and hygiene.

goes well and an ebay seller in Germany carries through with

I wouldn’t buy powder in the States to use in Europe. Carrying it through

his part after I sent him the funds, I should have a decent small

an airport might cause an unwanted adventure. Powder coatings

compressor next week. 400L/min (~14cfm), 65L (~17gallon). It’s

are very safe, but not all airport security personnel would know that.

a quiet one (65dB) which I needed since I’m in an apartment,

They might even think of your samples as drugs or explosives. Hence I

an Implotex that I got for over 60% off, which is about the best

recommend buying all your powder coatings locally.

deal I can get hereabouts. And it’s the largest size I could fit

As for type of powder, a few notes:

in the space I have. I’m visiting Oregon and Washington State

• Don’t buy any acrylics. They are great coatings for aesthetics and

next month and might pick up some stuff, like a couple pounds

durability but cause contamination of other more conventional powders

of powder. Do you maybe have any quick tips on powders to

(polyesters, epoxies, urethanes, etc.).

start with, or maybe more important, which kinds to avoid as an

• The website doesn’t mention hybrids (aka epoxy-polyester) powders.

absolute beginner? I googled around but didn’t find a lot, this

These are really good for indoor applications but will chalk and fade

guide but it’s mostly a description of powders without much

outdoors.

guidance. I think I’d like to try the textured and candy colors

• Forget fluoropolymers. They are uber expensive but have amazing

but I will start with some basic polyester powder and see how

performance for architectural applications (20-30 years Florida

that goes.

durability).

Best regards, Randy

- Polyesters in Europe are crosslinked with HAA instead of TGIC. HAA

Basel, Switzerland

(aka “Primid”) is a more benign chemical. Performance is similar to the TGIC powders we use in the US.

Hi Randy,

- As for suppliers of powders in Switzerland, I am almost certain that

Great progress. That compressor is a beauty. I like the dBs - quiet is

Tiger Drylac sells small quantities there. There may also be a lot of Italian

always better. As for choosing powder coatings, it really depends on

and German powder suppliers around. I would search on the net for

what you plan to coat. That website provides a decent explanation of

suppliers.

the conventional powders available. Getting started, I would stick with

Good luck with everything and safe travels to the Pacific Northwest.

polyester chemistry. It’s the most versatile for someone getting started.

Best regards, Joe Powder

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www.infragas.com

INFRARED RADIANT GAS SYSTEMS FOR THERMAL TREATMENTS

© Merck

HIGHLIGHT OF THE MONTH

Merck Effect Day 2023: Special-Effect Colours and Digital Solutions for Multiple Sectors Edited by ipcm®

Merck brought together its suppliers, employees, and customers to present its new industrial pigment collections for multiple industries and digital colour measurement solutions. During Merck Effect Day 2023, participants could also test laser technology with practical tests in the prestigious setting of the Leonardo da Vinci National Museum of Science and Technology in Milan.

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HIGHLIGHT OF THE MONTH

© ipcm

of global mobility contained in the Reset Future

traditional event organised by German

collection and organised into five trends: Technokind,

multinational Merck, was held on Tuesday 26th

Natural Therapy, Augmented Mode, Emotional

September 2023 at the Leonardo da Vinci National

Essence, and Evolving. The presentation of Laura

Museum of Science and Technology in Milan. On the

Zanini, Account Manager Decoratives&Functionals,

occasion, this company operating in the electronics,

focused on the new F20-52 SW Mineral Red pigment

pharmaceutical, chemical, cosmetics, and coating

of the Colorstream® family.

markets presented its customers and employees

Previewed at the European Coatings Show, the

with new products and future effect trends in all

trade fair for the global paint and coatings industry

these application areas. Based on the high level

held in Nuremberg (Germany) from 28th to 30th

of satisfaction among the participants of the 2022

March 2023, the Colorstream® Mineral Red enables

edition, with the majority of those present expressing

neutral red tones to be achieved in both liquid and

interest in an annual edition of the event, Merck

powder systems for interiors and exteriors, also in

organised a new opportunity to learn about its latest

combination with other coloured and special-effect

special-effect and functional pigments for the paint,

pigments. This guarantees an intense and long-

printing, packaging, and cosmetics industries. In

lasting red shade for a variety of application fields.

addition, they were able to interface directly with the

“Our new red pigment Colorstream® Mineral Red

Account Managers to discuss specific projects.

radiates luxury and reflects the latest styling trends.

The day opened with a welcoming speech delivered

It is a colour that makes the difference, an intense

by Fabio Carati, Senior Regional Marketing

red with exceptional covering power that retains its

Manager EMEA, who explained what environmental

tint from all viewing angles. As such, it enables us to

sustainability means for Merck and, more generally,

provide our customers with additional differentiation

for the Surface Solutions segment. Stefano Corrado,

options in the selection of colours for cars and other

Account Manager Coatings, presented the sources

applications.”

of inspiration for the colours dedicated to the theme

Iriotec® 8212, a solution for laser marking of

EN 1527

H

el

m

A.

T

he latest edition of Merck Effect Day, the

Hellas S

.

engineering plastics for the electric mobility and electronics sectors,

The next part of the day focused on the automotive sector, with Corrado

was then presented by Cristiano Casiraghi, Account Manager Plastics.

illustrating the new digital tool available in the site’s online Resource

Katarzyna Sztuka, EMEA Marketing Manager, introduced the 50 edition

Center dedicated to automotive design. At the end of the event, a focus

of Merck’s Cosmetic Color Forecast, an essential support for cosmetics

on sustainable solutions for the packaging industry.

and body care industry for more than 25 years. Carati also showed

“True beauty has a depth that is not limited to the surface. From

Merck’s new entirely automated system for quality control and colour

decorative printing to high-quality coating, our special-effect pigments

measurement, with the first fully automated unit for digital colour

have been helping make the world more colourful and functional for

measurement already implemented in Gernsheim (Germany), the

over half a century. Our pigments make it possible, for example, to

company’s largest pigment production site with around 560 employees.

create the glossy effects that are so much in demand in the automotive

Participants also made the acquaintance of mpix, one of the companies

industry. Their weathering resistance allows the vehicles to look as good

that have been collaborating with Merck for years for laser technologies.

as new even after years of travelling. And architects and designers can

The day continued with an overview of “Empower the day”, the colour

use them in architectural cladding applications to make buildings more

collection devoted to thermoplastic polyurethane and leather, with

attractive and weatherproof,” said Merck’s keynote speakers. “At the

practical examples of some surface effects achievable.

same time, our pigments can also be utilised in food products, ceramics,

A brief overview of the ever-new potential and inspirational resources

plastics, and even furniture. They are suitable for any requirement.

made available by the website dedicated to Surface Solutions: much

Special packaging solutions and labels with unique effects, for instance,

more than a simple corporate eShop, allowing to easily and quickly

make it possible to create eye-catching and unforgettable packages,

locate technical information and the multiple solutions offered by Merck.

which also prevent counterfeiting and increase security.”

th

© ipcm

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© ipcm

UCIF Informs

The Value of a Trade Association Today Manuela Casali, UCIF – Italian Surface Treatment Equipment Manufacturers’ Association, Milan, Italy

A

info@ucif.net

s the Italian Surface Treatment Equipment Manufacturers’

Our Association also promotes training and refresher courses open

Association, we often ask ourselves questions that are not easy

to business owners and their employees. These are made possible

to answer. Some of them concern the value we can bring, the

thanks to an extensive network of collaborations with private

value recognised by our members, and the value perceived by those

institutions, universities, and research centres. In particular, UCIF

who are not part of UCIF and are curious about what benefits we might

collaborates and is associated with Poliefun, an association operating

offer to them. We are all used to assigning an immediate value to

within the Politecnico di Milano for the promotion of enterprise culture

actions, programmes, projects. We often wonder “what’s in it for us” to

in the finishing sector.

convince ourselves that what we are giving our support and consent to

Finally, UCIF provides a range of assistance and consultancy services

something that is “worth it”.

on matters of interest to companies, such as the organisation of trade

UCIF is a trade association and, as such, it represents and protects the

fairs and events, specific training programmes, statistical analyses

interests of a specific category, that of finishing plant manufacturers.

and data collection, occupational health and safety, and compliance

Through ANIMA, we are the point of reference for our sector within

management (e.g. environmental, privacy).

Confindustria Meccanica, a position that in itself should deserve

Being able to receive first-hand information and advance notice on

trust and support. However, in Italy, sometimes this is not enough:

the upcoming regulations, standards, and trends is a value that in

in our country, associations are not always considered a value and

itself should entice any company to join a trade association. We are

companies often treat membership fees as a bargaining chip.

witnessing a profound regulatory revolution that will inevitably bring

The work of a trade association focusses mainly on two areas: dealing

concern and both positive and negative changes. Misinformation and

with member companies and mediating and representing them in

unpreparedness are no longer an option today.

government bodies. At UCIF, this takes the form of the activities we

Being professionally and adequately informed, being represented

carry out on a daily basis through four functions: representation,

at tables where it is still possible to have a voice, and having the

listening and sharing, facilitating innovation and training, and service

opportunity to exchange views with other members for facing any

provision. As an organisation established to protect economic

challenges together is certainly a value that outweighs the obstacle of

interests, UCIF’s first function is representation. The more members

paying a membership fee.

it represents, the more weight it has in meetings with other stakeholders. Strong representation generates strong interests.

Doing business nowadays is increasingly complicated due to the everchanging nature of regulations and markets: trade associations can support entrepreneurs by providing them with the services they need to carry out their daily activities at best. In the case of UCIF, a concrete example of representation is being able to stand within a sound, organised business system and therefore to support our members in their relations with institutions, public authorities, and other social partners. In particular, we have specific expertise on regulatory aspects and have the possibility to interface and interact with other European associations of a similar level.

Trade associations are also useful because they allow members to exchange information. For example, they can share experiences, create partnerships and collaborations, and organise meetings. An association thus becomes a tool that facilitates access to information and news. At UCIF, sharing is fostered through numerous online and in-person meetings as well as information and training sessions.

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UNIONE COSTRUTTORI IMPIANTI DI FINITURA

A L M T EC H N O LO GY

Since 1984

industrial coating plants

spray booths for car body shop

sandblasting booths

industrial coating booths YOU CAN SEE MORE THAN 1000 PHOTOS AND VIDEOS

ALUMINIUM IS THE MATERIAL OF THE FUTURE. IS ALREADY THE FUTURE. YOU PAINT, WE KEEP CLEAN A L M T EC H N O LO GY

A L M T EC H N O LO GY

Technics

A L M T EC H N O LO GY

Painting

Via Val di Stava, 14 - 37060 Sona (VR) Italy - Phone: +39 045 6081641 - www.eco-air.it - info@eco-air.it

A L M T EC H N O LO GY

© VRB

ART WITHIN SURFACES

IMPERFECTION/EVOLUTION: The Futurism-Inspired Book Created by VRB to Celebrate Its 40th Anniversary Alessia Venturi, ipcm®

“Depero Futurista” is the official title of the famous bolted book published by Fortunato Depero, an exponent of the Second Futurism movement, in 1927. One of the first modern artist’s books and a milestone in the history of graphic design, it had the dual function of documenting Depero’s work at the height of his success in Italy and promoting his brand in New York, where the artist would move in 1928. The first example of a book-object, characterised by a varied layout and held together by two large mechanical bolts, this work of art served as the inspiration for IMPERFEZIONE/EVOLUZIONE (i.e. IMPERFECTION/EVOLUTION), the book born from an idea and a project by Italian powder coating contractor VRB to celebrate its 40th anniversary.

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ART WITHIN SURFACES

P

roduced in a limited edition of 300 copies, the book IMPERFEZIONE/

© VRB

EVOLUZIONE (i.e. IMPERFECTION/

EVOLUTION) is a true work of art celebrating imperfection as a drive towards evolution and continuous improvement, both in coating and on planet Earth.

It was inspired by the work and artistic manifesto of Fortunato Depero, a master of the so-called Second Futurism. Futurism was an Italian literary, cultural, artistic, and musical movement that developed within the decadent civilisation of the early 20th century and represented one of the first European avant-gardes. It optimistically extolled the industrial age, the beauty of technology, of motion, of machines and races, and of big industries, reconsidering the role of art and intellectuals in society. All these concepts were present in the work of Depero, who was active not only in sculpture and painting

The box contains both the book and a small message explaining its title.

but also in stage design, advertising, and publishing. IMPERFECTION/EVOLUTION subtly and gracefully refers back to this great Italian

simple, requires the ability to constantly adjust

The textual elements of the book were printed

modern artist, not only in its aesthetics, e.g. its

its positioning to ensure perfect fit between

on Natural FSC Fedrigoni Arena Smooth Extra

cover and the aluminium box containing it, but

the box and the book. The illustration on the

White paper, the photographic ones on FSC

also in the layout and font chosen.

book’s cover is symmetrical: in this way, what

Gardagloss Art machine-coated glossy paper

one can see through the holes is always the

to give the images the correct brightness

same colour composition regardless of how

degree. FSC Magno Satin glossy paper was

The most striking aesthetic feature of the

the book is placed in the box. The colours used

used in the final part. The cover consists of two

book is its container, a box made of a powder-

for the cover illustration and the aluminium

3 mm-thick Favini Sumo FSC cardboard plates

coated 2 mm-thick aluminium sheet with an

box are green, red, and blue in their purest

laminated with two sheets of printed paper.

external illustration composed of three pieces

form, the initials of which (in Italian: verde,

The colourful stitched binding on the spine

also made of aluminium and inspired by the

rosso, blu) make up the name VRB.

of the book was deliberately left visible. The

iconic figure created by futurist Fortunato

The futurist font designed for this book is a

edges of the book’s pages were coloured using

Depero for Liquore Strega in 1928. It conveys

custom interpretation of Futura, a popular

the ancient technique of gilt edging, which was

the idea of a spray jet that borders at its

font, in its 2017 Bitstream version. Originally

employed to decorate and embellish volumes

furthest point with the edge of the box and

designed by Paul Renner and produced by

by applying a thin gold leaf to the edges of

therefore does not allow seeing the surface

German Bauer Type Foundry, Futura is the

their pages. Here, this technique was revisited

reached by the paint, leaving it undefined

sans serif, geometric typeface par excellence,

with a modern approach to reproduce on

and therefore freely interpretable. Each of

first presented at the Milan Triennale in 1933.

three sides the three colours used for both

the three pieces that make up the illustration

The name itself of this font recalls both this

the box’s cover and the stitching thread.

on the aluminium box has a hole, a technical

original typeface and Depero’s work. Futura fits

This book is therefore a unique work of art

detail that serves to hang the parts for coating.

this book perfectly: geometric and low-profile,

where complexity is translated into simplicity

A 10 mm-diameter bolt goes through the box

yet authoritative and highly characterised.

through human experience, which is exactly

and the book inside it. The hole that pierces

The customisation of the font was limited to

what drives VRB in its approach to market

the book in the centre is the result of a

introducing some elements from Depero’s

competition. The processes used to create it

craftsman operation that, although seemingly

aesthetics.

had never been implemented in all their steps

A unique book

international PAINT&COATING magazine - NOVEMBER/DECEMBER 2023 - N. 84

157

on a single book. At the same time, the complexity of its realisation

VRB’s choice was to set very precise boundaries for imperfection to

involved a precise sequence of processes that were chronologically

always provide its customers with products of the highest quality. With

linked to each other while never overlapping.

this book and the pictures it contains, VRB would therefore like to

Texts and images celebrating imperfection as an evolutionary drive

celebrate its nature as an “industrialised artisanal company”, which has retained the ability to make the most of the materials it works with while coming as close as possible to perfection. After the preface, the book

The book’s preface includes evidence from the natural world that

includes interviews with VRB founder Claudio Vassanelli, who recounted

perfection does exist. However, echoing a well-known statement

the origins and development of this firm, VRB President Mil Vassanelli,

by Rita Levi-Montalcini1 in an interview with Piergiorgio Odifreddi,

who illustrated the company’s vision, and Nicola Zorzan, VRB’s CEO and

perfection is not in the human beings’ DNA because imperfection is a

an enthusiast of Depero’s work and his futuristic approach, who talked

very powerful drive for evolution. The book gives numerous examples

about its mission.

of people who have excelled in many areas, such as sport, despite their

The main body of the book is an incredible collection of photographs

physical imperfections, as well as of cases in which imperfection was

of VRB’s production departments down to the smallest and most

taken advantage of in art and architecture to turn it into a strength.

fascinating details. The book ends with a list of all possible imperfections

Imperfection is also an inherent characteristic of all those processes that

that can arise on a powder coating film, including their photographic

still rely on their human component, including powder coating: many

representation. It is a reminder for everyone dealing with powder

imperfections can arise during this production phase, depending on

coating: this an imperfect process, which can however approach

different factors.

perfection thanks to technological, process, operational, and control developments.

“I consider imperfection a Darwinian spring of natural selection. For example, present day insects are identical to those of six million years ago: they were already perfect, and there was no reason for them to change. Man was instead imperfect, and this was the proxy for his own development and evolution.”

1

This book was the result of a collaboration between the teams of VRB and Nordlog, two companies belonging to the IFP Group.

IDEA: Mil Vassanelli - IFP President Nicola Zorzan - VRB and Nordlog CEO DESIGN AND COORDINATION: Barbara de Marzi - IFP Brand Manager GRAPHIC DESIGN, ILLUSTRATIONS, AND TYPOGRAPHY: Giuliano Garonzi from Studio Garonzi EDITORIAL CONSULTANCY AND TEXT EDITING: Gaia Passamonti from Pensiero Visibile PHOTOGRAPHS: Gabriele Compagni

© ipcm

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TECHNICAL CONSULTANCY AND PRINTING: Massimo Garbo from Graphicom

ROAD TO 2050

Fraunhofer IFAM Developed the Sustainable PFAS-Free Non-Stick PLASLON® Coating The new environmentally-friendly non-stick coating of Fraunhofer IFAM can replace products with per- and polyfluorinated chemicals on everyday products.

W

hether it is pans, cutlery or packaging, per- and

PLASLON® technology, a PFAS-free non-stick coating that meets the

polyfluorinated chemicals (PFAS) have been used for coating

required property profile and can replace the existing technology with

in a wide variety of everyday products and processes for

immediate effect. PFAS are a group of several thousand individual

many years. Due to known risks of these substances to humans and

chemicals. They do not originally occur in nature, are extremely stable

the environment, at least a partial ban on the production and use of

and are therefore constantly accumulating in the environment.

PFAS is expected to be implemented soon. The use of comparable

The fluorine compounds, also known as ‘eternity chemicals’, can occur

alternatives is therefore essential for numerous companies. Fraunhofer

in the blood serum of humans and lead to negative health effects

IFAM specializes in fluorine-free coatings and has developed the

(source: Federal Environment Agency). For this reason, the European

Pan samples coated with fluorine-free PLASLON® technology.

160 N. 84 - NOVEMBER/DECEMBER 2023 - international PAINT&COATING magazine

ROAD TO 2050

Chemicals Agency (ECHA) is considering a ban on the production, use

one hand and to display optimum non-stick properties on the other.

and marketing of PFAS. A decision by the European Commission on

The coating is also characterized by easy-to-clean properties and is

this is expected in 2025, according to the German Federal Environment

resistant to cutting and abrasion. It is non-porous and food safe. It also

Agency.

exhibits oleophilic behaviour regarding edible oils and fats.

Companies that use PFAS will face challenges because of a ban. In

A unique selling point of the PLASLON coating is that - unlike other

order to maintain processes and production, alternative solutions have

non-stick coatings - it is also suitable for enamel, glass, stoneware, and

to be found. Plasma technology offers ideal conditions for this. The

porcelain due to its good adhesion and outstanding hardness. Products

plasma coatings developed at Fraunhofer IFAM are not only fluorine-

made of these materials in particular are very scratch-resistant but

free (Zero-F), but also free of additives. They can be applied on almost

have poor non-stick properties.

all materials. Due to their property profile, some of the coatings are

The institute’s scientists also have the necessary know-how of suitable

particularly suitable as PFAS-free non-stick coatings, sliding coatings,

manufacturing processes to be able to finish products economically

and hydrophobic finishes.

and in large quantities. Depending on the customer’s needs, various

With the PLASLON coating, researchers at Fraunhofer IFAM have

concepts are available for this, such as XXL systems or throughput

developed a PFAS-free alternative characterized by excellent non-stick

systems. Combined with low energy consumption during the

properties combined with high mechanical resistance. The coating,

production, uninhibited heat transfer during use and a long service

which is produced by means of plasma technology, is designed as a

life of the coating, PLASLON is particularly sustainable and thus

gradient layer to enable excellent adhesion to the product body on the

trendsetting.

© Fraunhofer IFAM

© Fraunhofer IFAM

Low-pressure plasma system with easily exchangeable electrode systems, which also function as product carriers.

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MEETING THE INDUSTRY

COVERED by ipcm®

VRB Turns 40 and Celebrates with Futurism-Inspired Book IMPERFECTION/EVOLUTION The book IMPERFECTION/EVOLUTION deals with VRB’s history along these first forty years and follows a well-defined path from the company’s origin, vision, and mission to the knowledge acquired over the years.

L

ocated in Verona (Italy), VRB is one of Italy’s leading powder

was the concept behind a series of culinary and artistic experiences,

coating contractors. Its activity is not only limited to coating, but

which involved everyone present throughout the evening.

it encompasses a full range of industrialisation services that

Aperitifs and dinner were custom-designed for VRB by chef Nicodemo

include sandblasting, masking, unmasking, assembly, and shipment of

De Marco, conceived to create a sensory journey through various

the finished products to the end customers. The result is an aesthetic

taste experiences with the common thread of powder – mushroom

and functional product quality of the highest level, thanks to constant

powder, liquorice powder, raspberry powder, and so on – to recall

investment in technology, personnel, and research and development.

VRB’s core business, namely powder coating. The event’s guest of

Also through numerous photographs, it is an invitation to see

honour, Italian-Russian actress, comedian, writer, and eclectic artist

IMPERFECTION as a challenge, as a force keeping us alive, as a drive for

Arianna Porcelli Safonov, performed a monologue fittingly entitled

continuous improvement and thus towards EVOLUTION. It is made in

Imperfection/Evolution, with a hilarious depiction of engineers. At the

aluminium, with a bolt that connects and marks a story of overcome

end of the evening, VRB President Mil Vassanelli and CEO Nicola Zorzan

challenges while paying homage to Fortunato Depero’s famous bolted

presented the book project and once again celebrated the combination

book published in 1927 with the title “Depero futurista”.

of imperfection and evolution as a driver for development. Finally, each

On 27 October, VRB held an event devoted to the theme of

of the guests was gifted a copy of the book. You can find an in-depth

IMPERFECTION/EVOLUTION for over 120 guests including customers,

description of it in the “Art Within Surfaces” section on page 156 of this

suppliers, employees, and friends at the splendid Villa Mosconi Bertani

issue of ipcm®.

in Negrar, in the heart of the Valpolicella region. It was an event

VRB organised was a truly unforgettable evening, full of insights and

designed not as a book presentation but as an experience to be lived

inspiration to embrace imperfection as part of everyone’s journey of

and shared with key partners and friends. Its central theme was the

growth.

acceptance of imperfection as a vehicle for evolution. The attempt to achieve perfection often prevents action. Conversely, it is possible to progress and grow by embracing imperfection and learning from it. This

© VRB

© VRB

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For further information: www.vrb.it

© VRB

MEETING THE INDUSTRY

Almost 90% of the Exhibition Space of PaintExpo 2024 Already Booked 340 companies have already confirmed that they will showcase innovative industrial coating technologies, equipment and services at PaintExpo 2024.

P

leading trade fair for industrial coating technology from 9 to

A global showcase for the latest trends in industrial coating

12 April 2024 in Karlsruhe: Around six months before the start

Alongside companies from Germany, the majority of exhibitors are

reparations are in full swing for the next edition of the world’s

of PaintExpo, a large number of exhibitors have registered and 90

currently from Italy, Turkey and Switzerland. However, the event

percent of the exhibition space of the last event has already been

attracts exhibitors from far beyond Europe.

rented. There will also be a new feature: In advance of the trade

Companies from countries such as the USA and China will also be

fair, exhibitors can benefit from “digital themed routes” by using the

there. As things stand today, the proportion of international exhibitors

exhibitor and product directory on the PaintExpo website to draw

is over 40 per cent.

additional attention to topics revolving around sustainability, career

“The high level of international registrations is proof that PaintExpo

and exhibitor events.

will once again be a global showcase for the latest trends in industrial

Currently, 340 exhibitors have registered for PaintExpo 2024.

coating. The who’s who of the industry with their market and

“We are right on track and looking forward very much to the next

technological leaders will be there again,” explains Project Director

edition of the world’s leading trade fair for industrial coating

Mariella Riedel. Numerous first-time exhibitors will be celebrating their

technology. We are very pleased with the current level of registrations.

premiere at PaintExpo in April of next year, including B6 Innovations

Anyone who wants to exhibit at PaintExpo 2024 should register as

from Germany, Botko from Belgium, Mirodur from Italy and Rhopoint

soon as possible to secure a stand space,” says Project Director

Instruments from Germany.

Mariella Riedel, who took on responsibility for PaintExpo in April of this

For the first time since 2012, Harter is back as an exhibitor at

year and manages several international trade fairs for Leipziger Messe.

PaintExpo. Jonas List from Harter’s technical sales department explains why the company is returning to the world’s leading trade

© Leipziger Messe GmbH / Tom Schulze

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© Leipziger Messe GmbH / Tom Schulze

MEETING THE INDUSTRY

fair for industrial coating technology: “We have recently received a

Digital themed routes: a new feature at PaintExpo 2024

lot of enquiries from plant manufacturers who want to offer their

Alongside the numerous innovations being showcased by exhibitors

customers energy-saving and at the same time efficient dryer systems.

from the industrial coating industry, attendees of the trade fair can

This has prompted us to show our presence in the field of paint drying

look forward to an additional new feature: Digital themed routes will

again. Exhibiting at PaintExpo is a wonderful opportunity to enter into

be introduced for the first time at PaintExpo. This new service focuses

personal discussions with interested parties – about the numerous

on sustainability, career and exhibitor events and enables exhibitors

possibilities and advantages of our state-subsidised drying technology.”

to present their content relevant to these themes in the exhibitor and

Harter has been manufacturing heat pump-based drying systems

product directory on the PaintExpo website in advance of the trade

for more than 30 years – and when it comes to energy saving, the

fair. Visitors can then use this additional digital feature while they are

company has been at the forefront with its condensation dryers from

at PaintExpo to target specific products or services along the themed

the very beginning.

routes.

J. Wagner has exhibited at every PaintExpo since the first edition in 2006 – the company has also secured its stand for the upcoming

For further information: www.paintexpo.de/en

world’s leading trade fair for industrial coating technology.

“PaintExpo is an irreplaceable industry meeting place for us, where we present our products, solutions and services. Personal contact with existing and potential customers and business partners is enormously important for us, as we can continuously improve through mutual exchange. PaintExpo is one of the highlights of our trade fair year, as all the relevant players in the surface industry gather here. The internationality of the visitors is an important aspect for us as a global company,” reports Markus Sonnenstatter, CSO Industrial Solutions at J. Wagner. The manufacturer will be showing innovations in the area of wet coatings and powder, with a focus on sustainability and energy efficiency. At the J. Wagner stand, visitors can experience a wide range – from manual equipment to fully automated systems.

© Leipziger Messe GmbH / Tom Schulze

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COVERED by ipcm®

GET TECHNICAL 2023: Manufacturing is coming home Part II The edition 2023 of GET TECHNICAL took place at the Eurotherm premises in Turin, Italy, last November 21 and 22.

I

n 2017, the sppot eco-system was created by attracting the top

importance of human factor for a premium finishing process.

leading global surface finishing producers to give state of the

The afternoon session was only practical; after lunch and after a short

art surface finishing solutions to the bicycle and sporting goods

tour of Eurotherm facility, guests from the industry were able to see

industry. The sppot is a partnership of well-known, globally presented

practical demonstrations of finishing processes and to troubleshoot any

companies: TIGER Coatings, Berlac AG, WAGNER, Posterama, Eurotherm

kind of trouble they may face during their daily finishing activities.

Spa, Lesta and Duthoo Care and Repair Systems. In 2019 the sppot

Chairman of the event was Alessia Venturi, the editor in chief of

kicked off the BIG 3 event series, which consists of: The Colour Trend

ipcm®_International Paint&Coating Magazine, the only international and

Days, the exhibition Eurobike, and the GetTechnical program - aiming

globally distributed trade journal in the field of painting, powder coating

to connect OEMs, designers, Brand Owners, Industry suppliers, Tech

and surface finishing in general delivering high quality information to

staff and actual production teams to discuss hot topics & trends in

OEMs and job coaters.

the manufacturing and surface finishing world, and to promote best This is exactly what the edition 2023 of GET TECHNICAL – Manufacturing

Manufacturing ecosystems: the future of manufacturing in Europe

is coming home offered to a bunch of around 180 persons coming from

Re-shoring is the opposite of off-shoring and is an economic

all over Europe: OEMs and suppliers in the bike and sporting goods

phenomenon that consists in the return home of companies that

industries, job coaters and innovators joined the two-day, free-of-

had previously relocated production outside Europe, mainly to Asian

charge, live event dedicated to technical expertise and innovations.

countries such as China.

Organized in Turin at Eurotherm premises last November 21 and 22, the

With the pandemic and then, from 2022, with the war between Russia

morning session of the event started with a welcome note of the host

and Ukraine, re-shoring was dictated by simple economic factors.

and Eurotherm CEO Paolo Ghiazza, followed by a detailed presentation

Already with the coronavirus, the need to rethink reshoring strategies

of the spot ecosystem, its goals, its projects, and its events by Yavor

had forcefully emerged. In the first half of 2020, many companies

Peshev, sppot’s CEO, and with an analysis of the impact of Industry 4.0 in

were forced to create recovery plans to make up for the shortages of

the finishing field by Darren Bond, Eurotherm’s foreign sales manager.

materials from factories located in areas affected by the spread of the

The event went on with two panel discussions involving several speakers

pandemic before their own. This created the need to completely rework

from the industry and technical experts around two main topics: Re-

local supply chains.

shoring and the future of manufacturing in Europe; Circularity and the

The goal of this open discussion at GET TECHNICAL 2023 was to

practices for the finishing of bicycle and sporting goods.

© The Sppot

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© The Sppot

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MEETING THE INDUSTRY

COVERED by ipcm®

understand the opportunities and threats

how important is pre-treatment to the quality

companies which manufacture in Europe are

of a coating or finishing process, and how

facing. All the good reasons to set a production

important is the human factor in the Industry 4.0

in Europe, related to ESG and common

environment.

standards, high and stable quality, shared

Participants to this panel discussion were: Lex

values were analysed together with supplier

Putman, Manager Training & Support on coating

of components for bike production, OEMs and

processes; Miroslav Kertov, Field engineer,

Innovators.

Head of Lab & Innovations at Deyacolor; Alberto

The first panel discussion of the day was

Bevilacqua, Sales Manager at Winoa; Martin

preceded by a video from CONEBI - the

Semanik, Business Development at coatmaster.

European association of the Bicycle, E-Bike and Parts & Accessories Industries – about the

Technical demonstrations

European Cycling Declaration. The proposal for

In the afternoon the sppot organized real-time

a European Declaration on Cycling recognises

demonstrations of a surface finishing process

cycling as a sustainable, accessible and inclusive,

of frames and other bicycle components:

affordable and healthy means of transport, with

attendants could focus on some of the most

strong added value for the EU economy.

common troubleshooting within the whole

Participants to the panel discussion about The

process. The host of the event, Eurotherm Spa

Future of Manufacturing in Europe were Anton

set up a brand-new demonstration area with

Nastev, founder of Cycle Gets alloy bike frame

powder and liquid coating booths, equipped

manufacturer; Kostadin Kichev, Head of R&D

with Lesta’s robots, WAGNER’s spray guns and

Department at BOSCH Bulgaria; Viktor Mitkov,

manual application systems needed for surface

and Niki Videnov from MaxCom, a European

finishing of a bike frame. Posterama had a

bicycle manufacture since 1996.

decaling workshop. Duthoo had a workshop on

Circularity. The Human factor and product developments The goal of the second open discussion of the event was to discuss the importance of the

© The Sppot

© The Sppot

scratch repairments. Along with the process, visitors had the opportunity to check the latest colours and shades of TIGER’s powder coatings portfolio and Berlac’s liquid coatings.

human factor as a key aspect of the quality

Dinner at the museum

standards in the changing technological

On the evening of November 21, a networking

practices within the European productive

dinner took place on the stunning backdrop

ecosystems. Circularity is a process with

of the Museo Egizio in Turin, the world’s

increasing importance for the European

oldest museum devoted entirely to ancient

economy. It is a perception, a strategic

Egyptian culture. All guest were impressed by

approach for longer life cycles of products,

the beautiful setting, good food and flawless

any products. What the sppot wanted to state

organization.

during the panel discussion about circularity was that the longevity of a product starts at the

For further information:

production line and in particular at the surface

www.the-sppot.com

finishing shop: efficient pre-treatment, qualified employees and technicians on the line, strict quality control from the start to the very end of a surface finishing process.

During the discussion, technical experts told the audience what are the most common mistake on a painting line, how to avoid them,

international PAINT&COATING magazine - NOVEMBER/DECEMBER 2023 - N. 84

167

MEETING THE INDUSTRY

COVERED by ipcm®

The Axalta ANTICORROSION3 Event: the Answers to the Most Common Questions about Corrosion Protection The last leg of the Anticorrosion roadshow kicked off by Axalta last April was celebrated on September 21st at the Historical Alfa Romeo Museum in Milan (Italy).

S

ustainability, cost, life cycle, and material efficiency – these

the Axalta range of anticorrosion solutions1. These include:

are all issues our industry must face now to be future-ready.

• Alesta® ZeroZinc Uniprime – a universal primer that enables the use of a

Within the sustainability issue, the fight against corrosion plays a

single primer for any substrate

fundamental role because it affects the durability of assets: this means

• Abcite® 2060 - a single-layer anticorrosion solution that can be applied

costs for maintenance or premature replacement of the asset.

with flame spray technology

According to the WCO (World Corrosion Organization), corrosion

• AquaEC™ 3500 EP- the latest generation of cathodic tin-free

accounts for 3.4% of global gross domestic product. Axalta Coating

electrodeposition coatings which offers superior corrosion protection

Systems anticorrosion technologies portfolio has been recently

performance for sharp edges

updated with a bunch of new anticorrosion solutions for every possible

• Plascoat® PPA 742 primer - a single layer thermoplastic that can be

requirement.

used as primer and is specifically designed to be overcoated with Alesta®

Last April Axalta kicked off a European roadshow to announce new

topcoat.

additions to its all-in-one anticorrosion portfolio. The first leg of this

Those in attendance were also introduced to Axalta’s full suite of

European roadshow was celebrated at the Parc Olympique Lyonnais in

digital tools and educational resources aimed at providing the clearest

the French city of Lyon. The last leg was the Italian one, on September

and simplest route to optimal surface coating results. The event also

21st at the Historical Alfa Romeo Museum in Milan.

highlighted the importance of sustainability within the context of

The morning session, from 10 to 12.30 a.m. focused on general

anticorrosion. An increased focus on the environment has played a

information about corrosion processes with presentations by

significant role in the design of this latest range of anticorrosion solutions,

technicians and university professors about the following topics:

all of which are ISO 12944-6/9 accredited and provide exceptional

• Qualital (Institute for International Certification of Aluminium and other

performance and aesthetics without the use of solvent materials.

Materials) standards • Corrosion mechanisms

For further information: www.axalta.com/anticorrosion

• Surface pre-treatment • Coatings and accelerated corrosion tests.

After the lunch break, participants had the opportunity to visit the fascinating Alfa Romeo Museum, which tells the legendary story of the

Axalta Coating Systems Introduces a New Series of Anticorrosion Solutions for Every Possible Requirements in ipcm® n. 75, Vol. XIII May-June 2022, pags 74-78.

1

brand, via a project and an installation designed to reflect its values: historical presence, beauty and speed, an essential part of the Alfa Romeo DNA. The event continued with a technical afternoon session from 3 to 5 p.m., during which Axalta experts introduced the anticorrosion range of technologies available to the industry: • Alesta® ZeroZinc primer • Plascoat®/Abcite® thermoplastic coatings • AquaEC® e-coat • PercoTop® industrial liquid paints.

A selected group of customers, journalists and industry stakeholders were given a sneak preview of the latest groundbreaking additions to

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© Axalta

La finitura delle superfici è il nostro DNA

Pallinatura Professionale per automotive Tensioni residue di compressione prima della pallinatura*: 11 MPa una profondità di of 24 μm Granigliatrice a tavola rotante Rösler: la scelta per processi di pallinatura ripetibili

Tensioni residue di compressione dopo la pallinatura*: -1214 MPa ad una profondità di 24 μm

*I valori sono un estratto di una curva di misurazione della tensione residua, materiale 20MnCr5.

Finitura di Massa | Granigliatura | AM Solutions Rösler Italiana S.r.l | Via Elio Vittorini 10/12 | I-20863 Concorezzo (MB) Tel. + 39 039 / 611521 | Fax +39 039 / 6115232 | rosler-it@rosler.com | www.rosler.com

THE BEST IN SURFACE MATERIAL INNOVATION

SURFACE DESIGN SHOW IS THE UK’S LEADING EVENT FOR ARCHITECTS AND DESIGNERS Showcase your products in front of our quality audience of 5630 architects and designers.

Find out more here: surfacedesignshow.com/exhibit

Supplemento a IPCM n° 84 - Novembre/Dicembre 2023

ICT digital on www.myipcm.com

STS

impianti di lavaggio robotizzati per componentistica della meccanica agricola Alti gradi di pulizia.

Riduzione tempi di lavaggio e scarti

Bassi costi di acquisto ed esercizio.

Semplicità d’uso

PIÙ EFFICACIA

PIÙ ECONOMIA

PIÙ SICUREZZA

PIÙ AMBIENTE

Scheda sicurezza 0.0.0.

No alcoli, solventi e tensioattivi

Bassi consumi di energia e detergente No emissioni

soluzioni efficaci, ecologiche, economiche e sicure

ICT | HIGHLIGHT OF THE MONTH

GABRIELE LAZZARI ipcm®

From the Black Forest to the Global Industry: 25 Years of Ultrasonic Cleaning by Weber During the inauguration ceremony of its new Application Center, Weber looked back on the 25 years of company with keynote speeches from its main partners and live demonstrations of its solutions for ultrasonic cleaning, welding and cutting.

W

eber Ultrasonics AG was founded on 17th September 1998 by

Commerce and Industry who presented the anniversary certificate to

Dieter Weber. The company has then recently celebrated its

Weber during the event, highlighting the outstanding company’s position

25 anniversary, as well as the opening of its new Application

in both the national and international landscape, which was confirmed

th

Center in Karlsbad (Germany), with a special ceremony. On the occasion,

by the Global 2021 Award obtained by the German business for its

Weber has invited suppliers, partners and customers form Europe,

rapid response and adaptation to the global emergency situation for

America and Asia in order to offer them a comprehensive insight into

protective masks. In addition, the in-company training and continuing

the wide range of products and services offered by the ultrasonic

education play a central role.”

solutions manufacturer. The event included live demonstrations on

Björn Kornmüller, the mayor of Karlsbad, also congratulated and

cleaning, welding, and cutting applications as well as several experts

underlined the important role of the company as a major employer in

from various industrial sectors who had the opportunity to discuss

the region. “The founding of the company was thanks to the innovations

current challenges and present innovative solutions in keynote

of Dieter Weber. And even today, this spirit of research is something

speeches.

that one immediately associates with Weber Ultrasonics. The past years

Wolfgang Mangold, Weber’s current Chief Operating Officer, first

have been marked by numerous patents and application-oriented

welcomed the guests and acknowledged the achievement of the

product innovations.”

Weber family of entrepreneurs in building the brand and positioning it in the international market with a far-sighted strategic orientation:

Weber products for several markets

“On behalf of the entrepreneurial family and the management, I want

Over its history, the company has become one of the leading

to first express appreciation to the 125 dedicated employees. Today,

manufacturers of cleaning systems worldwide, but Weber has also been

we are proud to be the largest producer of ultrasonic components for

characterised by the continuous research of innovative solutions for

industrial parts cleaning in all of Europe. This is the result of their work,

new markets, in order to satisfy every need. As a matter of fact, it offers

expertise and team spirit, which made Weber the lighthouse in Europe

a wide range of technology covering applications that are completely

for ultrasonic cleaning systems.”

different from each other, such as olive oil extraction, plastic granulate

The success of the company was also recognised by Robert Huber, the

and aging whiskey. In addition, in 2009 it started to develop industrial

Chairman of the Foreign Trade Committee of the Karlsruhe Chamber of

systems for cutting and welding and founded the daughter company

© ipcm

© Weber Ultrasonics AG

Weber received the award for its 25th anniversary

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The audience during the keynote speeches.

ICT | HIGHLIGHT OF THE MONTH Classic portfolio updated Entec, which designs and manufactures solutions for biogas, cell

However, besides focusing on customer assistance and new markets,

technology and water treatment.

the company is also investing in updating and further optimising its

“Weber represents the benchmark on the market for cleaning systems,

classic ultrasonic cleaning systems and the Sonosub and Sonoplate

and our task is now to lead the course of the industry for the future

transducers, which can now reach the hygienic classes 4 – that is

generations. We will focus on new high-end solutions for niche markets

required for the surface quality of high-end solutions for the medical

and we will explore new regions, such as Malaysia, Thailand, South

branch.

Korea, Taiwan, Japan and other countries in the Asia- Pacific region,

“We are planning the roll-out of mega-sonic systems for wafer and chip

where the electromobility, the medical and the aerospace sectors are

cleaning, that some of our customers are already integrating inside their

rapidly growing. Our new hub is specifically dedicated to identify the

ultrasonic cleaning processes. We are developing pilot projects with

requests of these markets and develop suitable solutions,” continued

them in order to understand how we can further advance our systems,”

Mangold.

added Mangold.

“It has been great to gather here and celebrate the success of Weber

Customer support as a core business activity

with our clients and suppliers as well. It is a great opportunity to discuss

The new Application Center of Weber covers an area of 1,800 m2 and

the future of the industry and identify the new trends in industrial parts

offers a useful customer area with meeting rooms and application

cleaning with partners coming from markets that have several different

laboratories for welding and cutting applications. It also includes a

requirements but that all decided to rely on the quality of our products

cleaning laboratory where clients and experts from the company can

and the know-how of our technical team. We could not be prouder of all

jointly perform trials and tests. In addition, there are also development

the achievements that we have accomplished”, concluded Wolf.

laboratories for measurements and monitored endurance runs.

“The bundling of competences in the areas of Technology, Service and Sales, which were previously distributed at different locations, brings numerous advantages both for internal cooperation and for our customers. Our goal is not to sell ultrasonic hardware: we want to come closer to our customers to better understand their processes in details and perfectly integrate our solutions within their production line. In this way, we can be able to position Weber at the forefront of the market. The new Center supports the transformation of the company from a pure component manufacturer to a specialist for innovative industrial ultrasonic solutions,” emphasised Jürgen Wolf, the CEO of Weber.

PERFEKTE SAUBERKEIT. Teile-Reinigungsanlagen aus dem Hause Höckh erfüllen höchste Ansprüche an die Reinigungsqualität.

Unsere Standard- und Individual-Lösungen bieten für jeden Anwendungsfall etwas passendes – ganz gleich ob mit wässrigen Medien, Lösemitteln oder kombiniert.

Höckh Metall-Reinigungsanlagen GmbH | 75305 Neuenbürg Tel: +49 7082 - 410 931-10 | Mail: sales@hoeckh.com © Weber Ultrasonics AG

Some of the ultrasonic cleaning solutions showcased by Weber.

international PAINT&COATING magazine - NOVEMBER/DECEMBER 2023 - N. 84

173

ICT | TECHNOLOGY OVERVIEW

DORIS SCHULZ SCHULZ. PRESSE. TEXT, Korntal – Germany ds@pressetextschulz.de

Answers to the Transformation Processes in the Industry: Ecoclean Meets Current and Future Challenges with Diversification The economy is undergoing a transformation that poses challenges for many areas. New products and various megatrends require adjustments to manufacturing technologies as well as to the range of products and services. Ecoclean GmbH is proactively addressing this change through greater diversification of the solution portfolio for industrial component cleaning and the new business area of hydrogen technology.

E

nergy transition, sustainability, demographic change, mobility,

parts cleaning. Whereas yesterday it felt like the automotive industry

automation and digitisation and security: these megatrends are

was setting the general standards in terms of cleanliness requirements,

resulting in technological and social changes at an increasingly

today it is completely different industrial sectors, each with its own

rapid pace. This development demands increasingly higher flexibility

specific requirements. Ecoclean, one of the world’s leading suppliers

and agility from companies. This is also evident in the field of industrial

of equipment and systems for industrial component cleaning, surface

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ICT | TECHNOLOGY OVERVIEW

© Ecoclean GmbH

© Ecoclean GmbH

treatment and automation, is responding to these changes with a

range and extremely strict specifications regarding filmic contamination,

future- and market-oriented diversification strategy. The course for

outgassing rates for organic substances and residual moisture as well as

this was already set several years ago with corresponding financial

‘prohibited’ substances/elements play a quality-critical role.

and personnel investments. As a result, new solutions for high-tech

Likewise, stringent cleanliness requirements must be met for vacuum

industries can now be offered in addition to equipment and systems

technology components for the UHV, XHV and UCV range – for

for tasks in the previous industrial sectors, such as the automotive

example in high-power laser systems, high-tech measuring and analysis

and supplier industry, mechanical engineering, joining technology, the

equipment. Precision optics, micro-optical parts and sensor systems,

jewellery and watchmaking industry and the aerospace sector.

among others for semi-automated and autonomous driving as well as digitisation applications in industry, also require a very high degree of

High Purity - Cleanliness in the third dimension

cleanliness for lasting fault-free function. For these challenging tasks,

This includes, for example, the semiconductor industry and its suppliers.

Ecoclean offers industry and application-specific solutions from pre-

To be able to manufacture ever smaller and more powerful microchips

cleaning to intermediate and final cleaning connected to or integrated

by means of EUV lithography, extremely high demands are placed on

in a clean room. For the design of process and plant technology, the

the components for the production equipment in terms of purity. In

company has its own High Purity Test Center with a validated clean

addition to ultra-fine particulate residual impurities in the nanometre

room and corresponding measurement technology.

international PAINT&COATING magazine - NOVEMBER/DECEMBER 2023 - N. 84

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ICT | TECHNOLOGY OVERVIEW

Turnkey solutions for medical technology: MDR and FDA compliant

technically and economically optimal solution can be devised for every

High cleanliness requirements have always been commonplace in

which accelerates qualification and commissioning.

cleaning task. It can be easily duplicated for further production sites,

medical technology. With the introduction of the European Medical Device Regulation (MDR), the requirements for cleaning medical devices

Green hydrogen: energy source of the future

such as implants, instruments and equipment as well as for qualification,

By entering into the development, manufacture and sale of electrolysers

documentation and traceability of the processes have become even

for the production of green hydrogen and solutions for its use, the

stricter. In the meantime, the U.S. Food & Drug Administration (FDA) is

company is opening up a new business area. To this end, Ecoclean and

planning to harmonise its quality system regulation with the MDR, so

the Zentrum für Sonnenenergie und Wassersoff-Forschung Baden-

that uniform regulations will apply regardless of market access.

Württemberg (ZSW) have pooled their expertise in the joint project

To solve the very different tasks in medical technology in a requirement-

“EcoLyzer BW”. Based on the robust and well-tested system technology

oriented, efficient and sustainable manner, Ecoclean not only offers a

for alkaline pressure electrolysis developed by the ZSW and Ecoclean’s

complete and globally available portfolio of qualified cleaning systems.

expertise and decades of qualification in process engineering and

Cooperation with renowned partners also enable the realisation

industrial production technology, electrolysers are designed as a

of turnkey projects with corresponding packaging and cleanroom

modular system with compact standard modules.

solutions.

With power classes initially ranging from one to ten megawatts, they

Software specially developed for medical technology, RFID technology

enable the simple and cost-efficient construction of electrolysers

and audit trail ensure that all specifications regarding component

that can be adapted to a wide range of applications, for example in

identification, documentation and traceability are completely fulfilled. In

industry, mobility, energy supply for neighbourhoods and storage

addition, the company’s experts provide support with qualification (IQ,

of regeneratively generated surplus energy from wind power and

QQ and PQ) on request.

photovoltaic plants. A first solution in this area was completed in

Thanks to the company’s comprehensive medical technology and

September 2023 with a test rig for alkaline pressure electrolysis. It will

regulatory know-how, combined with extensively equipped technology

make it possible to test and validate electrolysis stacks with an output of

centres including a cleanliness laboratory and validated cleanroom, the

up to 500 kW and a diameter of 1,200 mm.

© Ecoclean GmbH

Protection upgraded

Specialità chimiche per il trattamento delle superfici Lavaggio Industriale

Pretrattamento metalli alla verniciatura

Lavaggio di precisione

Processi di conversione esenti

Sgrassanti interoperazionali

Cromo e Fosfati

Miscele di tensioattivi

Fosfatanti a bassa temperatura

Protezione temporanea

Passivanti per acciaio zincato a caldo Passivazione conduttiva su Alluminio TCP

Galvanica Funzionale

Galvanica Decorativa

Zinco e leghe di zinco

Rame, Nichel e Cromo

Passivanti e Sigillanti

Deposizione su plastica (POP)

Rivestimenti resistenti all'usura

Stagno e leghe di Stagno

Pretrattamento

Pretrattamento

SurTec Italia Sas di Externa Holding Srl Via Boito, 251 Tel.: +39 059 8579901 41019 Soliera (MO) E-Mail: info-it@surtec.com Italia Web: www.SurTec.com

ICT | CASE STUDY

DORIS SCHULZ SCHULZ. PRESSE. TEXT, Korntal – Germany ds@pressetextschulz.de

Snow Ensures Cleanliness for Space Missions: quattroClean Technology for Cleaning Lightweight CFRP Structures Even the tiniest grains of dust or particles of manufacturing residues can be decisive for the performances of satellites in space. A global player in the international aerospace industry uses the quattroClean snow jet technology from acp systems as a solution to clean the interior of coated baffle and CFRP structures – with and without integrated cable harnesses.

T

he family-run listed space and technology group OHB SE is

Meeting and proving high cleanliness specifications

one of the top three players in the European space industry.

Even tiny amounts of particulate manufacturing residues can impair the

Divided into the three segments of Space Systems, Aerospace

success of a mission for which the company bears responsibility. “That

and Digital, the Group employs a workforce of around 2,800 people.

is why, eleven years ago, we set up the Cleanliness and Contamination

The largest subsidiary, OHB System AG, based in Bremen and with a

Control division. In the meantime, eleven experts deal with the aspect

further site in Oberpfaffenhofen, has over four decades of experience

of cleanliness along the process chain, as well as contamination

in the development of high-tech solutions for space travel and other

engineering, proof of cleanliness, simulation of contamination transfer

applications, with composite materials such as CFRP playing a key

phenomena and cleaning operations in the high-end sector,” states Axel

role. The company’s portfolio of products and services encompasses

Müller, Lead Expert Contamination Control at OHB System.

the construction of complete satellite systems for earth observation,

In 2016, work began on certifying the CO2 cleaning technology as a

navigation, telecommunications, science and reconnaissance as well as

cleaning process for space travel within the company. This involved

the development and execution of space exploration missions and the

cleaning cable harnesses and CFRP structures with a diameter of

development of systems for human space flight. As a systems specialist,

approximately 2,000 x 2,000 mm, which have a special black light-

OHB System cooperates with leading national and international

absorbing coating. Thanks to this so-called baffle, only the light to be

companies, combining technologies to create new solutions.

detected or the desired image information is transmitted to optical

© OHB Systems

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ICT | CASE STUDY

components such as mirrors, lenses and detectors.

Cleaning in the cleanroom with direct proof of cleanliness

“For example, if isolated particles reach the mirror as a result of the

Unlike CO2, which is in a gaseous state at the end of the cleaning step, the

vibrations during launch, these are sufficient to cause light reflections

detached manufacturing residues and dusts remain as solids. This gave

that distort images and may even result in the failure of a mission,”

the cleanliness experts the idea of proving cleanliness at the same time as

explains Müller. “For us, however, the challenge lies not only in getting

cleaning.

the inner surfaces of baffle so clean in a damage-free process that

“In order to do this, we have developed a method whereby a stream of

no particles larger than ten micrometres are present but also in

ultra-clean air flows around the part during the cleaning process, which

proving this. And this proof is usually extremely labour-intensive, time-

transports the detached contaminants away from it to the extraction

consuming and costly.”

system. We have integrated a particle counter into this airflow, which

A corresponding cleaning solution based on the scalable quattroClean

displays the number and size of the particles present in real time,”

snow jet technology from acp systems AG was jointly developed and

reports Müller.

integrated into an ISO Class 3 cleanroom.

This measurably worsens the cleanroom class. However, by measuring the particle count per volume, it is possible to demonstrate that the

Four effects for highly clean surfaces

cleanliness level in the cleanroom is quickly restored when the CO2

The dry quattroClean technology uses liquid, climate-neutral carbon

cleaning process is interrupted. Then the next cleaning step begins. During

dioxide as a cleaning medium, which is guided through a wear-free

this, the number and size distribution of the remaining contaminations

two-substance ring nozzle. On exiting this nozzle, the carbon dioxide

are continuously reduced by the cleaning effect, and this is documented

expands to form fine CO2 snow, which is then bundled by a separate

in parallel. These cleaning and regeneration cycles are repeated until the

circular jacket jet of compressed air and accelerated to supersonic

baffle meets the required cleanliness specification in terms of acceptable

speed. The easily-focused jet of snow and compressed air develops a

residual contamination or particle size distribution, respectively.

combination of thermal, mechanical, solvent and sublimation effects

“To my knowledge, the quattroClean snow jet technology is the only

when it impacts on the surface to be cleaned. The interaction of these

cleaning process of its kind where the cleaning result can be displayed

four mechanisms of action removes particulate contamination right

live,” remarks Müller.

down to the submicrometric range and also filmic contamination reliably and reproducibly. The crystalline carbon dioxide sublimates completely

Sophisticated cleaning machine

during the process, leaving the cleaned surfaces dry.

Based on these results and the recent certification of the cleaning

© OHB Systems

© OHB Systems

The CFRP structures of satellites with integrated cable harness and thermal components.

The two laser pointers integrated into the nozzle head.

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ICT | CASE STUDY

solution for space applications, acp engineered a cleaning machine in

Collision control via digital twin

high purity design for cleaning the interior of large, fully-assembled,

Collisions, which could damage the CFRP structures, must be reliably

semi-enclosed CFRP structures of three different baffles. Among other

excluded during the cleaning process. At the same time, it is essential

things, the machine features a media treatment unit for the liquid

that each area is cleaned effectively. The motion sequences must

carbon dioxide, which ensures a purity of 99.995%; the compressed air

therefore be defined individually for each baffle. “We use a digital twin to

quality is 1.2.1. The baffles, which weigh up to 125 kg and are shaped

this end, which models the machine, the part and the cleaning process,

like a truncated pyramid rounded at the top, are fixed to an interface

as well as the cleaning result,” adds Müller.

plate and placed on the fork of the machine by a crane. This can be

To measure the distance away from the part, the nozzle head is

moved in the X, Y and Z directions. To make sure that all the inner

equipped with an ultrasonic sensor and two laser pointers. Thanks to a

surfaces of the parts – which have a maximum size of 1,600 x 1,600 x

camera system that is also integrated, live images can be displayed any

2,000 mm – are reached, the nozzle with swivelling jet is inserted into

time during the cleaning step. Proof of cleanliness is supplied by particle

the baffle on a lance, where it scans it in a meandering pattern and

counters integrated into the exhaust air stream.

rotates as it does so. During the cleaning process, the air inside in the

“With this machine, which is probably the only one of its kind in the

baffle is extracted and the particles contained therein are analysed

world, we can now clean the parts 10,000 times more effectively than

according to size and number as well as place and time of detection,

before. And this with huge time savings as well as significantly higher

thus allowing the cleaning result to be evaluated.

process reliability and reproducibility,” concludes Müller.

© acp systems AG

The baffle placed on the fork of the cleaning machine by a crane, with a camera system integrated into the nozzle head that displays the entire cleaning process live on the screen.

180 N. 84 - NOVEMBER/DECEMBER 2023 - international PAINT&COATING magazine

© acp systems AG

The swivelling nozzle head attached to a lance.

ICT | CASE STUDY

ILARIA PAOLOMELO ipcm®

Coltellerie Sanelli: Sustainable, High-Quality Cleaning of High-End Cutting Tools Coltellerie Sanelli, a leading manufacturer of top-quality knives for the catering and butchery sectors, has recently installed a new cleaning system supplied by Fismet to improve the quality of its cycle, limit consumption, and reduce waste of water and detergents.

P

remana, a village located in the province of Lecco (Italy), is

activity. The workshops grew larger and larger until they became true

renowned both nationally and internationally for the production of

factories. Today, there are more than 100 companies in the area, which

top-quality scissors and knives that are appreciated for their high

produce blades by implementing the traditional production methods

precision, durability, and craftsmanship. This tradition has very ancient

integrated with modern technologies to improve the quality and

origins as it dates back to the 12th century, when, following the discovery

efficiency of their activities.

of iron veins in the surrounding mountains, the first workshops crafting

Coltellerie Sanelli Srl is one of these manufacturers of excellence.

weapons and cutting objects opened to meet the needs of the war

Founded more than 150 years ago, it immediately made a name for

industry and, later on, the demands of various industrial sectors. As the

itself, first nationally and then worldwide, for the production of top-

centuries went by, the inhabitants of Premana continued to specialise

notch cutting tools, an achievement made possible by the combination

in the production of cutting tools, giving rise to a flourishing industrial

of the highest quality materials and state-of-the-art machinery. “Our

© Sanelli

Founded in 1864, Coltellerie Sanelli specialises in the production of knives of the highest quality for the catering and butchery industries.

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ICT | CASE STUDY

strength lies in the attention we pay to the choice of raw materials, our

Such global success has played a key role in Sanelli’s evolution. Initially

attention to detail in each processing stage, and the implementation

located in the heart of Premana, it moved its headquarters to a new

of the most advanced technologies,” states Antonio Sanelli, the owner

building in the 1980s to support its growth; then, in 2020, following the

of the company and a member of the fourth generation at its helm. As

acquisition of another long-standing, well-known knife manufacturer in

regards technology, in particular, the company’s most recent investment

Maniago (Pordenone, Italy), it purchased a new industrial plant located

dates back to the beginning of 2023, when it acquired a new cleaning

in Cortenova, a few kilometres from Premana. “From a logistical point of

system designed, built, and installed by Fismet Service Srl (Cornaredo,

view, the distance between Maniago and Premana was significant, hence

Milan, Italy) to significantly increase the efficiency and quality of the cycle

the need to move to larger premises. With our new factory, covering

that the knives undergo at the end of the production flow.

around 4,000 m2, we set ourselves the goal of increasing our production volumes and reaching new markets, including those of sporting and

A long tradition in the production of handcrafted knives

hunting knives,” indicates Antonio Sanelli. His son Maurizio Sanelli points

The history of Sanelli began back in 1864 when, after gaining knowledge

out: “This expansion project also gave us the opportunity to invest in

and experience by working for many years with some knife grinders

new machinery, including the cleaning plant supplied by Fismet.”

in the Veneto region, Antonio Sanelli’s great-grandfather decided to manufacture cutting tools to be sold throughout Italy. Over the decades,

From raw materials to end products: how Sanelli knives are made

the company gained a solid reputation in the market thanks to its

The manufacturing of Sanelli’s knives is complex and consists of

constant commitment to innovation and excellence in the production

numerous steps. The procured high-quality raw materials, such as

of professional knives and it specialised mainly in the catering and

specific steel for the blades and plastic for the handles, are subjected

butchery sectors. “Currently, Italy is our largest market, contributing

to blanking or laser cutting depending on the type of product. The

75% of our turnover. However, in recent years, we have expanded our

components then undergo a heat treatment phase that gives them

presence, crossing national borders and opening up new business

excellent hardness and durability, followed by grinding. “Sanelli is

opportunities. We have successfully expanded in European markets

equipped with a centralised, closed-loop sludge separation plant to

such as Germany and Scandinavia as well as outside Europe, particularly

recycle the water used in our grinding machines, thus reducing waste

in the United States and the Middle East,” states Antonio Sanelli.

and promoting sustainability,” says Antonio Sanelli.

open his own business, the first in the municipality of Premana, to

© ipcm

Overview of the new cleaning system designed and installed by Fismet Service.

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The cycle continues with blade taping and satin finishing. “Depending on customer requirements, we can also produce knives with a brighter, shinier finish, which we achieve through a mirror polishing process.

The blades are then sharpened manually in six stages. This operation requires great skill and precision and cannot be carried out with any machine because, until now, we have not found any system on the market that can replace human know-how.” Afterwards, the products reach the new cleaning system provided by Fismet, which has the task of removing any dirt or residues left during the previous processing steps. At the end of the process, the blades undergo quality controls to ensure conformity to specifications.

“Our knives’ handles, with a rigid red propylene interior and a green Santoprene® outer coating, are made using a patented double © ipcm

© ipcm

moulding process that gives them non-slip and anti-bacterial properties, making the products suitable for food contact. We developed this patented technology more than twentyfive years ago through an in-depth study in collaboration with the Politecnico di Milano aimed at designing an ergonomic and nonslip handle capable of reducing physical effort and fatigue,” adds Antonio Sanelli. Finally, to ensure batch traceability, each blade is laser-marked to display information about the characteristics of the steel used, the company logo, and the American NSF certification mark. This meticulous manufacturing cycle guarantees the high quality and safety of these knives, from the raw materials to the end products, also in compliance with ISO 9001 and food certification standards.

Cleaning requirements The cleaning system designed by Fismet was installed in the first months of 2023. “The need for this machine arose from our will to © ipcm

From top left clockwise: Baskets entering the machine; The knives arranged inside the baskets undergo the multi-stage cleaning cycle; Some cleaned knives.

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© ipcm

efficiently address the problem of cleaning our knife blades: after the satin finishing and polishing process, the blades are often

ICT | CASE STUDY

very dirty due to the use of a polishing paste and, without the aid of a machine, manual cleaning is time-consuming, making the process impractical,” explains Antonio Sanelli.

“Ensuring an optimal finish for our knives is crucial for us, as they are immediately packed and shipped to customers after cleaning and they must have an impeccable visual quality. A cleaning plant enables us to achieve this result consistently and reliably.” The implementation of this new system, in particular, has significantly simplified and speeded up the cleaning process thanks to its ultrasound technology, which thoroughly removes all impurities from the blades’ surfaces. “Finally, an additional requirement was related to sustainability and environmental friendliness:

© ipcm

this is why Fismet provided us with a closed-

The new machine is a closed-loop system, which means it has no external connection for water supply and vapour discharge.

loop system with no discharge to the outside and with an efficient filtration and recirculation system for water and the cleaning solution.”

• ultrasonic cleaning with an acid-based

then disposed of,” says Fismet Service owner

Features of the new cleaning machine

detergent

Sabino di Pierro. “This also allows replacing the

• 1 rinse with running water

detergent every six months, thus minimising

The cleaning machine installed by Fismet is

• 2 rinses with demineralised water

product consumption. The same recirculation

a fully automatic system where the baskets

• drying.

concept applies to rinse water. In addition, the

are loaded and unloaded on an automatic

“The new machine is a closed-loop system,

machine has a hot recirculation system that

belt conveyor and taken along the tanks by a

which means it has no external connection

allows heating the parts only once, resulting

manipulator. The cycle performed consists of

for water supply and vapour discharge. It

in significant energy savings and reduced

as follows:

operates in a highly efficient manner: the

operating temperatures.”

• ultrasonic cleaning with a detergent

cleaning solution is constantly filtered and

Another advantage is that water vapour does

• 1 rinse

de-oiled; dirt is collected in the filters and

not need to be disposed of because it is

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© ipcm

© ipcm

Sabino di Pierro (left), the owner of Fismet Service Srl, and Maurizio Sanelli, a member of the fifth generation at the helm of Coltellerie Sanelli.

On the right, the headquarters of Fismet Service in Cornaredo (Milan).

condensed and the distilled water is recovered. This cleaning plant has

design to finishing: as each of them is essential, technical assistance is

a production capacity of 12 cycles/hour and is equipped with remote

fundamental for us, because any machine failure or downtime could

control and technical assistance features. “During the testing phase,

disrupt our entire production chain, with economic consequences as

we worked remotely with Fismet’s technicians to handle any changes

well. Its ability to provide immediate support through both in-person

needed to fine-tune the machine. This solution is ideal for a company

and remote assistance was one of the reasons why we chose Fismet as

like ours, paying particular attention to sustainability, as it reduces the

our technology partner for the cleaning cycle.

pollutant emissions associated with travel,” notes Maurizio Sanelli.

“When we decided to install a new cleaning machine, we set ourselves the goal of choosing a technology that would allow us to reduce the

A partnership also focussing on circular economy and sustainability issues

pollution generated by this phase. Fismet’s system has enabled us

The new machine has been fully operational for about a month. “Initially,

reduce water waste and the amount of detergent used thanks to its

we conducted a series of tests to determine the optimal arrangement of

efficient recirculation system, also eliminating the need to discharge

the knives and calibrate the temperature for optimum cleaning results.

waste. This was a determining factor in our choice,” indicates Maurizio

We have already successfully cleaned over 50,000 knives so, although

Sanelli. “Fismet proved to be an all-round partner as it also assisted

this is a newly installed machine, we are satisfied with our collaboration

us in the maintenance and revamping of an already existing cleaning

with Fismet,” states Sanelli. “This industrial cleaning system manufacturer

machine, making significant improvements such as optimising its tanks

stands out for its ability to solve problems quickly and apply its know-

and implementing a robot and new safety systems. We use this plant

how to improve production processes. This approach was crucial,

to clean the blades between one process step and the other, whereas

given the complexity of the operations involved in our production

the new Fismet one treats them at the end of the production flow,”

cycle, which includes at least twenty different processing steps from

concludes Antonio Sanelli.

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not only to improve the quality of our production cycle but also to

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EDITED BY RÖSLER OBERFLÄCHENTECHNIK GMBH

ICT | TECHNOLOGY OVERVIEW

Untermerzbach – Germany

The Operational and Economic Benefits of Recycling Process Water with Centrifugal Technology Rösler, a German company specialising in manufacturing machines and integrated systems for mass finishing and shot blasting, has developed a modern water treatment and purification centrifuge technology to allow the recovery of process water after finishing operations, thus reducing the environmental impact and production costs.

D

uring mass finishing, the process water injected into the finishing

In addition to offering more effective workpiece processing, cleaning

machine is contaminated with the chemical ingredients of the

process water saves money and the environment through reduced

compounds, the fines from the grinding or polishing media and

consumption, compound usage, disposal costs and regulations.

the metal fines from the workpieces. In case of ball burnishing, when Under ecological and economic aspects, the cleaning and recycling

when the workpieces are covered with oil from machining or stamping

of industrial liquids poses a substantial technical challenge. Whether

operations, the water can even be contaminated with oil.

dealing with process water, coolants, sludge from the coating booths

As a family-owned company, Rösler bears a particular responsibility for

or other contaminated industrial liquids, the effectiveness and cost-

future generations. Therefore, sustainable environmental protection is

efficiency of the cleaning process depends entirely on the employed

a central element of its corporate culture. So, it has developed a series

technology. Rösler is meeting this challenge with the highly productive

of closed-loop water circulation systems using centrifuge technology to

and powerful cleaning centrifuges utilising centrifugal force for 2-phase

remove these contaminants regardless of their origin and allow clean

or 3-phase separation of different materials.

process water to be reused and/or safely discharged.

On the basis of its robust and proven centrifugal filtering technology,

The high-performance RZ 60 M is the smallest centrifuge of Rösler.

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© Rösler

Efficient cleaning of all kinds of industrial liquids

contain dissolved metals and become alkaline or acid. Or, for example,

© Rösler

acidic or alkaline compounds are used, the process water can also

The RZ 120 M centrifuge is the most productive model within the range of semi-automatic cleaning centrifuges.

ICT | TECHNOLOGY OVERVIEW

Rösler offers solutions that are characterised by significant technical

automatic centrifugal systems the sludge is automatically peeled out of

and economic advantages. With Rösler cleaning centrifuges, all kinds

the drum.

of industrial liquids can be effectively and efficiently cleaned and recycled, allowing clients to make a substantial contribution towards

Semi-automatic centrifuges

environmental protection and help to save money at the same time. As

The range of semi-automatic basket centrifuges of Rösler is

a matter of fact, the centrifugal filtering technology can reduce water

characterised by an excellent separation performance and a space-

consumption by up to 90%. Suitable for a wide range of sectors such

saving design that allows to place them directly next to the industrial

as glass, plating and ceramics industries, coating and industrial washing

processing units. In semi-automatic centrifuges, the sludge is manually

operations as well as coolants and oils, they can also be adapted to

eliminated from the rotary drum by removing the basket insert, while a

individual technical requirements.

collecting nozzle in picks up the cleaned liquid and transfers it either to an industrial processing unit located nearby or to an intermediate buffer

The centrifugal technology of Rösler

tank.

The contaminated liquid to be cleaned arrives directly from the

Optionally, all Rösler centrifuges are available in stainless steel AISI

processing equipment or it is transferred to the centrifuge by a pumping

304/316. In order to allow the clients to position them in multiple

unit (lifting station). The feed pump transfers the process liquid –

locations, the machines can also be equipped with a movable base.

contaminated with solids or oil – continuously into the rotating drum 2-phase cleaning centrifuges

that the generated high centrifugal force also catches very small and

The high-performance RZ 60 M is the smallest centrifuge of Rösler,

lightweight particles and ensures that these are deposited on the drum

ideal for cleaning tasks with relatively low volumes of liquids. Because

wall as dense sludge. In semi-automatic centrifuges, it can be easily

of its compact design, it has a very small footprint – so that it can then

removed with a basket insert placed into the rotary drum, while in fully

be placed in tight spaces. The 2-phase principle allows the efficient

3-phase centrifuges such as the RZ 120 M-3PH model allow also the separation of two liquids with a second collection tube in the rotary drum.

© Rösler

© Rösl

er

of the centrifuge. A rotational speed of up to 3,000 RPM guarantees

Fully automatic RZ 150 A centrifuge.

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separation of solid particles from all kinds of liquids. It is characterised

Fully automatic centrifuges

by minimal noise emissions and can handle liquid volumes of up to

Automatic centrifuges offer an excellent separation performance

60 litres/minute. The RZ 120 M centrifuge, on the other hand, is the

combined with a high reliability and equipment uptime, achieved by

most productive model within the range of semi-automatic cleaning

designing the base units and the components such as motor, pumps,

centrifuges. Besides offering a high throughput of 120 litres/minute, it

valves, rotary drum and peeling knife with a focus on longevity and

can also be supplied with a movable base, ensuring a high flexibility for

functionality. These systems are also characterised by easy and quick

its use in an industrial environment.

maintenance.

In most centrifugal systems available in the market, the peeling knife, powered by a gear motor, is continuously rotating in the rotary drum.

Besides the separation of solids, 3-phase centrifuges such as the RZ

In the RZ 150 A model, the peeling knife is stationary. During the

120 M-3PH model allow also the separation of two liquids (for example,

peeling cycle, a linear drive is moving the knife towards the drum wall,

water and oil) with a second collection tube in the rotary drum. Due to

causing the sludge to be peeled out without any load whatsoever on

the different densities of the three phases (solids, water and oil) they are

the drum bearings. After completing the peeling operation, the drum is

separated in the rotating drum through the centrifugal force. While the

automatically rinsed to remove any sludge residues, which could cause

solid particles are deposited on the wall of the insertable sludge basket,

an imbalance and premature wear of the bearings during subsequent

water and oil are removed by two separate collection tubes. The cleaned

cleaning cycles. All centrifuges are equipped with imbalance sensors.

water can be re-used, while the separated oil is deposited in a collecting

This protects them against any damage caused by a potential imbalance

tank for disposal.

in the rotating drum.

© Rösler

© Rösler

3-phase cleaning centrifuges

Two equipment examples with RZ 150 A fully automatic centrifuge.

190 N. 84 - NOVEMBER/DECEMBER 2023 - international PAINT&COATING magazine

EVOLUTION TO E-MOBILITY C O AT I N G

I M P R E G N AT I O N

CLEANING

Our 70 years experience in Surface Treatment is ready for the E-Mobility market.

Research, innovation, development.

In 70 years, our vision towards the future has never stopped.

Today, Tecnofirma provides quality to the electric market which is the most evolving technology in the automotive industry.

Our impregnation, cleaning and painting plants are the result of the constant commitment to offer cutting-edge solutions and products anytime, anywhere.

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ICT | CASE STUDY

MONICA FUMAGALLI ipcm®

© Tor.Met

A Cleaning Plant for Small Metal Parts That Is Perfectly in Line with the Principles of Tor.Met’s New, People-Oriented Factory A turning company specialising in the production of precision metal components, Tor.Met has inaugurated a new factory where people’s well-being is central. In particular, it chose to equip itself with a modified alcohol cleaning system supplied

by IFP Europe, which not only meets the requirements for perfectly clean components but also aligns with the company’s welfare-oriented vision.

A

driano Olivetti, the entrepreneur behind one of the most renowned companies on the Italian business scene, revolutionised the concept of the factory as it had been conceived until the mid-

1950s. “The factory cannot only look at the profit index. It must distribute wealth, culture, services, democracy. I see the factory as serving man, not man serving the factory,” is one of his most famous quotes, summing up his entire vision. Such “corporate humanism” transformed the city of Ivrea and its best-known company, Olivetti, into an experimental laboratory for the development of a new approach to work that was paradoxically closer to today’s mentality – Industry 4.0, ergonomics, production sustainability, and flexible working hours are the words that Adriano Olivetti would probably have used today to describe his idea of a people-oriented workplace – than to that of the 1960s and 1970s, in which socio-political conflicts came to the fore.

Tor.Met Srl is a company headquartered within the tap and fitting district in the province of Verbano-Cusio-Ossola, in the Piedmont region (Italy), and specialising in the production of precision small parts: its CEO Stefano Romanò recently inaugurated a new plant that reflects Olivetti’s social vision of a “factory serving man”. “Any company like ours, established as a family business in this area,” explains Romanò during our interview, “can get where we have got, with the right focus on investment and production diversification. At the same time, the other board representatives and I firmly believe that we would never have achieved our current results without our employees. That is why a prerequisite of our development strategy is putting them in the position of working at best, using the most advanced, environmentally friendly, and interconnected machinery. We have transformed our company into a place where it is even pleasant to stay outside working hours, for example thanks to the cycle path that runs around the entire perimeter of our new factory and its in-house gym, both of which are available to

Tor.Met specialises in the turning and milling of precision metal parts.

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all our 45 employees and their families.”

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The equipment selected for Tor.Met’s new, 6000 m2-wide building

medical industries. We have achieved a good level of diversification

included, among others, a brass, bronze, and steel small metal part

in our customer portfolio as well, which has enabled us to make the

cleaning machine designed and installed by IFP Europe (Galliera Veneta,

quantum leap from a family business to a company with a global

Padua Italy). “This new system,” adds Romanò, “was placed alongside

presence and 12 million Euros in turnover.”

another cleaning machine supplied by a foreign manufacturer, which

Its international reputation, however, has not made Tor.Met lose

we have already been using for three years, to be ready to cope with

touch with its roots: “We work and live in an area made up of small

future production peaks resulting from the exponential growth our

villages: ‘doing business’ here means increasing jobs and, at the same

company has been experiencing in recent years. We chose what we

time, creating an environment inside and outside the factory that is as

consider the best solution currently on the market: not only effective

healthy and liveable as possible, both for those who spend long hours

and environmentally friendly but also easy to use and pleasing to the

in it and for the families waiting for them at home. If our employees are

eye. This plant encompasses everything that has made Tor.Met a model

comfortable in their working environment, the quality of our production

company in our industrial district.”

and of the service we provide to our customers benefits as well.

That is why, when we decided to move to a new facility, our company

From market diversification to the “factory serving man”: Tor.Met’s model

management immediately realised the importance of building a factory

“Tor.Met was founded in the early 1970s by my grandfather and

above all for people.”

maintained the profile of a family business until the early 2000s, when

In addition to the cycle path and gymnasium with magnetic equipment,

it started a major export activity, mainly in European countries, which

there are an EV charging station and two electric bicycles at the

today accounts for 50% of our turnover.”

employees’ disposal outside the building, whereas inside the changing

Such expansion abroad has also allowed the company to diversify into

rooms and bathrooms are equipped with showers with hydro massage

new sectors. “Whereas we used to specialise in the processing of brass

and chromotherapy accessories, furnished with designer faucets

small parts for some of the most important national tap and valve

produced by local companies. Furthermore, the facility will soon be

manufacturers, from Fratelli Pettinaroli and Caleffi to Gessi and Paini,

powered by a 400 kW photovoltaic system capable of meeting its entire

today we are also present in the electrical and electronics, food, and

production needs during daylight hours.

© Tor.Met

according to the parameters of Industry 4.0 for machines, but also and

© ipcm

Night overview of the new factory and the brass bars with which production starts.

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© ipcm

A waste-conscious turning company Production diversification has entailed a differentiation in the machinery used as well. “Initially, our lathes only machined brass in all its alloys. We then also started processing other materials such as bronze and different types of steel, from free-cutting to AISI 316 steel. We now use three types of lathes: sliding-head lathes that process parts with diameters ranging from 2 to 32 mm, CNC fixed-head lathes that can machine components up to a diameter of 80 mm, and multi-spindle lathes that treat parts from 16 to 50 mm in diameter. We have over 40 lathes, all

© Tor.Met

controlled via PLCs in line with the Industry 4.0 requirements. We can easily program all their operating parameters, including cutting speed and type of treated material.

“We also pay special attention to scraps.

When we process large volumes of materials, the recovered waste is sent to an individual collection system, whereas in the case of small quantities, it is handled separately. The recovered metal material is then sent to some drawing mills. The oil from our machining operations and the oil recovered from the air purification plant, once filtered, are fed back into production. This is one of the reasons why we can call ourselves a zero-emission turning company, which is quite rare in the industry.

© Tor.Met

Another element that differentiates us is that we can offer customers a complete service that includes polishing, chrome-plating, gilding, and coating, which we outsource, as well as the assembly of small components, which we do in-house.”

From top: The machining department.

The laboratory.

The quality control.

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© ipcm

© ipcm

IFP Europe’s KP 100 HMA cleaning plant.

© ipcm

The basket loading area.

One of the main advantages of the system is its ease of operation via the control display.

The cleaning equipment aligns perfectly with Tor.Met’s principles

treatment cycle, performed entirely under vacuum down to 1 millibar, and

As well as being perfectly integrated into the Industry 4.0-oriented

as regards metal finishing technologies. Its configuration can be modified

production system, Tor.Met’s two cleaning plants also align with the

over time thanks to its modular structure: it is possible to integrate a

principles of the company: “They are both closed-loop machines with

third tank for specific cleaning liquids, a system for the application of the

no emissions into the atmosphere. When we decided to add a new

protective agent, additional filtration units, and one or more generators

modified alcohol plant to the system we were already using to cope

with their corresponding ultrasonic transducers.

with production peaks, we chose to rely on IFP Europe’s experience,

“Our lathes use neat oil that remains on the surface of our components,”

also demonstrated by the fact that many turning companies in this area

explains Tor.Met production manager Andrea Bertoli. “That is why 100%

had already installed the second generation of its machines. Initially,

of our production must be cleaned to remove both oil traces and chips.

our new KP 100 HMA plant was intended to supplement the existing

Machines like this one from IFP Europe are indispensable because they

one when the capacity of the latter was saturated. After assessing its

allow choosing the most suitable options according to the workpieces

cleaning effectiveness even on very complex-shaped parts, however,

to be treated: from static cleaning for more delicate parts to a more

we decided to use it at full capacity. Depending on our workload, we

dynamic process for less fragile ones. In terms of machine management,

choose which cleaning machine to use indiscriminately.”

our operators found the IFP machine more user-friendly than the other

its rich standard and optional equipment, this line is one of our flagships

one. Besides being very flexible, it has already enabled us to solve some

The ideal system for the most demanding cleaning tasks

critical issues, such as the perfect cleaning of blind holes in some brass

“The KP HMA plant series developed by IFP,” indicates Giacomo

components that the other machine had not been able to treat completely.”

Sabbadin, the CEO of IFP Europe, “is ideal for the most demanding

IFP Europe’s plant simultaneously loads 2 standard FAMI-modular baskets

applications, meeting the needs for high productivity and the removal

with loading dimensions of 450x600x200h mm. “With the PLC, we control

of large quantities of contaminating agents. With its modified alcohol

the baskets’ movement and the temperatures and we set cycles with a

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© ipcm

© ipcm

Cleaned components.

duration of 7 to 12 minutes, depending on the type of workpiece; we

A people-oriented factory is possible

also use a cycle for plastic that lasts 16 minutes because we have to

Today, Tor.Met represents a new factory model, an example for the

keep the temperatures lower. Currently, loading is done manually, but

companies in its industrial district and many other medium-sized

we are about to implement automatic loading and make the work of our

businesses in Italy. “Our structure also impressed the public authorities,

operators even more comfortable.”

so much so that numerous politicians attended the inauguration of our

“In addition to the machine’s performance characteristics, we appreciated

new factory back in September. For us, this is proof that we are working

two other aspects of our partnership with IFP Europe,” emphasises

well and in the direction we had set ourselves. We intend to make our

Romanò. “Again with a view to creating a pleasant working environment,

company a benchmark for our area, both as a manufacturing business

we asked its team to paint this already attractively designed system in

and as a facility open to citizens, who can make use of the spaces we

the same colours as our lathes, and they agreed. I was also impressed by

provide. We would not have reached this point if we had not chosen

the service offered to us. We moved from our old Omegna site in several

the best employees and the best plant engineering partners – including

stages over the course of a year: at some point, half of the machinery was

IFP Europe, which shares our objectives from both the production and

in the old plant and half in this new one, so we needed two functioning

social point of view, which is what is closest to our heart.”

machines to clean our parts. And, since the system we ordered was not

Tor.Met is proof that the “factory serving man” dreamed by Adriano

ready yet, IFP decided to install a used machine to enable us to continue

Olivetti is truly possible.

working while waiting for the new one to arrive.”

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GABRIELE LAZZARI ipcm®

MMV and the Importance of Choosing Circular Products and Processes in the Industrial Cleaning of Small Metal Parts Industrial cleaning of small metal parts is one of the production activities that demand ever-higher quality results and, at the same time, ever-lower consumption and emissions. MMV revolutionised its cleaning process by adopting DOLLMARSOL G120, a modified alcohol with a low environmental impact developed by Dollmar, achieving optimal results and creating a fully circular process.

B

e they used as intermediate or final process steps, cleaning

years of experience in the production of small metal parts, is an example

operations are now fully integrated into the production flow of

of how it is possible to implement responsible resource management

every manufacturing company. The selection of the right plant

and create a circular cleaning cycle without sacrificing industrial growth.

technology and cleaning products are therefore crucial to achieve

The company’s thirty-year collaboration with Dollmar has always helped it

optimal degreasing and removal of all impurities from the parts’

identify the most suitable technology for its current needs. In the last few

surfaces. The choice made by MMV, a company with more than forty

years, for example, it has been using the modified alcohol DOLLMARSOL

ICT | CASE STUDY

G120, which has not only optimised MMV’s cleaning process and reduced

solutions, such as the AS400 management software package.

consumption but also opened up new market opportunities, positioning

In order to cope with the increasing production rates brought by this

the company as a pioneer in its field.

growth, in 2006 the company moved to a new factory within the artisanal area of Scopa, a larger and more modern facility. The Group’s annual

One family, many industries

investments have gradually led it to expand its target markets to include

The growth of MMV spanned the history of R&D in the field of cleaning

motorbike and automotive components, cookware, filters, chrome pipes

products. MMV - Minuteria Meccanica Valsesiana S.r.l. (Scopa, Vercelli,

and taps, fittings for truck and trailer braking systems, valves for gas boiler

Italy) is a contract manufacturer of brass, aluminium, and steel mechanical

hydraulic circulation systems, and other parts for the electronics, solar

small parts. It is part of a corporate Group with over 300 employees

panels, and fastening system sectors.

also including Sirit, Kramer, and at the helm Tosi F.lli Srl (Varallo, Vercelli), founded by Renzo, Mario, and Serafino Tosi in 1963, which acquired MMV in 1981 to complement its small parts production.

The Group has always been focused on growing through investments in new machines, such as multi-spindle mechanical lathes, and digital

© ipcm

Below photos: The storage area for the procured bars with many different shapes and sizes and an overview of MMV - Minuteria Meccanica Valsesiana’s production plant.

© ipcm

© ipcm

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MMV: precision small parts for over forty years MMV has therefore been the Group’s heart for small part turning for more than forty years, producing over sixty-five million components in seven hundred types every year. MMV performs various machining operations on its procured metal bars, such as turning, drilling, milling, threading, and broaching with high production-rate machine tools such as bar transfer systems and single and multispindle lathes. “We can produce any type of high-precision turned small metal parts to customer drawings. Our production is indeed very diversified: for example, we use eight different brass alloys and we can machine round, hexagonal, and square bars from Ø4 to Ø45 through our high-tech plants,” states MMV owner Davide Tosi. “Our whole production flow is also supported by an efficient and systematic © ipcm

quality control process prior to the manual packaging of the components to be shipped

One of the many CNC machines at the company’s premises.

to our customers, mainly Italian companies that export their products abroad – which means that they all have different requirements and specifications. Furthermore, since some parts are assembled before packaging, it is essential that each component is of high quality and free of any contamination. That is why our production process ends with two metal cleaning systems supplied by IFP Europe (Galliera Veneta, Padua, Italy). Here, cleaning is performed in a vacuum with the addition of ultrasound and a modified alcohol supplied by Dollmar Spa.

A pioneer in metal cleaning Cleaning is therefore an essential step in MMV’s production cycle, which needs to process 240 50-kg baskets per day. The company has always devoted much attention to this operation. Its first cleaning machine was made in-house by one of the founders of the Group and the grandfather of the current © ipcm

The cleaning department.

200 N. 84 - NOVEMBER/DECEMBER 2023 - international PAINT&COATING magazine

owner. “That rudimentary solution performed a cleaning phase in barrels with kerosene

ICT | CASE STUDY

and a subsequent rinse with hot water in another tank, followed by a drying phase. Of course, over the years, we have constantly revolutionised our equipment by analysing the various technologies available to find the most suitable machine for every current need.

What has remained unchanged, however, is the collaboration with Dollmar, which has been lasting for over thirty years now,” emphasises Tosi.

The benefits of DOLLMARSOL G120 “In 2008, we decided to change our cleaning cycle to reduce the environmental impact of our operations. However, our production volumes had increased and so had our consumption, naturally. Together with Dollmar’s technicians, we selected modified alcohol as the ideal solution to replace perchloroethylene,” says Tosi.

“DOLLMARSOL G120 is an environmentally

© ipcm

© ipcm

friendly glycol ether (modified alcohol) with excellent solvent power and low toxicity, guaranteeing stability even after countless vacuum distillation cycles. Its formulation is compatible with all modified alcohol cleaning machines on the market. More generally, modified alcohol is suitable on all metals for the removal of pollutants such as machining oils and greases,” explains Mario De Cenzo, the sales manager of Dollmar’s Mechanical Division.

A circular cleaning process Using DOLLMARSOL G120, MMV can perform a circular cleaning process. The components to be treated are placed in a basket, which is then loaded into the cleaning chamber through a conveyor. The parts are cleaned in modified alcohol using ultrasound technology.

This is followed by a two-stage high-pressure distillation phase in which the product is fully recovered so that it can be recirculated, whereas the machining oil removed from the © ipcm

parts is extracted from the plant to be reused again in the machining process and dry swarf is fully recovered. “This cleaning process enables

The handling system that takes the baskets carrying the small parts to be treated inside the cleaning machines and the IFP Europe cleaning systems.

international PAINT&COATING magazine - NOVEMBER/DECEMBER 2023 - N. 84

201

ICT | CASE STUDY

us to remove any contaminants such as machining oils and swarf even

advantages of our manufacturing cycle. Many of them are positively

from parts with complex geometries and blind holes in a continuous-

impressed by the quality of our products and the attention we pay to

flow, circular cycle. All waste material can be recovered and fed back

researching innovative and circular cleaning solutions,” says Tosi with

into production: nothing is disposed of. As a result, consumption has

satisfaction.

dramatically reduced and the impact of this operation on the environment

“The changes that occurred in this company’s cleaning process reflect

and the health of our operators was reduced to zero,” states Tosi.

its high environmental and entrepreneurial awareness. Davide Tosi and MMV’s technicians are driven by a strong innovative spirit and thorough

The thirty-year collaboration with Dollmar

knowledge of the entire supply chain, which in turn fuel our continuous

“We have a transparent approach and we often invite our potential

and long-lasting collaboration in a synergetic manner,” notes Adina

customers to visit our facilities, so that they can see for themselves the

Diaconu, Dollmar’s marketing spokesperson.

© ipcm

© ipcm

© ipcm

Davide Tosi, the owner of MMV, and examples of the small metal parts produced by MMV.

202 N. 84 - NOVEMBER/DECEMBER 2023 - international PAINT&COATING magazine

Nuremberg, Germany

16 – 18. January 2024

Discover the world of die casting at the leading trade fair for the entire value chain!

EUROGUSS is the meeting place for die casting foundries, their customers, suppliers, equipment providers and service companies.

Experience innovative technology, processes and products!

Honorary sponsors: Verband Deutscher Druckgießereien (Association of German Die Casting Foundries, VDD) CEMAFON - The European Foundry Equipment Suppliers Association

BE PART OF IT!

euroguss.com

NEWS

ICT | INDUSTRY NEWS

EnviroTech Presented the Performance Benefits of the Vapour Degreasing Solvent ProSolv®5408e The safe and environmentally-friendly vapour degreasing solvent ProSolv®5408e provides consistent and uniform cleaning results, reaching all surfaces evenly, including intricate and complex geometries.

E

nviroTech has specifically developed ProSolv®5408e in order to

Although some vapour degreasing solvents in the past were

provide superior critical cleaning performances for manufacturers

environmentally concerning, modern solvents such as ProSolv5408e

of electronic and electrical components. As a matter of fact, the

are designed to be safer and more environmentally friendly. They are

high-performance solvent cleaner ensures a sustainable and future

indeed engineered to have lower toxicity, reduced volatility and minimal

proof vapour degreasing with High Solvency (KB Value 98) for removal

global warming and ozone-depleting potential. Moreover, the solution

of organic residues, compatible with organic and synthetic oils and

developed by EnviroTech has a low boiling point, so it evaporates quickly

most plastics and metals, a GWP of less than 1 based on a 100-year

when exposed to air. Overall, the combination of excellent solvency, low

Integrated Time Horizon (ITH).

surface tension, nonpolar properties, heat assistance, minimal residue

Leaving little to no residue behind, it is especially suitable for

and controlled vaporisation make ProSolv5408e highly effective for a

applications where water could cause corrosion or damage, such as

wide range of cleaning applications.

cleaning sensitive electronics or precision mechanical components. It does not require extensive mechanical agitation, reducing the risk of

Benefits of ProSolv5408e at a glance

damaging delicate parts while ensuring effective cleaning.

• Exceptionally low surface tension to penetrate micron sized holes and

Its unique molecular properties reduce the surface tension of the

close contact surfaces;

solvent, making it more effective at penetrating and breaking up dirt and

• Sustainable and secure for the future;

stains even in areas that might otherwise be hard to clean. Its ability to

• Non-carcinogenic;

dissolve allows then to disperse a wide range of contaminants, including

• Low boiling point;

dirt, oil, grease and wax. In addition, it can also act as rinsing agent,

• Easy handling;

carrying away dissolved dirt and contaminants when evaporating and

• Compatible with a broad range of substrates.

preventing the redeposition of dirt onto cleaned surfaces.

For further information: www.envirotech-europe.com

© Envirotech

204 N. 84 - NOVEMBER/DECEMBER 2023 - international PAINT&COATING magazine

ICT | MEETING THE INDUSTRY

DeburringEXPO Attracted Over 1,200 Professional Visitors with Specific Requests The organisers of the international trade fair for deburring technology and precision surface finishing DeburringEXPO expressed satisfaction for the 2023 edition.

N

Significant contacts promise good post-Event business

early all of the more than 1,200 expert visitors arrived at this year’s DeburringEXPO in Karlsruhe with specific tasks and

And this appears to be the case, as is evident from the following

strong demand for information from the 10 through the 12 th

th

comments from Steffen Hedrich, managing director of Kempf GmbH:

of October. For the majority of the 107 exhibiting companies from 13

“Practically every visitor at DeburringEXPO comes to the trade fair with

countries, this resulted in excellent contacts and new projects with good

an ongoing problem for which they require a solution. As a result,

prospects for post-event business. With more than 500 participants, the

discussions go into great depth very quickly. We also presented a world’s

bilingual expert forum also lived up to its reputation as a coveted source

first for deburring tasks which place stringent demands on chamfer

of knowledge.

quality, and it generated significantly better feedback than I expected

Deburring and the production of precision surface finishes are just

beforehand. For us it’s already clear that we’ll exhibit again in 2025.”

one aspect of surface treatment technology. But due to quality and

The fact that there was so much tangible action at DeburringEXPO was

cost considerations, manufacturing companies are focusing on them

due to the very high proportion of expert visitors. The most prominently

to an ever-greater extent. This is confirmed impressively by the current

represented sectors include machinery and systems manufacturing,

challenges and projects brought along to this year’s DeburringEXPO

metalworking and metal processing, medical and pharmaceuticals

by the 1214 visitors (roughly 10 % more than in 2021) from the 10

technology, tool and mould making, precision engineering and optics,

through the 12th of October.

the automotive industry, as well as aviation and aerospace technology.

20% of the event’s visitors came from outside of Germany and 18

Roughly 92% of all visitors are involved in company investment

countries were represented. The largest percentage of visitors came

decisions. The quality of the contacts and RFQs is correspondingly good,

from Germany, followed by Switzerland, Italy, Austria and Slovenia.

which were fielded at the event by a majority of the 107 exhibitors from

“The fact that participation at the trade fair paid off for the exhibiting

13 countries.

companies is more important than the figures themselves,” notes

“We took over the business from another company that exhibited

Hartmut Herdin, managing director of private trade fair promoters

at the trade fair on a regular basis and were thus also on hand this

fairXperts GmbH & Co. KG.

year. We were surprised by the highly specific tasks and RFQs, and by

th

© fairXperts GmbH & Co. KG

206 N. 84 - NOVEMBER/DECEMBER 2023 - international PAINT&COATING magazine

© fairXperts GmbH & Co. KG

ICT | MEETING THE INDUSTRY

the resulting quality of our leads. I think we’ll exhibit again at the next

various metalworking sectors with different tasks for deburring and

DeburringEXPO,” reports Shigeru Kajisaki, managing director of Yamazen

the production of precision surface finishes. We observed that the

Europe GmbH.

requirements for automation solutions are becoming more demanding

Dieter Münz, managing director of Ultratec Innovation GmbH, is also

and that greater degrees of automation are required.”

very satisfied with the way things went at the trade fair: “DeburringEXPO you do at the big metalworking events, but they all come with a specific

High levels of visitor satisfaction thanks to numerous innovations and know-how

task in mind. As a result, the success rate for good post-event business

The fact that the leading trade fair for deburring technologies and

is significantly higher here than at other trade fairs. This is why we will

precision surface finishing lived up to the expectations of the visitors as

definitely be back in 2025.”

well is made apparent by the evaluation of the visitor survey. Roughly

David Bartels, laboratory manager responsible for process engineering

95% were satisfied or very satisfied with the trade fair offerings. Without

sales at Höckh Metall-Reinigungsanlagen GmbH, who exhibited

a doubt, the numerous new and further developments presented by the

together with SGM s.r.l. (manufacturer of thermal deburring systems),

exhibitors contributed to the high levels of satisfaction. Further evidence

also drew a positive balance: “Deburring is one of the major topics at

of visitor satisfaction is the recommendation rate: more than 75%

DeburringEXPO, and cleaning is an upstream or downstream production

would recommend a visit to the leading trade fair as an information and

step. The joint trade fair presentation with SGM has resulted in

procurement platform to colleagues and business partners.

synergies that have enabled us to generate more interesting leads than

Right from its very first edition, the bilingual expert forum at

at previous events, including numerous new contacts.”

DeburringEXPO has established itself as a coveted source of knowledge.

Patrick Taschek, sales and project engineer at Rösler Oberflächentechnik

505 participants took advantage of the simultaneously interpreted

GmbH, recalls very detailed discussions and RFQs: “During the three

presentations (German <> English) at this year’s event in order to

days at the trade fair, we were visited by existing customers with whom

deepen their knowledge of deburring technologies and the production

we were able to discuss new projects. On the other hand, we were also

of precision surface finishes. For more than 30% of the visitors, the

able to establish good new contacts. Our meetings frequently focused

programme schedule for the expert forum was the decisive factor for

on reducing the number of manual processes, as well as simplifying and

selecting the day on which they visited the trade fair.

automating processing operations.”

The next DeburringEXPO will be held at the Karlsruhe Exhibition Centre

Jan-Niklas Merkel from the technical sales department at SHL AG

from the 14th through the 16th of October, 2025.

is our most important trade fair. You don’t have as many visitors as

also discovered that the trend towards more automation, which is not least of all due to the shortage of qualified personnel, was a dominant theme at this year’s DeburringEXPO: “The visitors came from

For further information: www.deburring-expo.de/en

From left to right: Several exhibitors from different segments presented new technologies and further developments which were met with great interest by the 1,200 professionals attending DeburringEXPO 2023.

An example of the automation of deburring and surface finishing processes, which was one of the main topics of the event.

© fairXperts GmbH & Co. KG

One of the twenty-three simultaneously interpreted (German <> English) presentations of the bilingual expert forum, that attracted more than 500 participants.

international PAINT&COATING magazine - NOVEMBER/DECEMBER 2023 - N. 84

207

ICT | MEETING THE INDUSTRY

The 20th Edition of parts2clean Attracted Over 3,000 Visitors More than 150 exhibitors reported that they obtained numerous high-quality contacts and signed direct business deals during parts2clean 2023.

D

eep-going technical discussions, a

high-purity snow blasting cleaning solutions,

strongly attended Expert Forum and a

we were previously more of a niche supplier at

positive overall mood on all three days

parts2clean. At this year’s event, however, we

of the fair testified to the fact that the 20th

were able to welcome a large number of trade

parts2clean, ending on September 28, fulfilled

fair guests from the fields of EUV lithography,

all expectations. More than 3,000 trade visitors

including system partners and suppliers,

came to the event, the majority of them armed

as well as electromobility. The latter ranges

with current tasks and projects as well as a

from battery manufacturers and suppliers of

thirst for new information. This resulted in

components for power dissipation and energy

numerous high-quality contacts, new projects

management right through to electric motors.

and even direct business deals for the more

For us, parts2clean 2023 went very well.”

than 150 exhibitors from 14 nations at the

Jan Gerbrands, CEO at Netherlands-based

event.

Brookhuis Applied Data Intelligence B. V.,

Cleanliness is playing an increasingly important

a manufacturer of products for optimizing

role in a growing number of industrial sectors.

cleanroom operations, expressed similar

This conclusion can be drawn after the close

sentiments: “It was a fantastic show for us,

of the 20th parts2clean, made clear by the

as we were able to generate many new

tasks and projects which more than 3,000

contacts.” And, according to Rainer Straub,

visitors brought with them to the Stuttgart

Board of Management and Vice President

Exhibition Center from 26-28 September.

Sales & Customer Service at Ecoclean GmbH:

The share of foreign visitors was 20 percent,

“parts2clean was significantly more successful

with the strongest attendance coming from

for us this year than in 2022, certainly due to

Germany, Switzerland, the Czech Republic,

the highlight theme of ‘High Purity’, which is a

Turkey, Austria and the Netherlands.

focal point in our program at Ecoclean. This

The highlight theme of “High Purity”, which was

helped us to attract new visitors.”

added to the core areas of this, the leading surface cleaning, made a major contribution to

Decision-minded trade visitors looking to invest

the substantial increase of around 33 percent

A total of over 150 exhibitors from 14

compared to the previous year. “In this way,

countries presented new, refined and

we have placed a stronger focus on the range

time-tested products as well as services

of solutions offered at parts2clean for tasks

for industrial parts and surface cleaning on

where the highest cleanliness requirements

around 4,500 m2 of display space. The fact that

need to be met,” reports Christoph Nowak,

most of them were able to hold highly detailed

Project Director at Deutsche Messe, “and

discussions about specific projects was due

we have thus succeeded in attracting more

to the above-average percentage of trade

visitors from the affected industries to

visitors (99 percent). About 88% of them are

parts2clean.”

involved in operational investment decisions,

This was confirmed by Günther Schmauz,

and about 78% visited the trade fair looking

board member at acp systems AG: “With our

to make purchases. And these were directly

international trade fair for industrial parts and

208 N. 84 - NOVEMBER/DECEMBER 2023 - international PAINT&COATING magazine

ICT | MEETING THE INDUSTRY

© Deutsche Messe AG

implemented at parts2clean, as Wolfgang

in English. These are thorough-going

Prem, Managing Director of Maschinenbau

discussions that deal with specific tasks, and in

Silberhorn GmbH, reported: “This year we are

some cases the visitors even bring along the

taking away a whole lot of good leads with

workpieces to be cleaned.”

visitors from companies we did not know in the tradeshow was that we were able to sell

Strong demand for information drives record attendance at Expert Forum

one of our new MWS cleaning systems to a

“A magnet for visitors has always been the

company from Israel directly at our booth. It

bilingual Expert Forum at parts2clean,”

was a first contact that occurred right here at

remarks Nowak. “But this year it underpinned

the show.”

its status as one of the world’s most sought-

Manfred Holzleg, General Manager of

after sources of expertise on industrial

Safechem Europe GmbH, also expressed his

parts and surface cleaning, drawing record

satisfaction: “At parts2clean, we always have

attendance.” And the numbers spoke for

the opportunity to meet a diverse audience.

themselves: A total of 2,700 times knowledge

This year, we were able to hold numerous

transfer par excellence by listening to the

discussions, especially with visitors from

simultaneously translated (German <>

industries that are new to us, and we can

English) lectures by renowned speakers from

also open up new business fields as a result.

science, research and industry to generate or

However, parts2clean is also important for

deepen cleaning knowledge. “The enormous

us from the point of view that the world

popularity of this forum shows that there is

market and technology leaders from the

an immense need for information – both for

various areas of industrial cleaning technology

traditional cleaning tasks as well as high-purity

come together here, and we can exchange

applications, which will continue to increase

information about developments and trends

due to changing and new requirements,” adds

in an interdisciplinary manner.”

Nowak.

Bahadir KöK, Sales Manager of the Turkish

The last day of parts2clean also offered a

company Everest Elektro Mechanik Makina

special highlight, featuring the presentation

Sanayi Ve Tic. A.S. took a similar view:

of the FiT2clean Award. This was the second

“parts2clean is one of the most important

time that the German Industrial Parts Cleaning

trade fairs for Everest. In order to become

Association (FiT) honored outstanding

more independent from the automotive

achievements and solutions for parts cleaning.

industry, we have developed new systems

Intelligent Fluids GmbH secured the €10,000

in line with the current standards in medical

innovation prize for the development of

technology, which we are presenting here. We

water-based, sustainable phase fluids that

also invited our dealers from various countries

can replace standard solvents in numerous

to attend the fair so that we can present these

cleaning applications.

before. But the highlight of our participation

new developments to them.”

Maria Laure from the New Business Perfect

For further information:

Welding division at the Austria-based

www.parts2clean.de/en

Fronius International company assesses her participation in the trade fair in the following light: “We participated in parts2clean for the third time and have noted a positive development, both in terms of visitor numbers as well as the international makeup. We conduct around 50 percent of our discussions © Deutsche Messe AG

international PAINT&COATING magazine - NOVEMBER/DECEMBER 2023 - N. 84

209

ICT | MEETING THE INDUSTRY

Diverse, Dynamic, Innovative: EUROGUSS 2024 Set to Be a Mirror of the Die Casting Industry The organisers of the 15th edition of EUROGUSS have announced that the entire exhibiting space has already been booked by around 600 businesses. The international trade fair will then provide the opportunity to discuss the most urgent trends and challenges that the die casting sector is facing.

D

espite the current situation in the die casting sector, with hot

devices, joining processes, process optimisation, energy efficiency,

topics such as the transformation in the field of drivetrains or

material testing, die casting machinery and 3D printing.

consistently high energy costs, the industry is both dynamic and

Traditionally, casting foundries continue to represent the bulk of the

innovative. The major issue of mega-casting is revolutionising car body

exhibitors. But the event is also welcoming their sub-suppliers from the

manufacturing in the automotive industry and is drawing attention to

entire periphery, such as machine manufacturers, mould fabricators,

die casting over and beyond its traditional bubble. These opportunities,

alloy suppliers, casting machinists and software vendors. All four halls

but also the associated challenges, urgently need to be discussed in an

have been already fully booked by almost 600 exhibitors, with more

overarching way across the entire supply chain for light metal casting,

than half coming from over thirty countries such as Italy, Turkey, Spain,

and above all with customers. EUROGUSS will always be the ideal

Austria and Switzerland.

gathering point for facilitating these discussions.

They will showcase their technologies as well as their expertise at the

The 15th edition of EUROGUSS, the international trade fair dedicated

German Die Casting Congress, which will offer interesting presentations

to die casting technologies, products, machinery and processes, will be

by speakers from the industrial and scientific communities and OEMs

held from 16 to 18 January 2024 at the NürnbergMesse in Nuremberg

on new technologies, process and material developments. Another

(Germany). The exhibition – that takes place every two years – will once

highlight will also be the EUROGUSS Talent Award, that recognises

again allow participants to showcase their latest innovative solutions for

bachelor’s and master’s theses by young talents during the Student Day

a wide range of applications, including aluminium, magnesium and zinc

on 18th January.

th

th

die casting. Attendees will also be able to experience offerings for rapid prototyping, CNC machines, metal alloys, die casting moulds, peripheral

For further information: www.euroguss.de/en

© NürnbergMesse

210

N. 84 - NOVEMBER/DECEMBER 2023 - international PAINT&COATING magazine

www.gattomatto.biz

WATER BASED PARTS WASHER, THE AGREEMENT BETWEEN NATURE AND TECHNOLOGY

107

MACHINES MODELS, INFINITE COMBINATIONS

WWW.TEKNOX.NET BOLOGNA - ITALY ADVANCED TECHNICAL SOLUTIONS FOR SURFACE TREATMENT

Questa testata è associata a UNIONE COSTRUTTORI IMPIANTI DI FINITURA

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